REVISION CONTROL SHEET DOCUMENT TYPE: TECHNICAL …

REVISION CONTROL SHEET

DOCUMENT TYPE: TECHNICAL SPECIFICATION NO: PC-E-289

TITLE: TECHNICAL SPECIFICATION FOR MANUFACTURE OF WATER LUBRICATED BALL BEARINGS FOR FM HEAD OF

700 MWe PRESSURISED HEAVY WATER REACTORS

REV. NO. & DATE

DESCRIPTION OF REVISION

REVISED BY NAME & SIGNATURE

CHECKED BY NAME & SIGNATURE

REVIEWED BY NAME & SIGNATURE

APPROVED BY NAME & SIGNATURE

1.0 SCOPE

This specification establishes the requirements for the manufacture, inspection, testing, packing and supply of Water Lubricated Ball Bearings for FM Heads of 700 MWe Pressurised Heavy Water Reactor (PHWR).

2.0 CONTENTS

The requirements of this specification are presented under the following headings:

Description Section Applicable Drawings 3 General Function and Description 4 Requirements for Design of Bearings 5 Material and Workmanship 6 Quality Control Requirements 7 Packing and Shipment 8 Information and Documents to be furnished by the Supplier 9 Sub-contracting 10 Approval of Supplier’s Drawings and Procedures by the Purchaser 11 Additional Inspection and Tests 12 History Docket 13 Warranty 14 Purchaser’s Drawings, Specifications, Samples etc. 15

3.0 APPLICABLE DRAWINGS

*/35221/2272/DD Specification for Water Lubricated Bearing WLB-1&2 */35221/2098/DD Specification for Water Lubricated Bearing WLB-3&4 */35221/2010/DD Specification for Water Lubricated Bearing WLB-5 */35221/2015/DD Specification for Water Lubricated Bearing WLB-6&7 */35221/2059/DD Specification for Water Lubricated Bearing WLB-8 */35221/2176/DD Specification for Water Lubricated Bearing WLB-9 */35221/2177/DD Specification for Water Lubricated Bearing WLB10

* = Applicable 700 MWe Projects 4.0 GENERAL FUNCTION AND DESCRIPTION

These bearings are required to work under radial and axial loads for various drive mechanisms which are required to work only under water lubricated conditions. For each bearing the functional requirements, method of assembly in FM Head, operating conditions, pre-loading methods etc. are indicated in the drawing referred to in Section-3.0.

5.0 REQUIREMENTS FOR DESIGN OF BEARINGS

All the requirements such as materials of construction, sizes, dimensional tolerances, design radial and axial loads, life required in revolutions, speed of revolutions etc.,

NUCLEAR POWER CORPORATION OF INDIA LIMITED TECHNICAL SPECIFICATION FOR MANUFACTURE

OF WATER LUBRICATED BALL BEARINGS FOR FM HEAD OF 700 MWe PRESSURISED HEAVY WATER REACTORS

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are indicated in the relevant drawings. The Water Lubricated Bearings manufacturer shall furnish detailed manufacturing drawings showing all dimensions with their tolerances to suit the requirements given in the Purchaser’s drawings and to meet the requirements of Bearing precision class of ABEC-1 or better. The detailed drawings are to be sent for Purchaser’s approval before commencement of manufacture.

6.0 MATERIAL AND WORKMANSHIP 6.1 All materials and parts used in the manufacture of Water Lubricated Ball Bearings

shall be new and shall conform to the material designations indicated in the drawings applicable to this specification. The raw material shall meet the chemical, metallurgical, mechanical and NDT requirements as per the relevant material specification. The bearings shall be manufactured with high quality workmanship to ensure satisfactory operation and the specified service life.

6.2 Specific Requirements

In addition to the requirements as indicated above, the Supplier shall meet the following specific requirements with regard to the manufacture of rings, balls, cages, rivets etc.

6.2.1 Rings

Technical specification for SS 440 C raw material to be procured by the Supplier for manufacture of bearing rings is covered under Appendix-1 to this specification. The bearing Supplier shall meet all the requirements indicated in this Appendix during the procurement of SS 440C bars. The bearing rings shall be manufactured from the above accepted raw material meeting the requirements indicated in the drawing. Rings shall be heat treated with adequate precautions so that no inter-granular corrosion takes place. Hardness check of all bearing rings before and after heat treatment shall be carried out with Rockwell Hardness testers, which are calibrated and meeting the requirements of ASTM-E-18. Prior to hardness testing, scale or other foreign material shall be removed from the component. The component surface shall be prepared so as to get the actual hardness reading. Finish grinding and light polishing of all rings shall be carried out before passivation. All the heat treated and finish machined rings, prior to assembly, shall be fluorescent magnetic particle tested for crack detection to ensure that they are defect free. After magnetic particle testing, the rings shall be demagnetized, cleaned and passivated.

6.2.2 Balls Balls shall be manufactured from Stellite No. 3 material. The Stellite No. 3 shall conform to the following chemical composition:



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Carbon : 2.00 to 2.60 Manganese : 1.00 (max) Silicon : 1.00 (max.) Chromium : 29.00 to 33.00Nickel : 3.00 (max.) Tungsten : 11.00 to 14.00 Iron : 3.00 (max.) Cobalt : Balance

The balls shall have a minimum hardness value of 54 Rockwell ‘C’ on parallel flats and this hardness shall be uniform within 3 points. Balls used for hardness measurement shall not be used in the ball bearing assemblies. The balls shall meet the requirements of AFBMA Grade 25 or better. The balls shall also meet the requirements indicated below: a. Finished balls shall be 100% inspected for size, grade, form and surface texture. b. 100% visual inspection of the finished balls shall be carried out to ensure freedom

from defects. In addition, samples from each lot shall be viewed at 10X magnification to a sampling plan prepared by the quality control department of the ball manufacturer in accordance with BS 6001:2006. If rejectable balls are found, the whole lot shall be subjected to inspection at 10X magnification.

c. The Supplier shall carry out triple axis radiographic inspection on 100% of balls and results of inspection shall be reported. Inspection shall be as per ASTM-E-94 and ASTM-E-142.

d. The Supplier shall carry out crushing load test on at least 1% (min. 3 nos.) on

each size of the ball per each lot. The balls shall satisfactorily withstand crushing load required for various sizes of the balls as given below:

Ball size (D), mm dia. Minimum acceptable crushing load (Newtons) 3.969 (5/32”) 3680 7.9375 (5/16”) 7230 9.525 (3/8”) 8670 15.875 (5/8”) 14460

16.669 (21/32”) 15180 25.40 (1”) 23110

The schematic for carrying out crushing load test is indicated below:



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The test results shall be reported by the Supplier to the Purchaser. If any of the balls fail to meet the minimum acceptable crushing load, then the entire lot shall be rejected. Balls used for crushing load testing shall not be used in the ball bearing assemblies.



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6.2.3 Cages 6.2.3.1 Cage shall be manufactured from Silicon Iron Bronze material to AMS 4616. The

Silicon Iron Bronze shall conform to the following properties:

a. Chemical Composition:

Copper : 90.0 (min.) Silicon : 2.4 to 4.0 Zinc : 1.5 to 4.0 Iron : 1.0 to 2.0 Manganese : 1.00 (max) Phosphorus : 0.1 (max.)

b. Mechanical Properties (min.)

Tensile Strength : 56.0 ksi (39.35 Kg/mm2) Yield Strength (at 0.2% offset)

: 20 ksi (14.07 Kg/mm2)

Elongation in 4 D : 30% Hardness : 90 HB

c. Grain Size The average grain size as determined in accordance with ASTM-E-112 shall be

not larger than 0.20 mm. d. Ultrasonic Examination

All bars of size 50 mm diameters and above shall be 100% ultrasonically examined over the entire surface. Ultrasonic examination of each bar shall be carried out in accordance with specifications ASTM-A-388 and ASTM-A-745 using straight beam technique from two directions approximately at right angles to each other. The entire volume of each bar shall be examined.

Acceptance Standard

Acceptance level is QL-1 of ASTM-A-745, i.e reference block having defect standard of 3.18 mm diameter flat bottom hole. Indications from a defect more than that from 3.18 mm diameter flat bottom hole in the defect standard shall be a cause for rejection of the bar.



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6.2.3.2 In addition, the finished cage shall be subjected to 100% visual examination. The locating diameters shall be smooth, free from injurious tool marks. All surfaces shall be free from burrs.

6.2.4 Rivets

Rivets shall be made from Stainless Steel wire type 304/302 meeting the requirements of ASTM-A-580. The wire shall be cold drawn and annealed. In addition, the material shall be examined to ensure that it is free from susceptibility to inter-granular corrosion as per ASTM-A-262 Practice-A.

6.2.5 Assembly

a. Before assembly, balls, cages and rivets shall be thoroughly cleaned in petroleum spirit.

b. During and after the cleaning process, components shall not be touched with bare

hands. Clean hooks, tongs, gloves or suitable meshed sleeves shall be used.

c. After assembly of bearing, radial and axial internal clearances shall be checked and certified for conformity. The bearing shall be held suitably on the OD/ID and rotated with hand. The rotation shall be smooth without noise.

d. For bearings with riveted cages, the rivet head shall be correctly formed and shall

be free from cracks.

e. The following materials must not be allowed to contact the bearings or component parts during manufacture and assembly:

1. Zinc (also in the form of galvanizing or zinc rich paints). 2. Copper – also in sulphate form. 3. Aluminium 4. Cadmium – plated components 5. Mercury 6. Cerrabend 7. PVC 8. Neoprene 9. Fire retarded polythene 10. Chlorinated rubber - also in paint 11. Lead 12. Felt tip pens.

7.0 QUALITY CONTROL REQUIREMENTS 7.1 General Requirements



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7.1.1 Along with his quotation, the Supplier shall submit a brief quality control plan

indicating the various quality control measures that would be followed with regard to all aspects of the execution of the purchase order. Broadly, the quality control plan shall contain details of:

a. Quality control in case of raw material procurement. b. Incoming raw material inspection such as chemical and metallurgical analyses

that are to be carried out, mechanical properties required and non-destructive testing to be done.

c. Quality control during heat treatment of rings.

d. Non-destructive testing to be carried out after heat treatment such as hardness

testing, magnetic crack testing.

e. Dimensional control during manufacture and maintenance of dimensional records of the finished parts.

f. Quality control measures to be followed during assembly of bearings.

g. Quality control methods to be followed in packaging and transportation.

7.1.2 Dimensional Inspection: 100% visual and dimensional inspection, including inspection of geometric features

and surface finish, shall be performed on all dimensions of the components and their numerical values shall be recorded to ensure their conformance to the respective drawings. Deviation from dimensional and other requirements of the drawings shall form grounds for rejection of the components. These recorded dimensions shall be made available to the Purchaser for review. Manufacturer shall inspect the following and maintain a proper record of the same.

a) Dimensions, surface finish, geometric features, proper deburring to ensure

absence of burrs and sharp corners, and alignment of all components b) Dimensional and functional checks of bearing assembly;

c) Completeness and conformance of all components/assemblies to the requirements

specified in this specification.

In certain cases, form tolerance such as run out, squareness and concentricity tolerances may be inspected and accepted on the basis of in-process inspection when the component is on the machine. In all cases where manufacturer desires to carry



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out quality control on the basis of in-process inspection, he shall obtain Purchaser’s prior approval and shall intimate Purchaser’s quality surveillance representative well in advance.

7.1.3 Quality Assurance Plan (QAP) Quality Assurance Plan for the work covered by this specification shall meet the

minimum requirement of control and test given below. However, after placement of Purchaser order, but prior to taking up manufacture, the Supplier shall submit a detail QAP covering all the aspects of manufacture and inspection of Water Lubricated Bearings for approval by Purchaser. This shall cover all the requirements of drawings and this specification. The final QAP as approved by Purchaser shall be used during manufacture.

Sl. No.

Control & Tests

Type of check Action by manufacturer

Quality Surveillance by Purchaser or his authorised representative

1. Conformation of all raw materials to material designations (except Balls)

Chemical composition I/R R, H

2. Heat treatment of Raw Materials (except Balls)

Loading, unloading, time-temperature charts etc.

I R, C

Hardness testing before and after heat treatment I R, C, H

3. Testing of raw materials (except Balls)

Tensile Testing

I R, C, H

Macro-etch Testing Inclusion Rating Micro structure Grain sizeIGC Test Non-Destructive Testing

4. Inspection of machined components

100% Dimensional inspection of components

I R, C

Surface finish and other geometrical features. I R, C



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Non Destructive examination e.g Magnetic Particle / Liquid Penetrant examination

I R, C, H

De-magnetisation, cleaning, passivation, visual

I R, C, H

5. Certification of conformation of Balls to material designations

Chemical composition R R, H

6. Inspection of Balls

100% visual examination at 1X

I/R R, C, H

Sample visual examination at 10X 100% Dimensional check including sphericity Hardness testing of balls Crushing load test 100% 3-directional X-ray examination of balls

7. Assembly Assembly of rings, balls, cage, riveting etc. checking of radial and axial internal clearances and smooth rotation of 100% bearings by hand. Ensure conformation to drawings and specification requirements and match marking of a set of bearings wherever called for.

I R, C, H

8. Packing Protection against corrosion, damage etc. I R, C, H

9. Identification Batch No., Serial No. etc. I R, C, H



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Legend:

I Complete action and inspection by Manufacturer on a 100% basis.

R Review of test records, test reports, procedures, test certificates, records of process parameters etc.

C Checking the actual component or witnessing the inspection / testing activity on a

suitable percentage / random basis.

H Purchaser Hold Point 7.1.4 Tra ceability of each bearing with respect to raw materials, heat treatment and

inspection reports is required. For this purpose, the Supplier shall suitably identify each bearing (or bearing set) by marking the bearing (or bearing set) serial number on the cage face. All reports and certificates referred in para 8.3 shall have cross reference to this bearing identification number.

7.1.5 Quality surveillance relating to the supply of WLB shall be carried out by the

Purchaser or his authorized representative. Quality surveillance during manufacture, inspection, assembly and testing will be carried out by the Purchaser or his authorized representative. The address of the Purchaser’s Quality Surveillance agent will be indicated after placement of purchase order. The Supplier shall provide all the necessary facilities to the Purchaser or his authorized representative for carrying out the quality surveillance.

7.2 Inspection and Test Failure: If any component fails to meet any inspection or test requirement of this specification

and if the Supplier intends to offer the equipment or the part for acceptance, either in failed, reworked or repaired condition, then, he shall notify the Purchaser or his authorized representative of his intentions. For this purpose, the Supplier shall submit a ‘Design Concession Request’ (DCR) with full particulars and descriptions of the deviations and proposed method of rectification. The DCR suitably countersigned by the Supplier’s Chief Quality Control Executive shall be submitted to the Purchaser’s Quality surveillance representative who in turn will pass this on with his comments, to the Purchaser’s Design Engineering department. The rectification/or use of the component by the Supplier shall be taken up only after the approval of the DCR by the Purchaser. The failed equipment or part may be accepted at the discretion of the Purchaser, as deviated part, or required to be reworked, repaired, reinspected or totally rejected. Purchaser’s procedure ED-PROC-7 shall be followed in this regard.

8.0 PACKING AND SHIPMENT



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8.1 Bearings shall be individually packed in a polythene bag and sealed, then inserted and sealed in another polythene bag.

8.2 A self adhesive label with the bearing designation and allocated serial number shall

be affixed to outside the sealed polythene bag before insertion into the outer polythene bag. These bags shall then be packed in cardboard boxes. The boxes shall be properly identified with suitable tags indicating the items and the quantity. The packing shall be of high quality and adequate to prevent damage during transit.

8.3 Prior to the actual shipment of the bearings, the Supplier shall submit all the test

results, inspection reports and certificates. The inspection reports and certificates required are as follows:

The Purchaser or his authorized representative will issue shipping release for the bearings based on these inspection reports and certificates. Among other requirements, these shall cover the following in particular:

Rings

1. Steel manufacturer’s cast number, chemical analysis details, non-destructive testing reports and results of metallurgical evaluation carried out for acceptance of the raw materials for manufacture of the bearing.

2. Heat treatment batch number, time, temperature, quenching and tempering

parameters, mechanical properties achieved and hardness test results.

3. 100% dimensional inspection report after finish machining.

4. Reports of fluorescent magnetic particle inspection after finish machining. Balls

1. Ball manufacturer’s cast number, chemical analysis details and results of

metallurgical evaluation carried out for acceptance of the balls. 2. Reports of triple axis radiography.

3. Certification regarding the results of 100% inspection of size, grade, form and

surface texture.

4. Certification regarding 100% visual examination at 1X.

5. Certification regarding visual inspection of samples from each lot at 10X. Details of sampling plan followed shall be indicated.



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6. Reports of crushing load test.

Cages and Rivets

1. Raw material manufacturer’s cast number, chemical analysis details, mechanical properties and results of non-destructive testing, metallurgical evaluation, etc. carried out for the acceptance of the raw material.

2. 100% dimensional inspection report.

3. Certification regarding 100% visual examination.

Ball Bearing Assemblies

1. Certification regarding checks for internal clearance. 2. The actual static and dynamic load rating and the expected life for each size of the

bearing shall be indicated.

3. Certification regarding smooth and noise free rotation of the bearing. Certificate of Conformity

An overall certificate of conformity indicating the complete compliance of all

bearings to the requirements of drawings, specification and the Purchaser Order. The Purchaser or his authorized representative will issue shipping release for the

bearings based on these inspection reports and certificates. The Supplier shall ship the bearing consignment only after receiving the shipping release.

9.0 INFORMATION AND DOCUMENTS TO BE FURNISHED BY THE

SUPPLIER

9.1 Along With Quotation

a. The Supplier shall submit a brief list of work executed by him to standards and tolerances similar to those specified in this Tender Document. Also a list of machine tools and equipment including heat treatment furnaces and inspection equipments available with the Supplier shall be furnished.

b. Drawings of each water lubricated ball bearings indicating all the relevant

dimensional and material details shall be furnished by the Supplier. c. Details of inspection equipment and method of inspection of various features of

bearing rings, cage and balls shall be furnished by the Supplier



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d. Confirmation that Supplier will meet all the requirements indicated in the

drawings and this specification.

e. The Supplier shall clearly indicate in his quotation, the static load capacity, dynamic load capacity, expected life of each bearing. If bearing life requirements specified can not be achieved, then the Supplier shall indicate in his quotation the expected replacement frequency.

f. A brief quality control manual that would be followed during the execution of the

order (see para 7.1.1). 9.2 After the Placement of Purchase Order prior to taking up of manufacture of

Bearings

a. Detailed Quality Assurance Plan (QAP). b. Ultrasonic testing procedures for SS 440C material for bearing rings.

c. Heat treatment procedures for SS 440C material for bearing rings.

d. Fluorescent magnetic particle testing procedure for bearing rings.

e. Triple axis radiographic examination procedure for Balls.

f. Crushing load test procedure for Balls.

g. The manufacturing schedule with imminent check points.

h. Three sets of drawings of the water lubricated bearings specifying all details of

materials, dimensions etc. for Purchaser’s approval.

i. Packing procedures to be adopted. Manufacture of bearings shall be taken up only after obtaining clearance from the

Purchaser. 9.3 At the Time of Final Shipment of Bearings All certificates, inspection reports, test results (see para 8.3) shall be furnished. 10.0 SUB-CONTRACTING



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Any or part of the work by the Supplier shall be sub-contracted only with the written consent from the Purchaser. The Supplier shall be responsible to the Purchaser for all the work sub-contracted by him.

11.0 APPROVAL OF SUPPLIER’S DRAWINGS AND PROCEDURES BY THE

PURCHASER 11.1 As specified elsewhere in the specification, various manufacturing documents,

inspection reports, inspection procedures, manufacturing drawings etc. are to be submitted to the Purchaser by the Supplier. Verification and approval of the above is for the benefit of the Purchaser and shall not relieve the Supplier from full responsibility for ensuring correct interpretation of drawings and specifications or for the completeness and accuracy of the shop drawings and procedures submitted by the Supplier.

11.2 Waiving of quality requirements or acceptance of parts shall not relieve the Supplier

from the responsibility of furnishing parts and workmanship in accordance with the terms of the contract.

12.0 ADDITIONAL INSPECTION AND TESTS

In addition to the inspection and tests indicated in this specification, the Purchaser shall have the right to ask for additional inspection or testing as he deems necessary and the additional cost for such inspection and tests shall be borne by the Purchaser.

13.0 HISTORY DOCKET

The manufacturer shall furnish to the Purchaser five (5) copies of Inspection History Docket covering all aspects of manufacture, inspection and testing such as heat treatment records, mechanical testing records, dimensional inspection etc. All these documents shall be signed by a responsible technical person of the manufacturer.

14.0 WARRANTY

Warranty period for each assembly shall be 24 months from the date of shipment of Water lubricated Bearing or 6 months from the date of actual use whichever is earlier.

15.0 PURCHASER’S DRAWINGS, SPECIFICATIONS, SAMPLES ETC.



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15.1 Purpose

All drawings, specifications, patterns, samples, models and prototypes that may be furnished to Supplier by Purchaser are the property of Purchaser and are intended to be complementary and to provide for and comprise every thing necessary for the completion of works/supply. These are not to be used for any works or performance other than those for which these have been provided and shall be returned to Purchaser immediately on completion of work/supply, in good condition.

15.2 Property of Purchaser

If, during the process of execution of the contact, any improvement, refinement or technical changes and modifications are effected by Supplier, such changes shall not affect the title to the property of Purchaser and all the information, specifications, drawings etc including the improvement/ modifications effected by Supplier shall continue to be the property of Purchaser. Supplier shall not have any claim or rights whatsoever in respect of Purchaser’s drawings, specifications, patterns, prototypes etc. even where improvement, refinement, modifications etc. have been effected by Supplier.

15.3 Confidential Information

The drawings, specifications, patterns, samples, models, prototypes and such other information furnished to Supplier relating to the supply/works, sub-system/equipment etc. are to be treated as confidential which shall be held by Supplier in confidence and shall not be divulged, transferred, exchanged, gifted or communicated to any third party without the prior written consent of Purchaser. Supplier therefore binds himself, his successors, heirs, executors, administrators, employees and the permitted assignees or such other persons or agents directly or indirectly concerned with the works/supply to the confidential nature of the drawings, specification, prototypes samples etc.



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APPENDIX-1

TECHNICAL SPECIFICATION FOR SS 440C BARS FOR MANUFACTURE OF WATER LUBRICATED BEARINGS

1.0 SCOPE

This specification establishes the requirements for manufacture, inspection, testing and supply of Electro Slag Refined (ESR) or Consumable Electrode Vacuum Arc Re-melted (CVAR) quality 440C Stainless Steel Bars for manufacture of bearing rings of Water Lubricated Bearings.

2.0 STEEL MAKING PROCESS 2.1 The bars to be supplied as per this specification are to be made of 440C stainless

steel. The steel shall be made by a process that is capable of producing high quality product and shall be either Electro Slag Refined (ESR) or Consumable Electrode Vacuum Arc Re-melted (CVAR) quality to meet the requirements of this specification.

2.2 All bars shall be hot rolled /forged, rough machined or peeled. 2.3 Unless otherwise specified the dimensional tolerance of all the bars shall be governed

by the requirement of ASTM-A-484. 2.4 Bars shall be supplied in annealed condition. 3.0 INSPECTION & TESTING REQUIREMENTS 3.1 Chemical Analysis

Chemical analysis of each heat of steel shall be made in accordance with the test methods of ASTM-A-751. The steel shall conform to the following chemical composition: Carbon : 0.95 to 1.10 Manganese : 1.00 (max) Phosphorus : 0.025 (max.) Sulphur : 0.025 (max.) Silicon : 1.00 (max.) Chromium : 16.00 to 18.00 Nickel : 0.75 (max.) Copper : 0.50 (max.) Molybdenum : 0.40 to 0.65



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Two product samples shall be analysed at random for each heat in accordance with ASTM-A-751. The chemical composition as analysed shall meet the requirements specified above.

3.2 Macroetch Testing

Specimens representative of cross section of billets shall be macroetched and rated in accordance with Test Methods ASTM-E-381 acid and water (1:1) at 160 to 180o F (71 to 82oC). Acceptance standard shall be equal or better than: a. Plate-1 of ASTM-E-381

Sub-surface condition - S2 Random condition - R2 Centre segregation - C2

b. Plate-II of ASTM-E-381

1. Centrally located ring patterns up to a maximum of 60 mm dia only are acceptable.

2. Flute, cracks, gassy appearance, butt tears, splash, flakes, etc. are not acceptable to any degree.

3.3 Inclusion Rating Micro-inclusion rating tests shall be carried out in accordance to the methods

specified in ASTM-E-45. The average of the worst fields for each inclusion types for a heat shall be equal or better than:

A, B & C types of inclusion - 1.0 thin - 0.5 heavy D type of inclusion - 1.5 thin - 0.5 heavy 3.4 Response to Heat Treatment Specimens with sections 9.5 mm in thickness cut from a bar, billet, forging shall be

placed in a furnace that is at 1875 ± 10oF (1023.8 ± 5.5oC), allowed to heat to 1875 ± 10oF, held at this temperature for 25 minutes and cooled in still air. The hardness of such specimens shall not be less than 58 HRC. Also, samples heat treated as above shall show a fracture grain size of No.6 or finer.



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3.5 Micro Structure and Hardness

The steel shall be free of excessive carbide segregation and when annealed the steel shall have a spherodized micro structure and hardness shall be 255 BHN maximum.

3.6 Visual Inspection

Prior to packaging, all the bars that are ready for shipment shall be 100% visually examined for any cracks or other unacceptable injurious defects that can be visually seen. For acceptance, the bars shall not have any visual cracks or other injurious defects.

3.7 Non-Destructive Test Requirements 3.7.1 General

All non-destructive tests set forth below shall be carried out on the bars after completion of annealing and machining (centreless grinding /turning/peeling) operation.

3.7.2 Magnetic Particle Examination All bars of all sizes shall be inspected by wet magnetic particle examination in

accordance with ASTM-E-138. Acceptance standard shall be as follows:

a. Only indications with major dimension greater than 1.5 mm shall be considered relevant.

b. The following relevant indications are unacceptable: 1. Any linear indication greater than 1.5 mm long for bars less than 15 mm diameter,

greater than 3.1 mm long for bars from 15 mm diameter to under 50 mm diameter, and 4.7 mm long for bars 50 mm diameter and greater.

2. Rounded indications with dimensions greater than 3.1 mm for bar diameters less

than 15 mm and greater than 4.7 mm for bar diameter 15 mm and greater.

3. Four or more indications in a line separated by 1.5 mm or less edge to edge.

4. Ten or more indications in any 3800 sq.mm of area whose major dimensions is not more than 150 mm with the dimensions taken in the most unfavorable location relative to the indications being evaluated.



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c. Any indications in excess of the acceptance standards at para (b) above which is

believed to be non relevant shall be regarded as a defect and shall be re-examined to verify whether or not actual defects are present. No relevant indications and broad areas of pigmentation, which would mask indications of defects, are unacceptable.

d. All bars shall be demagnetized after magnetic particle examination. Residual

magnetism in the bars shall be less than 2 gausses. 3.7.3 Ultrasonic Examination All bars of size 50 mm diameters and above shall be 100% ultrasonically examined

over the entire surface. Ultrasonic examination of each bar shall be carried out in accordance with specifications ASTM-A-388 and ASTM-A-745 using straight beam technique from two directions approximately at right angles to each other. The entire volume of each bar shall be examined.

Acceptance Standard

Acceptance standard shall be as per reference block having defect standard of 2.0 mm diameter flat bottom hole. Indications from a defect more than that from 2.0 mm diameter flat bottom hole in the defect standard shall be a cause for rejection of the bar.

4.0 IDENTIFICATION AND MARKING OF BARS 4.1 Each bar shall be identified with the relevant heat number punched on both end faces

and logo. 5.0 TEST REPORTS TO BE FURNISHED BEFORE SHIPPING THE

MATERIAL Certificates, test reports and inspection reports signed by a responsible technical

representative of the Supplier covering all tests and analyses shall be furnished to the Purchaser. When inspection or testing is subcontracted to an outside agency the certificates/and reports shall be signed by a responsible technical representative of such agency and countersigned by the supplier.

The following certified test reports shall be furnished to the Purchaser and

Purchaser’s acceptance of material shall be obtained. All the test reports shall be appropriately co-related with the heat number and size of the bars.



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_____________________________________________________________________________________________ 35221/PC-E-289 June 2008

5.1 Steel melting process. 5.2 Test reports for chemical analysis as per para 3.1 above. 5.3 Test reports of macroetch tests as per para 3.2 above. 5.4 Test reports of inclusion rating tests as per para 3.3 above. 5.5 Test reports of response to heat treatment as per para 3.4 above. 5.6 Test reports of microstructure and hardness as per para 3.5 above. 5.7 Certificate of visual examination that the bars supplied are free from visual defects

(para 3.6). 5.8 Test reports for magnetic particle and ultrasonic examinations carried out on each bar

(para 3.7). 5.9 Certificate stating that identification of bars has been done as per para 4.0 above. 5.10 Certificate of compliance. 6.0 QUALITY SURVEILLANCE 6.1 The overall quality control of procurement of the bars shall be the responsibility of

the water lubricated bearing supplier. However, the bars procured shall be subject to quality surveillance by Purchaser or his authorized representative by verification/witness of inspection / test reports of chemical analysis and mechanical/NDT tests.

6.2 Clearance shall be obtained from Purchaser or his authorized representative before

taking up the machining of these bars. 6.3 Items found unsatisfactory as per the requirements of this specification or items with

any defects beyond acceptable limits specified, showing up during machining, shall be replaced by water lubricated bearing supplier by items which are satisfactory.

6.4 Bars found unsatisfactory as to workmanship or material shall be removed by the

supplier and replaced by bars, which are satisfactory.