General Technical Specifications for CS & SS Pipes and Pipe Fittings
1.
Quotation should clearly indicate that supply of items are confirming to
specifications and typical QA plans given in this specification.
2.
Supply of pipe shall be only from reputed Indian manufacturers. Original
Manufacturer’s test certificate and heat treatment details (co-relatable with heat
no.) shall be offered to NPCIL-QA for verification of heat no., mechanical &
chemical properties and hydro-test details. A copy of same duly signed by NPCIL
QA shall accompany the supply.
3.
In case of non availability of original manufacturers test certificates of Indian
manufactured pipes the whole lot of material shall be subjected to material
testing, i.e., mechanical properties & chemical composition checking (minimum of
two samples/size/heat/lot and maximum as decided by NPCIL-QA) at NPCIL
Approved labs in front of NPCIL representative witnessing. In case of failure of
item while Testing, the testing charges will not be given to the supplier.
4.
In case Indian manufacturers are not available for that item, foreign
manufactured item will be acceptable. In that case, the supplier should mention
the make & origin of the material in his offer and the whole lot of material shall
be subjected to material testing (one sample per each length or sample size as
decided by NPCIL-QA) at NPCIL approved labs in front of NPCIL-QA witnessing.
However products, those made in China, are not acceptable.
5.
Hence supplier should quote the testing charges per sample basis (inclusive of
cost of sample or pipe length used for testing) separately in the quotation.
Payment will be made only for the supplied length or supplied quantity only. For
mechanical testing; testing charges per sample shall be quoted for both
mechanical and chemical testing.
6.
If original manufacturer test certificate (co-relatable with heat no) is available and
NPCIL-QA insist for additional tests on sample selected by QA engineer, the same
shall be tested at NPCIL approved or Govt. approved lab with NPCIL-QA
witnessing. The testing charges will be paid as per offer/PO clauses. Positive
Material Identification (PMI) test or any spectrography test in place lab testing is
not acceptable.
7.
Manufacturer’s Mill Test Certificate shall indicate, wherever applicable, results of
Heat treatment (solution annealed), 100% Hydrostatic pressure test along with
other details. However micro-test for solution annealed and Hydrostatic pressure
test are not required.
8.
Supplier shall execute 100% testing as indicated in QA Plan and submit internal
reports to NPCIL-QA for review and supplier is required to do the same tests for
20% of quantity in presence of NPCIL-QA engineer or witness by NPCIL-QA. In case
of failure of material, during NPCIL QA witnessing the whole lot of that size item
will be rejected.
9.
All materials will be subjected to pre-dispatch inspection and material shall be
dispatched only after inspection and issue of shipping release by NPCIL QA.
10. If supplier doesn’t agree to the above conditions, the offer will be summarily
rejected without further review.
11. Material identification such as mark/stamp and heat no. /lot no shall be available
on each item as per ASME standards
12. Wall thickness measurement for pipes and pipe fittings are to be done through
ultrasonic thickness gauge as per ASME Boiler & Pressure vessel code Sec-V-1998SE-797. Wall thickness measurement shall be done randomly at any cross section of
the fitting for 100 % of items by the supplier. The report of wall thickness
measurement shall be submitted to NPCIL QA for review before 20% witnessing.
13. Procedure for testing of IGC or Ultrasonic examination (applicable only for SS
pipes & pipe fittings) shall be prepared by level-II qualified operator and
submitted for approval of purchaser, prior to inspection.
14. The NDT testing done only by qualified personnel only will be acceptable.
15. Necessary measuring instruments shall be given along with calibration certificate
for carrying out measurements.
16. Pipe surface inside and outside should be clean and free from any dent or corrosion
mark.
17. Supplier shall take care that the testing marks/indentations shall be on the least
important face/ part of component, to ensure sealing faces.
18. Dimensional checks to be done as per the respective ANSI standards.
19. No rectification of damages by any means is allowed. However prior approval shall
be obtained for rectification.
20. Both the ends of pipe shall be protected by PVC caps to avoid transit damage and
entry of foreign material.
21. Pipe lengths shall be within 5 to 7mtrs length each.
22. +/-10% quantity tolerance is acceptable.
23. For pipe fittings; samples for testing will be taken from raw material pipe prior to
fabrication; hence only offers from manufacturers are preferable. If traders quote,
Acceptance certificate for the same shall be submitted.
24. GI pipes and GI pipe fittings are excluded from QA inspection. However inspection
of these materials will be done at site on receipt. Hence Mill test certificates shall
be furnished along with material. If advance payment involves; PDI will be
incorporated.
25. The material shall be packed properly to avoid damages during transit. If items
found in damaged condition on receipt at site, the material may get rejected even
after QA inspection & clearance by NPCIL QA.
26. No manufacturer’s TC in Xerox will be considered as original under any
circumstances
27. No manufacturer’s TC issued in the name, other than the vendor, on who order going
to be placed, will be considered original.
28. In case of original correlated manufacturer’s TC, number of test samples will be as
per relevant material Specification, Or else number of test samples shall be drawn
by NPCIL Engineer, that will depend upon the quantity, size etc. and be sufficient to
have an confidence about the property of the material ,their repeatability and
consistency.
29. Performance bank guarantee is not applicable as these items are raw material in
nature.
30. Mechanical testing other than hardness test is not applicable for fittings less than
2”NB.
TECHNICAL SPECIFICATIONS FOR STAINLESS STEEL SEAMLESS PIPE AND PIPE FITTINGS:
1.
All SS pipes shall conform to ASME SA 312 TP 304L and dimensions to ANSI B
36.19M.
2.
All SS pipe fittings material shall be conform to ASME SA 182 F304L or ASME SA 403
WP 304L and dimensions to ANSI B 16.9 & 16.11.
3.
All SS flanges shall confirm to ANSI B 16.5 and 16.25.
4.
IGC test as per SE-262 Pr-A shall be carried out, if gets failed in practice-‘A’;
Practice-‘E” shall be carried out for all pipe, pipe fittings and flanges.
5.
Thickness measurement for pipe and pipe fittings shall be carried out as per SE-797
(100% by supplier and 20% witnessing by NPCIL-QA).
6.
All pipes shall be tested for uniformity & flaw detection by ultrasonic examination
as per SE-213. Preparation of specimen/blocks, notch cutting, verification of
machined specimen/blocks, and calibration of equipment as per approved
procedure are in scope of supplier. The Calibration block preparation for UT flaw
measurement is under scope of supplier. Supplier shall carry out test for 100%
quantity with approved qualified personnel and submit the report to NPCIL-QA.
Witness by NPCIL-QA on 20% random selected samples will be done after review of
report. The supplier should ensure the thorough cleaning of ID & OD of pipes after
UT testing.
7.
In case of ultrasonic examination is not feasible for small size pipes, Eddy current
test shall be carried out as per Section- XI, Appendix - IV and Section - V Article 8 of
the ASME Code - 2001.
8.
The supplier shall submit all internal reports, original MTC, dimensional reports to
NPCIL –QA for review. Based on review, witness inspection by NPCIL-QA will be made.
9.
QAP shall be submitted for approval, however draft QAP has been attached. Separate
QAP for SS pipes and SS pipe fittings shall be prepared.
Quality Assurance plan for Stainless steel pipes
S.
Operation
No.
Inspection by
Supplier
Inspection by NPCIL- Remarks
QA
1.
Chemical Analysis
Verification of
co-relating MTC
2.
Mechanical
Verification of
1. Review of co-relatable
MTC.
2. Sample collection and
test witness, if required.
1. Review of co-relatable
To be verified for each Heat .no.
Analysis shall be done from
NPCIL approved lab only.
To be verified for each Heat .no.
Analysis
co-relating MTC
Verification of
relating MTC
4.
Hydrostatic test
(Verification
of
Material
Test
Certificates
–
Original / endorsed)
Visual inspection
5.
Dimensional check
6.
8.
IGC Test as per
ASTM-E_262
Practice –‘A’/‘E’
Ultrasonic
Examination
Marking
9.
Packing
10.
Issue of inspection
Certificate
&
shipping Release
Checking for
Certificates &
enclosed for
shipment
3.
7.
11.
MTC.
2. Sample collection and
test witness, if required.
Verification of co-relatable
MTC
Analysis shall be done from
NPCIL approved lab only.
100% Visual
inspection
100% Visual inspection
Rust preventive oil/coating
should be removed before visual
inspection. No Dents/ corrosion
marks are permitted.
100% Dimensional
check. (OD, Wall
thickness, length
etc.)
One sample from
each heat no.
20% Dimensional check.
(OD,
Wall
thickness,
length etc.)
Ultrasonic Thickness Gauge
to be used for wall thickness
measurement.
One sample from per each
heat no.
As per Standard A-262;
100% as per
ASTM-SE-213
100% for checking
the Markings.
Checking for
proper packing
NA
20% as per ASTM-SE213
100% for checking the
Markings
NA
Calibration block preparation is
under scope of supplier.
Each pipe shall be marked as
given in ASTM A106 & A530.
Provision of PVC Caps at free
ends of the pipes to be ensured.
------
Check for all the
enclosed documents
N.A
co-
Issue of inspection report
& Shipping Release.
To be verified for each Heat .no.
-------
Typical QA plan for Stainless steel pipe fittings Butt weld end.
S.
No.
Operation
Inspection
Supplier
by
1. Chemical Analysis
Verification
MTC
of
2. Mechanical Analysis
Verification
MTC
of
3. Visual inspection
100%
inspection
4. Dimensional check
100% Dimensional
check
Visual
Inspection by NPCIL- Remarks
QA
1. Review of co-relatable
MTC.
2. sample collection and
test witness, if required.
1. Review of co-relatable
MTC.
2. sample collection and
test witness, if required.
100% Visual inspection
RANDOM
Dimensional
check: 20% of the offered
quantity in each type of
fittings. Wall thickness will
be measured at any cross
section
of
the
fitting(especially
at
extradoss area of the
Analysis shall be done from
NPCIL approved lab only. To
be verified for each Heat no.
MTC shall be of NPCIL
approved lab. To be verified
for each Heat no.
Rust preventive oil/coating
should be removed before
visual inspection. No Dents/
corrosion marks are permitted.
Wall
thickness
measurement to be
done by ultrasonic
thickness gauge. In case
of any deviation is found in
the random inspection, entire
quantity of the particular item
5. IGC Test as per
ASTM-E_262
Practice –‘E’
6. Material
identification mark/
stamp
One sample from
each heat no/lot
no.
100% for checking
the Markings.
7. Packing
Checking
for
proper packing
NA
8. Issue of inspection
Certificate
&
shipping Release
9. Checking
for
Certificates enclosed
for shipment
elbows)
100% witness
will be rejected.
Test witness by NPCIL-QA.
100% for checking the
Markings
Each fitting shall be marked as
given in ASTM A 234
standard.
Check for all the
enclosed
documents
NA
Issue of inspection report &
Shipping Release.
------
N.A
-------
TECHNICAL SPECIFICATIONS FOR CARBON STEEL SEAMLESS PIPE AND PIPE FITTINGS:
1. All CS pipes shall conform to ASME SA 106 Gr-B and dimensions to ANSI B 36.10M.
2. All CS pipe fittings material shall be conform to ASME SA 105N or ASME SA 234 Gr
WPB (for BW fittings) and dimensions to ANSI B 16.9 & 16.11.
3. All CS flanges shall confirm to ANSI B 16.5 and 16.25.
4. Thickness measurement for pipe and pipe fittings shall be carried out as per SE-797.
100% by supplier and 20% witness by NPCIL-QA.
5. The supplier shall submit all internal reports, original MTC, dimensional reports to NPCIL
–QA for review. Based on review, witness inspection by NPCIL-QA will be made.
6. QAP shall be submitted for approval however draft QAP has been attached. Separate
QAP for SS pipes and SS pipe fittings shall be prepared.
Typical Quality Assurance plan for Carbon steel pipes
S.
No.
Operation
Inspection by
Supplier
1.
Chemical Analysis
Verification of
relating MTC
co-
2.
Mechanical Analysis
Verification of
relating MTC
co-
3.
Hydrostatic test
Verification of
(Verification of
relating MTC
Material Test
Certificates –Original
/endorsed)
co-
Inspection by
NPCIL- QA
Remarks
1. Review of co-relating
MTC.
2. Sample collection and
test witness, if required.
1. Review of co-relating
MTC.
2. Sample collection and
test witness, if required.
Verification of
corelating MTC
Analysis shall be done
from NPCIL approved lab
only. To be verified for
each Heat no.
MTC shall be of NPCIL
approved lab. To be
verified for each Heat no.
To be verified for each
Heat .no.
4.
Visual inspection
100% Visual inspection
100% Visual inspection
5.
Dimensional check
100%
Dimensional
check.
(OD,
Wall
thickness, length etc.)
100%
Dimensional
check.
(OD,
Wall
thickness, length etc.)
6.
Marking
100% for checking the
Markings.
100% for checking the
Markings
7.
Packing
Checking
packing
NA
8.
Issue of inspection
Certificate
&
shipping Release
Checking
for
Certificates enclosed
for shipment
NA
Issue of inspection report
& Shipping Release.
Check
for all the
enclosed documents
N.A
9.
for
proper
Rust
preventive
oil/
coating should be removed
before visual inspection.
No Dents/ corrosion marks
are permitted.
Ultrasonic
Thickness
Gauge to be used for wall
thickness
measurement.
(Randomly at any location
of the each pipe)
Each pipe shall be marked
as given in ASTM A106 &
A530.
Provision of PVC Caps at
free ends of the pipes to be
ensured.
------
-------
Typical QA plan for Carbon steel pipe fittings Butt weld end.
S.
No.
Operation
Inspection by
Supplier
Inspection by NPCILQA
Remarks
1. Review of
co-relating
MTC.
2. Sample collection and
test witness if required.
1. Review of
co-relating
MTC.
2. Sample collection and
test witness if required.
100% Visual inspection
Analysis shall be done from
NPCIL approved lab only. To
be verified for each Heat no.
1.
Chemical Analysis
Verification of
MTC
2.
Mechanical Analysis
Verification of
MTC
3.
Visual inspection
100% Visual
inspection
4.
Dimensional check
100%
Dimensional
check
for
the
RANDOM
Dimensional
check: 20% of the offered
quantity in each type of
fittings. Wall thickness will
be measured at any cross
section
of
the
fitting(especially
at
extradoss area of the
elbows)
100% for checking the
Markings
5.
Material
identification mark/
stamp
100%
checking
Markings.
6.
Packing
Checking for
proper packing
NA
7.
Issue of inspection
Certificate
&
shipping Release
NA
Issue of inspection report &
Shipping Release.
MTC shall be of NPCIL
approved lab. To be verified
for each Heat no.
Rust preventive oil/coating
should be removed before
visual inspection. No Dents/
corrosion marks are permitted.
Wall
thickness
measurement to be
done by ultrasonic
thickness gauge. In case
of any deviation is found in
the random inspection, entire
quantity of the particular item
will be rejected.
Each fitting shall be marked as
given in ASTM A 234
standard.
Shall
provide
adequate
packing to avoid transit
damages to fittings.
------
8.
Checking
for
Certificates enclosed
for shipment
Check for all
the
enclosed
documents
N.A
-------
Note:
1. Tenderers, who supplied similar materials with inspection to NPCIL, shall sent the POs and
inspection reports along with offer.
2. The tendered shall be aware of all testing procedures, NPCIL-QA inspection processes and
requirements before submitting their offer.
3. Supplier shall have original manufacturer test certificates with heat treatment details and
hydro static test details.
4. The offer with ready stock or within 7 days delivery period (excluding inspection process)
will be considered.
5. The below attached form for details of testing done shall be filled and sent along with
material dispatch for every shipping release and DC.
**********
***********
************
(To be filled by supplier)
PO No.: CMM/MAPS/
Supplier Name and address:
dtd.
Material Testing:
PO Sl. No.
Heat no. / Lot
no.
No. of samples
tested for
physical and
Chemical
Shipping Release No.:
QA witness
stamp made on
lab report
Y/N
Y/N
Y/N
Y/N
IGC testing (for SS pipe and pipe fittings)
PO Sl. No.
Heat no. / Lot
No. of samples
no.
tested for IGC
testing
Whether QA
witness with
stamp made on
lab report
Y/N
Y/N
Y/N
Ultrasonic Examination SE-213 (for SS pipes)
PO Sl. No.
Qty in meters
No. of lengths (one length
is 6 mtrs)
Testing
details
Material
testing
(Chemical &
Physical)
IGC testing
No. of
samples
N
NPCIL-QA stamp
punched on
each
component
Y/N
Y/N
Y/N
Y/N
Remarks
Whether Test report duly
signed by NPCIL-QA
attached
Y/N
Y/N
Y/N
Y/N
Testing charges per
sample/length
T
Amount
A=N X T or
lumpsum
Ultrasonic
Examination
Total amount claimed ∑A:
(Rupees………………………………………………………………………………………………only)
Marking as per standards are made on each component & rounded with
paint
NPCIL-QA stamp punched on each component and rounded with paint
Whether All Lab reports of Mechanical testing, IGC testing, Ultrasonic
examination reports, Ultrasonic thickness measurement report,
Dimensional report duly signed by NPCIL-QA with stamp are attached
Copy of Original manufacturer’s Mill test certificates duly verified and
signed by NPCIL-QA with stamp are attached in same order
Po sl.no. of each item shall be indicated in its corresponding LAB reports,
MTC, other reports etc (either with pencil or pen)
In additional to above, whether booklet is made with copies of following
documents and sent along with material dispatch. (3sets)
a. Shipping release copy
b. Quality Surveillance Reports
c. Guarantee certificate
d. Approved QAP
e. DCR copies if any
f. All Lab reports, MTC, etc as indicated above
g. Approved procedure pertaining to above PO
h. Test and calibration certificates of instruments/equipments used
(duly verified and signed by NPCIL-QA)
i. Ultrasonic examination SE-213 reports
j. Ultrasonic thickness measurement reports and Dimensional
report.
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Signature with stamp & date