BHEL,Tiruchirapalli-620014.

Quality Assurance TECHNICAL DELIVERY CONDITION

Product : STEEL CASTINGS.(VALVES)

Document No: TDC:0:412 Rev No : 18 Effective Date: 25.01.2012 Page- 1 of 7

Revision record: Rev 16: 27.04.2011 (1) Modified in entirety.

Rev.17 – 1) Cl.7.0 Table-1 NDE requirements, 2) Cl.7.1, Cl.9, Cl.11.0 – Revised. RT zone Sketch added.
Rev.18 – 1) Cl.7.0 Table-1 Wedge NDE changed, 2) Cl.9.0 – PED requirements for welding & NDE added.
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1.0 MATERIAL:
Specification : ASME / ASTM {Latest on date of Purchase Order (PO)}:
CARBON STEEL (CS) : SA / ASTM A216 WCB, WCC & 352 LCB , LCC
ALLOY STEEL (AS) : SA / ASTM A217 WC6, WC9, C12A.
STAINLESS STEEL (SS): SA / ASTM A351 CF3M,CF8,CF8C & CF8M.
Additional Requirement : As listed below(Supplementary to Specification)
Size, Qty, Grade/Class : As per Purchase order & Drawing / Pattern.

2.0 CHEMICAL COMPOSITION AND PROCESS:

Melting: As per the Specification, Fully Killed.
Carbon= 0.25% maximum : for SA / ASTM A216 WCB only.
Carbon= 0.15% maximum : for SA / ASTM A217 WC6 & WC9 (For the castings used in QCNRV, CRHNRV,TOA
Valves & Conventional valves having contours for welding.)
Product Analysis on test bar for each melt including residual elements shall be carried out.

Additional requirements for API-6D materials:

CS: Carbon=0.23% max.(in ladle) and 0.25% max.(in Product analysis)
Carbon Equivalent=0.43 max.(in ladle) and 0.45 max.(in Product analysis)
Carbon Equivalent=%C+(%Mn/6)+(%Cr+%Mo+%V)/5+(%Ni+%Cu)/15
SS: Carbon=0.03% max. except as below.
Carbon=0.08% max.for stabilized steels with Nb >10xC.and
for stabilized steels with Nb and Ta mass of (Nb+Ta)>8xC.
.
3.0 DIMENSIONS AND TOLERANCES:
Tolerances as per the Drawing.
Non tolerance Dimensions for valve components as per the Drawing:VL:STDC:023 (Latest)

4.0 HEAT TREATMENT :(HT)

CS. Castings of High Pressure Valve.(Cl.1500 & above),QCNRV & CRHNRV: Shall be in Annealed Condition.
AS. Castings: Normalized and Tempered.
Normalizing Temperature: for SA/ASTM A217 WC6, WC9: 920-950 ºC and for C12A: 1050-1080 ºC.
Tempering temperature (Minimum): SA/ASTM A217 WC6: 680ºC; WC9: 720 ºC; C12A: 750-780ºC
Others: Heat Treated as per the Specification.

5.0 MECHANICAL TESTS:

Test bars to be cast integral with the casting or separately. If cast separately, they shall be cast at the same time as
the castings and from the same ladle. A metal strip with heat number stamped shall be fused with the test bar during
casting, to maintain traceability. If one(1) casting is made from more than one heat, separate test bars for each cast
to be poured & all test bars shall satisfy the requirements. Following tests to be conducted per heat / Heat treatment
batch, as per ASTM A370. .

Material specification
S. NO TEST
SA/ASTM A216, 217 SA/ASTM A352 SA/ASTM A 351
1 Tension Test As per the Specification
2 Hardness Test As per the Specification 225 BHN. max. Not applicable
Angle of Dia of
Bend Pin
WCB 90º 2t
3 Bend Test Specimen 1”x ¾" WCC 90º 2t Not applicable S3 of SA703
WC6 120º 3t
WC9 90º 3t
C12A 90º 2t
4 Charpy- U Impact for all QCNRV.CRHNRV As per IBR. at Room temperature.
Not applicable Not applicable
BODIES FOR IBR. Acceptance: Avg /Single=36J/32J min.
5 Charpy- V Impact for CE Marking-Pressure
At 20 Deg.C temperature. As per
Equipment Directive (PED) items as Not applicable
Acceptance: Avg /Single=40J/27J min. Specification
Specified in the Purchase Order.
6 Charpy- V Impact for API -6D items if Test Temperature=As per specification
As per
design temperature below minus 29ºC ( - Acceptance: Avg/Single=34J/25J Not applicable
Specification
29 ºC)
7 Charpy- V Impact for LPBP BODIES At 20 Deg.C temperature.
Not applicable Not applicable
Acceptance: Avg /Single=27J/21J min.
 BHEL,Tiruchirapalli-620014. Quality Assurance TECHNICAL DELIVERY CONDITION

Product : STEEL CASTINGS.(VALVES)

Document No: TDC:0:412 Rev No : 18 Effective Date: 25.01.2012 Page- 2 of 7

6.0 FETTLING, DRESSING & CLEANING:

 Dressing of castings- Free from risers, in gates, notches, undercuts and deep marks etc.
 Fused wires, parting line fins, chills etc. shall be removed by grinding.
 Gas cutting if employed shall be done before Heat treatment.
 Preheat the material to 200 Deg. C. before gas cutting the Alloy steels.
 Castings shall be blast cleaned both inside and outside for the removal of fused sand, scales etc.
 Visual inspection of castings for surface quality as per MSS-SP-55 shall be carried out.

7.0 NON DESTRUCTIVE TESTING (NDT) AFTER HEAT TREATMENT:

The NDE requirements for the castings shall meet the following as shown in Table-1 below.
Castings shall be free from surface and internal defects like porosity, shrinkage, sand inclusion,
crack, cold shut and other harmful defects. All castings shall be of Radiographic Quality.
Radiographic Testing Procedure: As per ASME B16.34.
Magnetic Particle Inspection (MPI): As per ASTM E709
Liquid Penetrant Inspection (LPI): As per ASTM E165
Table: 1
Product Components Charecteristics Type of NDE Check
RT RT Area RT Acc. Std MT $ MT Area
Conventional Body,Bonnet < 600Class 10%# ASME B16.34 (latest) / As per Table: 2 -- --
Valves Pr.part Yoke On critical area as
(Gate, Globe Body,Bonnet, 600Class & 100% indicated in the --
Drawing.
& Check) Cover above
and API 6D Body,Bonnet, 1500Class & 100% 100% All accessible
Gate Valves Cover above surfaces
All Special including belly
Wedge -- -- -- 100%
Class Valves
Base All 10%# Critical Zones as given Class-4 of ASTM 100% All accessible
in the Drawing/ area E446/ E186. surfaces .
Safety Valve Weld ends of 100% shown in the sketch in For Butt weld ends -- --
Page-5. The areas Table-2
All Castings where RT cannot be
carried out MPI shall be
Base & All 10%# done. -- --
Safety Relief Bonnet
Valve SRV Nozzle All 100% All area Class-2 of ASTM -- --
E446/ E186
Body 150 & 300 10% Butt Weld Ends, As per Table: 2 100% All accessible
Class surfaces
including belly
600Class & Critical Zones as given As per Table: 2
QC NRV, above in the Drawing/ area
CRH NRV shown in the sketch in
Body All 100% Page-6. The areas All accessible
100%
(Special) where RT cannot be surfaces
carried out MPI shall be including belly
done.

Body All 10%# Critical Zones as given As per Table: 2 -- --

in the Drawing/ area
shown in the sketch in
Soot Blower
Page-5. The areas
Valve where RT cannot be
carried out MPI shall be
done.
Body < 600Class 100% Critical Zones as given As per Table: 2 --
600Class & in the Drawing/ area --
CRH shown in the sketch in
above
Isolating Page-5. The areas
100%
All accessible
1500Class & where RT cannot be surfaces
Device
above carried out MPI shall be including belly
done.
Body All 100% Critical Zones as given As per Table: 2 -- --
in the Drawing/ area
shown in the sketch in
LP Bypass
Page-6. The areas
Valve where RT cannot be
carried out MPI shall be
done.
$ LPI Can be substituted for MPI in all inaccessible area and for stainless steel castings. # Refer Cl 7.1
 BHEL,Tiruchirapalli-620014. Quality Assurance TECHNICAL DELIVERY CONDITION

Product : STEEL CASTINGS.(VALVES)

Document No: TDC:0:412 Rev No : 18 Effective Date: 25.01.2012 Page- 3 of 7
Table: 2
ACCEPTANCE
TYPE OF < 600 CLASS ≥ 600 CLASS
LEVEL
DISCONTINUITY
CATEGORY Thickness ≤2” Thickness >2” Thickness ≤2” Thickness >2”
Gas Porosity A A2 A3 A1 A2
Sand/Slag inclusion B B3 B3 B2 B2
Shrink Type-1 C CA2 CA3 CA1 CA2
Shrink Type-2 C CB3 CB3 CB2 CB2
Shrink Type-3 C CC3 CC3 CC2 CC2
Crack D NONE NONE NONE NONE
Hot Tear E NONE NONE NONE NONE
Unfused Inserts
F NONE NONE NONE NONE
(Chills/Chaplets)
a. Butt welding ends shall be free of shrinkage, crack & hot tear.
b. For butt weld ends Gas hole/Porosity and sand inclusions to be within level A1 &B1 respectively

7.1 # 10% Sampling shall be done as follows: (Wherever specified):

The vendor shall select 10% the Casting from the lot consisting of same size and type, (along with melt
number and Sl.nos of the castings covered in the lot ) for Radiography. A lot to be specified as the total
number of castings as above, supplied in 4 months period (Jan-Apr, May-Aug, Sep-Dec). The vendor
shall radiograph these specified castings and incorporate the lot size and meltno and Sl.no in the RT
reports along with the other sl.nos of the other castings covered in the lot. If the identified casting is
defective then 2 more castings shall be radiographed.If these 2 castings are defect free then the lot is
acceptable.If any one of these castings is defective then all the remaining castings shall be radiographed
and all defective areas shall be repaired. BHEL will carry out audit on the lots at the vendor works at any
time.
7.2 Acceptance for MPI & LPI: ASME B16.34.
(1)Cracks are not permitted.
(2)For linear indications (with length > 3 times width) other than cracks,indications must be separated by
a distance greater than the length of an acceptable indication. Maximum allowable length of the
indication shall be:
(a) For thickness (t) up to 13mm= 8mm,
(b) For thickness from 13 to 25mm = 13mm
(c) For thickness above 25mm =18mm.
(3)For rounded indications (circular or elliptical with length < 3 times width), 4 or more indications in a
line separated by 1.5 mm or less edge to edge are unacceptable. Maximum allowable diameter of the
indication shall be:
(a)For thickness up to 13mm =8mm, and (b)For thickness above 13mm =13mm
8.0 Development Stage of Casting:
a. During developmental stage, Foundry to ensure, first sample pieces meet dimensional, NDE &
Quality requirements in this TDC, before starting bulk production. Sample castings, 3 Castings
with nominal bore (NB) ≤100mm. & 1 casting with NB > 100mm for each type of casting shall be
inspected for dimension and RT requirements at BHEL/Vendor works. RT shall be carried out on
entire area of the casting to the acceptance requirement of Table-1 & 2. In addition 100% MPI on
all critical areas like change of sections, riser & in gate portions shall be carried out. Casting to be
inspected for dimensions after proof machining wherever necessary. If machining operation is
involved the same shall be done and defect free condition shall be ensured. If any defect noticed in
RT and machining, the type of defect shall be analysed and accordingly size of gate, runner, riser
and pouring methodology to be modified to get defect free casting. Sampling shall be continued till
achieving sound casting. After satisfactory development of sampling bulk production shall be
started. However weld repaired areas identified in visual examination for doubtful indications to be
probed by MPI. Accepted sample castings may be considered for fixing the nominal weight of the
castings.
b. During developmental stage RT on sample castings of yoke, yoke clamp & wedge/disc shall meet
Level-3 of ASTM E446/E186/E280

c. Radiography not required after satisfactory development of casting & production based on
established method for following parts: SRV Bonnet,Disc holder,Upper and Lower adjusting rings,
Packed cap,Cover plate,Yoke and SRV guide flanges
 BHEL,Tiruchirapalli-620014. Quality Assurance TECHNICAL DELIVERY CONDITION

Product : STEEL CASTINGS.(VALVES)

Document No: TDC:0:412 Rev No : 18 Effective Date: 25.01.2012 Page- 4 of 7

9.0 REPAIR:
Castings with unacceptable cracks, hot tears, shrinkage, etc. to be rectified by grinding & if required by
welding. Welding to be done by qualified welder and qualified procedure as per ASME Section IX .For
IBR items welder shall be qualified as per IBR.

Guidelines for repair of Steel castings shall be as per SIP:VS:17 (latest).for activities like defects require/
not require weld repair, welding, Post weld heat treatment, NDE and surface treatment. All repaired
areas after PWHT shall NDE tested and Hardness tested. Hardness shall meet material Specification.

For CE-Marking (PED) casting, permanent joining (welding and weld repair) of components must be
carried out by suitably qualified personnel according to suitable operating procedures. Also Non-
destructive tests of permanent joints must be carried out by suitable qualified personnel. The procedures
and personnel must be approved by a competent third party which, at the manufacturer's discretion, may
be:
- a notified body,
- a third-party organization recognized by a Member State of European Community

10.0 SURFACE TREATMENT:

SS castings to be pickled & passivated (after repair & HT if any) as per ASTM A380. Satisfactory
passivity of the surface to be checked using SS passivity test kit (Free iron test). After passivation,
rinsing & test, the rinsed demineralised water to be checked for chloride with 1% Silver nitride, which
shall not exceed 0.5 PPM

11.0 DIMENSIONAL CHECK:

For all QCNRV & CRHNRV Body Castings: Thickness of the body shall be checked throughout the
surface on a grid of 100mm x 100mm and recorded & submitted to BHEL.

12.0 MARKING AND PACKING:

Following details to be marked on each casting on a raised pad using low stress stamps and Castings
shall be suitably packed to avoid damage during transit.

1. Foundry code, 2.Specification, grade & Melt number, 3.Other details as per drawing.

13.0 INSPECTION AND CERTIFICATION:

13.1: For IBR items
a) If the Foundry is recognized as "Well known Foundry" under IBR, Items shall be inspected by foundry
and works certificate along with IBR Form III F shall be issued.
b) If the Foundry is not recognized as "Well known Foundry" under IBR, Items shall be inspected by an
Inspecting Authority approved by IBR and work certificate along with IBR Form III G shall be issued.
13.2: For CE-marking items, the materails shall be inspected by M/s. LLoyd's/ TUV/ BVQI or anyother
agengy approved for PED of CEmarking, if the foundry is not certified to ISO 9000 by any of the .
above organisation.
13.3 For API items, the castings shall be inspected by the foundry and works certificate with details like
PSL No., Temperature class rating, size shall be issued.

13.4 Test certificates shall contain the following details.

1.Purchase Order No.(BHEL),TDC No. & Test certificate number
2. Specification and Grade with applicable year of code, Heat Number, Quantity & Size
3. Steel making process, Chemistry including incidental elements - Heat wise.
4. Heat treatment details of the material and test bars.
5. Mechanical test results, NDE test results with reference & acceptance standard.
6. Repair details including HT, if any, Cleaning & Surface treatment details.
7. Any other information like clearance of sample casting.
8. Dimensional Inspection Report where applicable.
 BHEL,Tiruchirapalli-620014. Quality Assurance TECHNICAL DELIVERY CONDITION

Product : STEEL CASTINGS.(VALVES)

Document No: TDC:0:412 Rev No : 18 Effective Date: 25.01.2012 Page- 5 of 7

14.0 AUDIT CHECKS AT BHEL:

BHEL reserves the right to carry out audit checks for chemistry, HT condition, mechanical test and NDT
on representative test bars or job. Items found defective during check or subsequent processing at
BHEL are liable for rejection.

15.0 END USE:

For use in valves and other components like flanges, fittings etc. for high temperature & high pressure
applications meeting IBR, ASME Section I, ASME B 16.34, PED and API.

Sketch of zones for RT

SV and SRV Base castings

Radiography Area

Reheater Isolating Device Body

Radiography Area
BHEL,Tiruchirapalli-620014. Quality Assurance TECHNICAL DELIVERY CONDITION

Product : STEEL CASTINGS.(VALVES)

Document No: TDC:0:412 Rev No : 18 Effective Date: 25.01.2012 Page- 6 of 7

Soot Blower Valve Body

R
e
f

Radiography Area

Quick Closing Non Return Valve Body

Section-XX Radiography Area

Cold Re Heat Non Return Valve Body

Section-XX Radiography Area

BHEL,Tiruchirapalli-620014. Quality Assurance TECHNICAL DELIVERY CONDITION

Product : STEEL CASTINGS.(VALVES)

Document No: TDC:0:412 Rev No : 18 Effective Date: 25.01.2012 Page- 7 of 7

LP Bypass Stop cum Control Valve Body

Radiography Area

D.SUDHAKARAN M.RAJAKUMAR S.SELVARAJAN V.RAVIKUMAR

QUALITY ASSURANCE ENGG/VALVES QUALITY ASSUARANCE QUALITY ASSURANCE
PREPARED BY APPROVED BY
REVIEWED BY