AA 195 11

CORPORATE PURCHASING SPECIFICATION Rev. No. 09

PAGE 1 OF 6

CARBON STEEL CASTINGS-FUSION WELDING QUALITY

1.0 GENERAL

This specification governs the quality requirements of Carbon Steel Castings-Fusion

Welding Quality.
The Information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED

2.0 APPLICATION
It must not be used directly or indirectly in any way detrimental to the Interest of the company.

For pressure containing parts for high temperature service and of quality suitable for
assembly with other castings or wrought steel parts by fusion welding.

3.0 CONDITION OF DELIVERY

Normalised / Normalised & tempered

COPYRIGHT AND CONFIDENTIAL

Rough machining of the castings shall be carried out, unless otherwise specified in BHEL
order/drawing.

Castings shall not be painted

4.0 COMPLIANCE WITH NATIONAL STANDARDS

There is no Indian standard covering this material. However, assistance has been derived
from ASTM A 216-1993, Gr: WCC, in preparing this specification.

5.0 DIMENSIONS AND TOLERANCES

The castings shall be true to the pattern/drawing.

Holes for machining up to and including 50 mm in diameter are to be cast solid, unless
otherwise stated in BHEL order/drawing.

Unless otherwise specified in BHEL order/drawing, untoleranced dimensions for the

castings shall be as per tolerance class 4 of BHEL standard AA 023 04 02.

APPROVED :
Revisions :
INTERPLANT MATERIAL RATIONALISATION
36th MOM of MRC-FCF+HTM COMMITTEE-MRC (FCF+HTM)

Rev. No. 09 Amd.No. Reaffirmed Prepared Issued Dt. of 1st Issue

Dt: 01.10.2005 Dt : Year;04-11-2011 HYDERABAD Corp. R&D MARCH, 1978
AA 195 11
Rev. No. 09 CORPORATE PURCHASING SPECIFICATION

PAGE 2 OF 6

6.0 MANUFACTURE

The steel for the castings shall be made by basic electric furnace process or such other
process as may be agreed to between BHEL and the manufacturer.

The steel shall be fully killed.

7.0 HEAT TREATMENT

Heat treatment shall be carried out at suitable temperatures to give the properties specified.

Any flame or arc cutting which may have to be done, shall be carried out before heat
treatment.

Test pieces shall also be heat treated along with the castings they represent.

8.0 FINISH
All castings shall be properly fettled and dressed and all surfaces shall be thoroughly cleaned.

Machined surfaces shall have the surface finish as indicated in the drawing

9.0 FREEDOM FROM DEFECTS

Castings shall be free from defects such as porosity , blow holes, sand inclusion, shrinkage,
cavities, hard spots, cold shuts, cracks, etc., which may adversely affect machining and utility
of castings.

When it is necessary to remove risers by flame cutting, care shall be taken to make the cut at
a sufficient distance from the body of the casting so as to prevent any defect being introduced
into the casting due to local heating.

10.0 CHEMICAL COMPOSITIION

The melt analysis of steel and the permissible variation in the composition of the castings
from the melt analysis shall be as specified below:

Melt analysis, Permissible

Element Percent, max Variation, percent

*Carbon 0.25 0.02

Silicon 0.60 0.05
*Manganese 1.20 0.06
Sulphur 0.045 0.008
Phosphorus 0.040 0.008
------------------------------------------------------------------------------------------------------------------
 AA 195 11
CORPORATE PURCHASING SPECIFICATION Rev. No. 09

PAGE 3 OF 6

Note: 1. In the interest of uniform welding, the concentration of the unspecified alloying
elements shall not exceed the limits specified below. Whenever specified in the
enquiry/order, the test results of these elements shall also be included in the test
certificate. However, the manufacture shall ensure that these elements are within
the limits specified.

Element Percent, Max.

Copper 0.30
Nickel 0.50
Chromium 0.50
Molybdenum 0.20
Vanadlum 0.03

1. Total content of these unspecified elements 1.00

2. For each reduction of 0.01% below the specified maximum carbon content, an increase
of 0.04% Mn above the maximum specified will be permitted up to a maximum of 1.40%.

11.0 TEST SAMPLES

Manufacturers shall carryout mechanical testing as per following sampling plan.

11.1 Unless otherwise specified for castings weighting up to 500 kg. piece weight one keel block,
separately cast per melt per heat treatment batch shall be supplied according to the sketch
given below:

11.2 Unless otherwise specified castings weighing more than 500 kg shall be provided with
integrally cast keel block.

11.3 Retests shall be carried out as per IS : 8800

11.4 Keel blocks with proper identification and representative of the castings shall be supplied
along with the consignment for testing at BHEL works.
AA 195 11
Rev. No. 09 CORPORATE PURCHASING SPECIFICATION

PAGE 4 OF 6
DETAIL OF KEEL BLOCK

12.0 MECHANICAL PROPERTIES:

The test pieces, after being heat treated as per clause Cl.7.0 above, shall show the following
properties:

12.1 Tensile

The test pieces shall show the following properties when tested in accordance with ASTM A
370

Tensile strength : 485 - 655 N/mm2

Yield strength : 275 N/mm2, min.
Elongation on 50mm gauge length : 22 percent, min.
Reduction in area : 35 percent, min.

12.2 Hardness (Brinell): for information only:

150 - 205 HB.

13.0 NON-DESTRUCTIVE TESTS:

The following tests shall be conducted:

1) Ultrasonic examination to BHEL standard AA 085 01 04 / AA 085 01 05

2) Liquid penetrate examination to BHEL standard AA 085 0131.
3) Magnetic particle examination to BHEL standard AA 085 01 33 and norms of acceptance
as per BHEL standard AA 085 01 34.

Norms of acceptance shall be as specified in BHEL order/drawing

 AA 195 11
CORPORATE PURCHASING SPECIFICATION Rev. No. 09

PAGE 5 OF 6

14.0 REPAIR OF CASTINGS

The manufacturer without the prior permission of BHEL shall not carry out repair of castings.

15.0 SCOPE OF THIRD PARTY INSPECTION:

Wherever, separate quality plan is not attached, the scope of third party inspection shall be
as follows:

1. Review of supplier’s declared chemical composition.

2. Selection of test samples for mechanical tests and witness of mechanical tests.
3. Witness of Non-destructive tests as applicable.
4. Review of HT charts.
5. Dimensional inspection.

16.0 TEST CERTIFICATES

Three copies of test certificates shall be supplied unless otherwise stated in BHEL order,
preferably in the test certificate format annexed to this specification (Annexure -1).

In addition, the supplier shall ensure to enclose one copy of the test certificate along with their
dispatch documents to facilitate quick clearance of the material.
The test certificate shall bear the following information:

i) Dimensional inspection.
ii) Detail of heat treatment
iii) Chemical composition & unspecified alloying elements whenever called for
iv) Results of mechanical tests
v) Results of NDT tests.

17.0 PACKING AND MARKING

Castings shall be suitably packed to prevent corrosion and damage during transit. Machined
surfaces shall be properly protected with anticorrosive compounds. Each package or casting
(when supplied separately) shall be legibly marked with the following information.

AA 195 11: C.S. Castings - F.W. Quality

BHEL Order No.
Consignment/Identification No.
Melt No.
Weight
Supplier's Name
18.0 REFERRED STANDARDS (Latest Publications Including Amendments):

1. AA 023 04 02 2. AA 085 01 04 3. AA 085 01 05 4. AA 085 01 31

5. AA 085 01 34 6. ASTM A 216 7. ASTM A 370 8. IS : 8800
AA 195 11
Rev. No. 09 CORPORATE PURCHASING SPECIFICATION

PAGE 6 OF 6

ANNEXURE 1 - RECOMMENDED TEST CERTIFICATE FORMAT FOR CASTINGS