“Manufacturing and supply of stainless steel pipe Manufacturing and supply of stainless steel pipe fittings” 1.0 Scope of work This document lists the technical requirements for

“Manufacturing and supply of stainless steel pipe fittings”

1.0 Scope of work

This document lists the technical requirements for manufacture and supply of stainless steelpipe fittings for low conductivity water applications. Pipe fittings consist of connectors,unions and adaptors for pipe assemblies to be used at a pressure of 10 bar (G).

The scope of work includes procurement of stainless steel 316L rods as per ASTM A276,machining, inspection, packing and supply of pipe fittings to RRCAT, Indore.

Bidder shall quote for complete set (see Table-2) and not for individual parts. The bids will beevaluated on the basis of cost of one set of pipe fittings as defined in section 2.3. For thereasons of achieving interchangeability, uniformity, and the quality control of themanufacturing process of pipe fittings, the order shall not be split on different bidders.

Bidder qualification criteria

All lathe operations (Turning, Thread cutting etc.) shall be done on CNC lathe to achieverepeatable dimensions. Bidder shall have CNC lathe not older than 5 years which shall bedeployed for machining the pipe fittings. Details of the make, model, year of manufacturingand a colour photograph of the CNC lathe planned to be used for this job shall be given in thebid.

2.0 Technical requirements

All lathe operations (turning, thread cutting etc.) shall be done on the CNC lathe to achieverepeatable dimensions.

2.1 Manufacturing drawing

Drawings applicable for machining of pipe fittings are mentioned in Table-1.

Table-1

S.N Drawing No. Title

1. RRCAT/IAD/MML/335/R0 sh 1 of 2 Male hose connector

2. RRCAT/IAD/MML/335/R0 sh 2 of 2 Female hose connector

3. RRCAT/IAD/MML/336/R0 sh 1 of 3 Flat seat machined unions withmale/female threaded end connection

4. RRCAT/IAD/MML/336/R0 sh 2 of 3 Flat seat machined unions with hoseend connection

5. RRCAT/IAD/MML/336/R0 sh 3 of 3 Flat seat machined unions withmale/male threaded end connection

6. RRCAT/IAD/MML/337/R0 sh 1 of 1 Reducing adaptor

7. RRCAT/IAD/MML/338/R0 sh 1 of 1 Hexagonal connector and cap

8. RRCAT/IAD/MML/339/R0 sh 1 of 1 Weld adaptor

9. RRCAT/IAD/MML/340/R0 sh 1 of 1 Reducing adaptor and bush

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2.2 Material

The pipe fittings are to be machined from austenite stainless steel grade 316L as per ASTMA276.

Bidder shall submit mill certificate / test report of chemical, mechanical properties anddimensions of the raw bars to RRCAT for acceptance before starting any machining work.

2.3 Quantity

One set of pipe fittings is to be supplied against this tender. One set of pipe fittings consistsof all the fittings mentioned in Table-2.

Table-2

SN Drawing no PartNo.

Part description Qty.(Nos)

1 RRCAT/IAD/MML/335/R0sht. 1 of 2 “Male hoseconnector”

1 ¼" × 10 mm BSPP Male hose Nipple 25

2 3/8" × 10 mm BSPP Male hose Nipple 25

3 1/2" × 21 mm BSPP Male hose Nipple 50

4 3/4" x 21 mm BSPP Male hose Nipple 25

5 1" × 27mm BSPP Male hose Nipple 25

6 1"x 42 mm BSPP Male hose Nipple 25

71-1/2" × 27 mm BSPP Male hose Nipple

25

81-1/2" × 42 mm BSPP Male hose Nipple

25

2 RRCAT/IAD/MML/335/R0sht. 2 of 2 “Female hoseconnector”

1 ¼" × 10mm BSPP female hose Nipple 25

23/8" × 10mm BSPP female hose Nipple

25

31/2" × 21 mm BSPP female hose Nipple

50

43/4" × 21 mm BSPP female hose Nipple

25

5 1" × 27 mm BSPP female hose Nipple 25

6 1" × 42 mm BSPP female hose Nipple 25

71-1/2" × 27 mm BSPP female hose Nipple

25

81-1/2" × 42 mm BSPP female hose Nipple

25

3 RRCAT/IAD/MML/336/R0sht. 1 of 3 “Flat seat

1 1-½" BSPP male /female thread 25

2 1" BSPP male /female thread 25

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machined unions withmale/female threaded endconnection”

3 3/4" BSPP male /female thread 25



4 RRCAT/IAD/MML/336/R0sht. 2 of 3 “Flat seatmachined unions with hoseend connection”

1 1-½" BSPP x 42 mm hose end 25

2 1" BSPP x 32 mm hose end 50

3 1/2" BSPP x 22 mm hose end 50



5 RRCAT/IAD/MML/336/R0sht. 3 of 3 “Flat seatmachined unions withmale/male threaded endconnection”

1 1-½" BSPP male/male threaded end 25

2 1" BSPP male/male threaded end 25

3 3/4" BSPP male/male threaded end 25

4 1/2" BSPP male/male threaded end 50

6 RRCAT/IAD/MML/337/R0sht. 1 of 1 “Reducingadaptor”

1 ½" × ¼" BSPP Reducing Nipple 25

2 ½" × 3/8" BSPP Reducing Nipple 25

3 3/4" × 3/8" BSPP Reducing Nipple 25

4 3/4" × 1/2 BSPP Reducing Nipple 25

5 1" × 3/8" BSPP Reducing Nipple 25



8 1-½" × 1/2" BSPP Reducing Nipple 25

9 1-½" × 3/4" BSPP Reducing Nipple 25

10 1-½" × 1" BSPP Reducing Nipple 25

7 RRCAT/IAD/MML/338/R0sht. 1 of 1 “Hexagonalconnector and cap”

1 1/4" BSPP hexagonal connector 25




5 1" BSPP hexagonal connector 50

6 1-1/2" BSPP hexagonal connector 25

7 1/4" BSPP hexagonal Cap 25




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11 1" BSPP hexagonal Cap 25

12 1-1/2" BSPP hexagonal Cap 25

8 RRCAT/IAD/MML/339/R0sh 1 of 1 “Weld adaptor”

1 1/4" BSPP male weld adaptor 50




5 1" BSPP male weld adaptor 50

6 1-1/2" BSPP male weld adaptor 50

7 1/4" BSPP Female weld adaptor 50




11 1" BSPP Female weld adaptor 50

9 RRCAT/IAD/MML/340/R0sht. 1 of 1 “Reducingadaptor and bush”

1 ½" × ¼" BSPP Reducing adaptor 50

2 ½" × 3/8" BSPP Reducing adaptor 50

3 1" × 1/2" BSPP Reducing adaptor 50

4 1" × 3/4" BSPP Reducing adaptor 50

5 1-1/2” x 1” BSPP Reducing adaptor 50

6 1-1/2”x1”BSPP Reducing Bush 50

7 ½" × 3/8" BSPP Reducing Bush 50

8 1" × 3/4" BSPP Reducing Bush 50

9 3/4" × 1/2" BSPP Reducing Bush 50

10 1" × 1/2" BSPP Reducing Bush 50

2.4 Machining

The components shall be machined on CNC machine for achieving repeatable dimensions.

All sharp corners, burrs and thread burrs shall be removed.

The component machining shall be carried out in the sequence given below:

Prototype stage qualification: Machine two number of each type of fitting and carry out itsinspection.

The fitting shall be assembled and pressure tested at 10 bar, no water leaks should be seen.

Submit the machined parts with inspection report to RRCAT for verification. (Hold Point)

RRCAT will give feedback within one week of receiving parts and inspection report.

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Series manufacturing: Machine full quantity of pipe fittings using established process andinspection method.

In case, prototype parts do not meet the requirements shown on the drawings, one moreprototype shall be machined and inspected. This process shall continue till the prototype isqualified. Series manufacturing shall be taken after prototype qualification.

2.5 Inspection

The responsibility of completing all the tests lies with the bidder.

Each fitting shall be marked as per nomenclature given below on the face of the connector.Bidder shall decide the marking identification in consultation with RRCAT.

Full prototypes and 10% of series fittings shall be assembled and pressure tested at 10 bar, nowater leaks should be seen. The fittings shall remain usable after the test.

Dimensional inspection shall be carried out by manufacturer for 100 % components (threadswill be inspected by thread gauges) and report in excel sheet format with acceptabledimension in block font shall be submitted to RRCAT for approval. RRCAT representativewill visit the bidder’s facilities during manufacturing to witness in-process and finalinspection. Out of tolerance dimension shall be shown in red color. The componentidentification number shall be mentioned on its inspection report.

Supplier shall demonstrate the inspection methods and recheck any dimension asked by theRRCAT representative during inspection at supplier’s site.

Welding test on prototypes: Prototypes of the pieces to be welded shall be welded using TIGwelding and inspected by Dye Penetrant test. The weld shall pass the Dye Penetrant test forpressure fitting as per IS/ASME requirements.

3.0 Acceptance criteria

Pipe fittings will be accepted on the basis of material and inspection tests reports as given insection 2.4 and 2.5.

4.0 Packing

Each fitting shall have suitable polymer protective cap screwed on threaded part to protectthem from damage. Pipe fittings shall be packed in HDPE Crate with suitable PE foamcushion and lid to protect them during transport and for long term storage. Suitable quantity ofitems to be packed in one crate (with crate properly marked) shall be decided by supplier andinformed to RRCAT prior to dispatch.

Packaging of the items shall provide adequate protection against handling forces. Supplier willbe responsible for proper packaging, transport and safe delivery of the consignmentdispatched against this order. The pipe fittings shall be delivered as packed at IRPSU, RRCATIndore, India.

5.0 Delivery schedule

The pipe fittings shall be delivered to regional stores unit, RRCAT as per the time schedulementioned in Table-3. Bidder shall confirm the schedule.

Table-3

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# Activity description Incremental time period from POrelease date

1. Prototype qualification 1 month

2. Delivery of full quantity 2 months

3. Cumulative time period from PO date 3 months

6.0 Quality control

The quality control procedure for manufacturing and testing of pipe fittings is mentioned inthe flowchart shown in Figure-1.

Figure-1. Flowchart showing quality control of pipe fittings

7.0 Mandatory questionnaire to be filled and upload

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Offer raw material for inspection

Prototype manufacturing after

approval from RRCAT

Hex dimensionalMakeUniformityMaterial – Chemical test Welding

Repeat Prototype

Inspect prototype as per section 2.4 and 2.5 and submit it to

RRCAT for approval

DimensionalMaterialSpanner force dimensionThread fittingOD, IDWelding testWater pressure test

Not OK

OK

Series production as per process followed

for prototypes

Visual and dimensional inspection of 100% components100% inspection of threads using thread gauge

Following questionnaire shall be filled and upload with file name “mandatory questionnaire”.Not sending this file along with bid itself will lead to rejection of the bid.

SN Description Information / value/ make/ model/confirmation detail to be provides by thebidder

1 Make, model, year of manufacture ofand colour photograph of the CNCmachine proposed to be used as persection 1.0 of the specification

Provide details in the bid

2 All lathe operation (turning, threadcutting etc.) will be done on the aboveCNC Lathe only

Confirm YES/NO

3 Study of drawing as per section 2.1 Bidder to confirm if he has studied thedrawing and understood all detail.

4 Make and model of thread inspectiongauges proposed to be used for threadinspection

Provide detail

5 Source of raw material SS316L Give proposed makes and availability ofchemical test certificates before start tomachining.

6 Agreement by the bidder to do thepressure test, welding and dye penetranttest as required in section 2.4 and 2.5

Yes/No

7 Have you made similar componentspreviously?

YES/NO

8 Inspection report for each componentsshall be provided in Excel sheet.

YES/NO

9 What shall be the colour of font to beused for out of tolerance dimension?

Black or Red

(Choose one)

10 Will you protect thread of eachcomponents with polymer protectioncap?

YES/NO

11 Have you understood the quality controlflow chart?

YES/NO

Seal and signature of the bidder

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****End of specification****

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Documents

“Manufacturing and supply of stainless steel pipe Manufacturing and supply of stainless steel pipe fittings” 1.0 Scope of work This document lists the technical requirements for