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CALTEX MATERIAL AND EQUIPMENT SPECIFICATION NYS-E1.25 NICKEL ALUMINIUM BRONZE CASTINGS FOR WATER SERVICE
A SCOPE
This Specication outlines the Purchasers requirements for material, fabrication, quality, inspection and testing of nickel aluminium bronze castings for water service. This paragraph bullet indicates that a specic item requires the Purchasers approval in writing.

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SCOPE MATERIAL SPECIFICATION MANUFACTURE DESIGN WORKMANSHIP CHEMICAL COMPOSITION CASTING REPAIR TESTING REQUIREMENTS QUALITY ASSURANCE

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CONTENTS
A 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 1 3 3 3 3 3 3 4 5 5 5 5

PURCHASERS APPROVALS CHECKLIST VENDORS CHECKLIST LIST OF REFERENCES

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1.0

MATERIAL SPECIFICATION
Nickel aluminium bronze castings shall conform to the requirements of the latest editions of BS 1400: Alloy AB2 (or ASTM B148: Alloy number C 95800) and the conditions stated herein.

Alternative materials may be acceptable. However, deviation from the above AB2 type of material requires the Purchasers approval.

2.0

MANUFACTURE
Castings shall be produced by the sand casting process. Other manufacturing methods that will satisfy the requirements of the applicable materials standard and this Specication may be used, subject to the Purchasers approval.

3.0

DESIGN
The Vendor shall be responsible for all aspects of the casting design, which shall be in accordance with the applicable and specied Codes and Standards and this Specication. Copies of calculations for pressure containment and structural design shall be provided.

The Vendor, prior to casting, shall review the fabrication drawings to ensure that it is possible to produce sound castings. Any proposals to modify the drawings by introducing taper sections, increasing corner radii, etc, to allow the production of sound castings shall be submitted to the Purchaser for approval.

4.0

WORKMANSHIP
(i) The casting shall be of uniform quality and shall conform to the chemical and mechanical property requirements of the applicable material standard and this Specication. (ii) The castings shall be dimensionally accurate. Wall thicknesses and sections shall meet the requirements of the approved drawings. Unless specied on the drawing, dimensional tolerances shall conform to BS 6615, casting tolerance grade CT 9. (iii) Castings shall be sound and free from sand inclusions, cracks, hot tears, porosity and signicant shrinkage. Refer also to 7(iv) and 7(vi). (iv) Castings may be deemed not to comply with this Specication and to be unacceptable due to casting defects, even if they satisfy all other requirements of the standards.

5.0

CHEMICAL COMPOSITION
The chemical composition shall be as specied in the applicable Material Specication with the exception that the total impurities shall not exceed 0.30%, with lead not exceeding 0.02%. Manganese content shall be 0.83.0%.

6.0

CASTING REPAIR
(i) Weld repairs as covered by ASTM B148 will normally be permitted.

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(ii) Weld repairs in excess of those covered in the scope of ASTM B148 shall be specically approved by the Purchaser, and records shall be maintained as per ASTM B148. (iii) All welding procedures shall be approved by the Purchaser. Note, the following procedures are preferred: TIG DC Electrode negative, helium gas shielding MIG DC Electrode positive, argon gas or argon/helium mixture shielding Filler metal shall comply with BS 2901: Part 3 C20 or equivalent (eg Murex Bostrand AT 246), subject to the Purchasers approval. Pre-heat and interpass temperatures shall not exceed 150C (300F).

If welding repairs in excess of the scope covered by ASTM B148 are approved by the Purchaser, the component shall be temper annealed at 675 10C (1247 18F) for six hours, followed by cooling in still air. (iv) Should weld repairs be necessary, all defects shall be completely removed. This shall be conrmed by dye penetrant testing, or another method subject to approval by Purchaser. (v) All repairs in excess of that described in ASTM B148 shall be 100 percent radiographed after postweld heat treatment (PWHT). Defects in excess of severity level three in ASTM E272 shall be cause for rejection. (vi) The weld preparation shall be completely overlled with weld metal to allow machining back to sound material.

(vii) No peening or impregnation type repairs shall be carried out, unless specically agreed to, and approved by, the Purchaser.

7.0

TESTING REQUIREMENTS
(i) Three test specimens shall be made for chemical and mechanical testing, to allow for retesting in case of failure of initial tests. Samples shall receive the same heat treatment, should this be necessary (refer to 6(iii)), as the casting. They shall be taken from each melt, should the casting be produced from more than one furnace melt. Retest results shall be approved by the Purchaser. Test bars may be cast separate from the casting. (ii) The chemical analysis shall include Cu, Fe, Ni, Mn, Si Mg, Pb, Zn, and Sn. Values shall be reported to the second decimal place. (iii) Mechanical testing shall include tensile strength, yield strength and elongation. (iv) The casting shall be visually inspected after all fettling and machining operations have been completed. (v) All surfaces, as cast, dressed or machined shall be subject to dye penetrant examination. Dye penetrant examination shall be carried out using visible, solvent-removable, liquid penetrant, nonaqueous, wet developer as specied in the latest edition of ASME SE165. Cracks, hot tears, shrinkage and chain line porosity are not acceptable. For pin hole porosity, the maximum number of indications must not exceed eight instances of 3mm diameter bleed out in any area of 5000mm2. The sum of the diameters of indications in an area of 5000mm2 shall not exceed 24mm. This examination shall be repeated after any weld repairs and PWHT, if applicable.

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(vi) The casting soundness shall be assessed by spot radiography of designated areas. These will usually be at signicant changes of section in the casting. Areas for this examination shall be agreed with the Purchaser prior to casting. (vii) The casting shall be hydrotested at 1.5 times the design pressure for at least 30 minutes, following all fettling, machining and repairs.

8.0

QUALITY ASSURANCE
(i) The Vendor shall submit quality assurance documentation giving the results of all tests, details of repairs and compliance with this Specication and test schedule. (ii) The Purchaser, or his representative, will visit the Vendor in order to monitor compliance with this Specication. (iii) The casting shall be visually inspected by the Purchaser or his representative before and after repairs in excess of the scope of those covered by ASTM B148. (iv) The Purchaser or his representative shall witness the preparation for any repair in excess of the scope of those covered in ASTM B148, and shall witness the hydrotest.

PURCHASERS APPROVALS CHECKLIST

1.0 2.0 3.0

6.0(ii) 6.0(iii) 6.0(iv)

6.0(vii) 7.0(i) 7.0(vi)

VENDORS CHECKLIST

3.0

8.0 (i)

8.0 (ii)

LIST OF REFERENCES
ASTM B148 ASTM E272 ASME SE165 BS 1400 BS 2901:Part 3 BS 6615 Specication for Aluminum-Bronze Castings Reference Radiographs for High-Strength Copper-Base and Nickel-Copper Alloy Castings Standard Practice for Liquid Penetrant Inspection Method Specication for Copper Alloy Ingots and Copper Alloy High Conductivity Copper Castings Specication for Copper and Copper Alloys Specication for Dimensional Tolerances for Metal and Metal Alloy Castings