CES 98Reaffirmed 9/98 NYS-E1.251 of 5

CALTEX MATERIAL AND EQUIPMENT SPECIFICATION NYS-E1.25

NICKEL ALUMINIUM BRONZE CASTINGS FOR WATER SERVICE

A SCOPEThis Specification outlines the Purchasers requirements for material, fabrication, quality,inspection and testing of nickel aluminium bronze castings for water service.

M This paragraph bullet indicates that a specific item requires the Purchasers approval in writing.

CES 98Reaffirmed 9/98 NYS-E1.252 of 5CONTENTSA SCOPE 1

1.0 MATERIAL SPECIFICATION 3

2.0 MANUFACTURE 3

3.0 DESIGN 3

4.0 WORKMANSHIP 3

5.0 CHEMICAL COMPOSITION 3

6.0 CASTING REPAIR 3

7.0 TESTING REQUIREMENTS 48.0 QUALITY ASSURANCE 5PURCHASERS APPROVALS CHECKLIST 5

VENDORS CHECKLIST 5

LIST OF REFERENCES 5

CES 98Reaffirmed 9/98 NYS-E1.253 of 51 MATERIAL SPECIFICATION

Nickel aluminium bronze castings shall conform to the requirements of the latest editions of BS1400: Alloy AB2 (or ASTM B148: Alloy number C 95800) and the conditions stated herein.

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

2.0 MANUFACTUREM Castings shall be produced by the sand casting process. Other manufacturing methods that will

satisfy the requirements of the applicable materials standard and this Specification may be used,s

3.0 DESIGNThe Vendor shall be responsible for all aspects of the casting design, which shall be in accordancewith the applicable and specified Codes and Standards and this Specification. Copies of calculationsfor pressure containment and structural design shall be provided.

M The Vendor, prior to casting, shall review the fabrication drawings to ensure that it is possible toproduce 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 thePurchaser for approval.

4.0 WORKMANSHIP(i) The casting shall be of uniform quality and shall conform to the chemical and mechanicalproperty requirements of the applicable material standard and this Specification.

(ii) The castings shall be dimensionally accurate. Wall thicknesses and sections shall meet therequirements of the approved drawings. Unless specified on the drawing, dimensional tolerancesshall conform to BS 6615, casting tolerance grade CT 9.

(iii) Castings shall be sound and free from sand inclusions, cracks, hot tears, porosity andsignificant shrinkage. Refer also to 7(iv) and 7(vi).(iv) Castings may be deemed not to comply with this Specification and to be unacceptable due tocasting defects, even if they satisfy all other requirements of the standards.

5 CHEMICAL COMPOSITIONThe chemical composition shall be as specified in the applicable Material Specification with theexception 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.0(ubject to the Purchasers approval..0i) Weld repairs as covered by ASTM B148 will normally be permitted.

CES 98NYS-E1.25 Reaffirmed 9/984 of 5M (ii) Weld repairs in excess of those covered in the scope of ASTM B148 shall be specifically

approved by the Purchaser, and records shall be maintained as per ASTM B148.

M (iii) All welding procedures shall be approved by the Purchaser. Note, the following proceduresare 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 1508C (3008F).

M 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 6 108C (1247 6 188F) for six hours, followed bycooling in still air.

M (iv) Should weld repairs be necessary, all defects shall be completely removed. This shall beconfirmed 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 radiographedafter postweld heat treatment (PWHT). Defects in excess of severity level three in ASTM E272shall be cause for rejection.(vi) The weld preparation shall be completely overfilled with weld metal to allow machining backto sound material.

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

7.0 TESTING REQUIREMENTSM (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 benecessary (refer to 6(iii)), as the casting. They shall be taken from each melt, should the casting beproduced from more than one furnace melt. Retest results shall be approved by the Purchaser. Testbars 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 bereported 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 beencompleted.

(v) All surfaces, as cast, dressed or machined shall be subject to dye penetrant examination. Dyepenetrant examination shall be carried out using visible, solvent-removable, liquid penetrant, non-aqueous, wet developer as specified in the latest edition of ASME SE165.

Cracks, hot tears, shrinkage and chain line porosity are not acceptable. For pin hole porosity, themaximum number of indications must not exceed eight instances of 3mm diameter bleed out in anyarea 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.

CES 98Reaffirmed 9/98 NYS-E1.255 of 5M (vi) The casting soundness shall be assessed by spot radiography of designated areas. These will

usually be at significant changes of section in the casting. Areas for this examination shall be agreedwith 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 Specification and test schedule.

(ii) The Purchaser, or his representative, will visit the Vendor in order to monitor compliancewith this Specification.

(iii) The casting shall be visually inspected by the Purchaser or his representative before andafter 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 ofthe scope of those covered in ASTM B148, and shall witness the hydrotest.

PURCHASERS APPROVALS CHECKLIST

1.0 6.0(ii) 6.0(vii)

2.0 6.0(iii) 7.0(i)

3.0 6.0(iv) 7.0(vi)

VENDORS CHECKLIST

3.0 8.0 (i) 8.0 (ii)

LIST OF REFERENCES

A M B148 Specification for Aluminum-Bronze CastingsASTM E272 Reference Radiographs for High-Strength Copper-Base and Nickel-Copper Alloy CastingsASME SE165 Standard Practice for Liquid Penetrant Inspection MethodBS 1400 Specification for Copper Alloy Ingots and Copper Alloy High Conductivity Copper CastingsBS 2901:Part 3 Specification for Copper and Copper AlloysBSTS 6615 Specification for Dimensional Tolerances for Metal and Metal Alloy Castings

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