GI Fittings.docx
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GI Fittings.docx
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GIFittings
MahanagarGasLimited(MGL)
ENGSPEC/GIFITTINGS/04/15
TechnicalSpecificationforGIFittings(MalleableCastIron)
foruseatpressuresupto100mbar(g).
CONTENTS
ABBREVIATIONS
1.SCOPE
2.REFERENCES
3.MATERIAL
4.DIMENSIONSANDDIMENSIONALTOLERANCES
5.THREADS
6.FREEDOMFROMDEFECTS
7.GALVANIZING
8.PRESSURETEST
9.COMPRESSIONTEST
10.SAMPLING
11.POWDERCOATING
12.MARKING
13.INSPECTION/DOCUMENTS
14.QUALITYASSURANCEPLAN
15.TECHNICALBIDEVALUATIONCRITERIA(TBEC)
ABBREVIATIONS
IS:
INDIANSTANDARDS
MGL:
MAHANAGARGASLIMITED
BIS:
BUREAUOFINDIANSTANDARDS
ITP:
INSPECTIONTESTPLAN
MTC:
MATERIALTESTCERTIFICATE
PO:
PURCHASEORDER
TPIA:
THIRDPARTYINSPECTIONAGENCY
TechnicalSpecificationforG.I.Fittings(MalleableCastIronFittings)
1.SCOPE.
ThisspecificationcoverstherequirementsforMalleableCastIronFittingsforuseofnaturalgas,withworkingpressureupto100mbar(g).
SuchGIfittingsshallbetestedandapprovedinaccordancewithalltheprevailingrequirementsofPNGRBtechnicalstandards&specificationsincludingSafetystandardsforCityorlocalnaturalgasdistributionnetworks(alsoknownasT4S).
2.REFERENCE.
Unlessotherwisespecified,thelatesteditionsofthestandardsmentionedhereinthisspecification,includingalladdendaandrevisions,shallapply.
3.MATERIAL.
ThematerialusedforthemanufactureofMalleableCastIronFittingsshallconformtoanyofthegradespecifiedinIS14329:
1995andIS1879:
2010.
4.DIMENSIONS&DIMENSIONALTOLERANCES.
DimensionsofvarioustypesoffittingsshallbeasspecifiedinSections2to10ofIS1879:
2010,asapplicable.AllthedimensionsgiveninthesesectionsenablethefittingstobeassembledwithpipesthreadedinaccordancewithIS554:
1999.WallthicknessoffittingsandtolerancesonthemshallbeasgiveninTable2ofIS1879:
2010.Incaseofreducingfittings,thedimensionsateachoutletshallbethoseappropriatetothenominalsizeofthatoutlet.Elbows,Tees,Socketsandcapsshallbeofreinforcedtype.
5.THREADS.
ØOutletsoffittingsshallbethreadedtodimensions&thetolerancesasspecifiedinIS554latestedition.
ØAllinternal&externalthreadsshallbetapered.
ØAfterthreading,thepipebodymaybehotdipgalvanizedaspernormalpracticefollowedbycoldgalvanizing(spraying)ofthethreadedportions.Thethreadedportionsshallbeprotectedusingendcaps,etc.
ØForcheckingconformityofthreads,gaugingpracticeinaccordancewithIS8999:
2003shallbefollowed.
ØChamfering:
Theoutletofthefittingsshallhaveachamfer.Thechamfershallhaveanincludedangleof900±50forinternalthreads&700±100forexternalthreads.
6.FREEDOMFROMDEFECTS.
Onvisualexamination,theinside&outsidesurfacesoffittingsshallbesmooth&freefromanydefectssuchascracks,injuriousflaws,finesanddepth,etc.
7.GALVANIZING.
ØFittingsshallbegalvanizedtomeettherequirementsofIS4759latestedition.
ØZincusedforgalvanizingshallconformtoanyofthegradesspecifiedinIS209:
1992‘Zincingot’orIS13229:
1991‘ZincforGalvanizing’shallbeusedforthepurposeofgalvanizing.
ØGalvanizingBath:
Themoltenmetalinthegalvanizingbathshallcontainnotlessthan98.5%bymassofzinc.
Ø.Coatingrequirements:
Massofcoatingshallbe610gms/m2.Incaseofpipenipples(manufacturedinaccordancewiththerequirementsofIS1239Part1:
2004),themassofcoatingof400gms/m2shallalsobeacceptable.
ØFreedomfromdefects:
Thezinccoatingshallbeuniform,adherent,reasonablysmooth&freefromsuchimperfectionsasflux,ashbarepatches,blackspots,pimples,lumpinessruns,ruststrains,bulkywhitedeposits&blisters;otherwisethepipesshallbeliableforrejection.
SamplingPlanforgalvanizing
ØAllmaterialsofthesametypeinacoatingbathhavinguniformcoatingcharacteristicsshallbegroupedtogethertoconstitutealot.Eachlotshallbetestedseparatelyforthevariousrequirementsofthespecification.ThenumberofunitstobeselectedfromeachlotforthispurposeshallbeasgiveninTable2ofIS4759:
1996.
ØThesampleselectedaccordingtoColumn1&2ofTable2,IS4759:
1996shallbetestedforvisualrequirementsasperclause6.2ofIS4759:
1996.Vendorshallhaveappropriatecorrespondencebetweengalvanizinglotnumberandmanufacturinglotnumberforidentification/traceability.
ØThesamplefoundconformingtoaboverequirementsshallthenbetestedformassofzinccoatinginaccordancewithClause9.2ofIS4759:
1996.
ØCriteriaforconformity:
AsperClause8.3ofIS4759:
1996.
ØTestprocedureshallbeasperClause9ofIS4759:
1996.AllgalvanizingtestresultsshallbeincludedintheManufacturer’sTestCertificate.
8.PRESSURETEST.
PneumaticpressuretestasperClause11ofIS1879:
2010shallbecarriedoutoneach&everyfittings.VendorhastosubmittheInternalQualityControlcertificateforthesame.MGLshallwitnesspneumatictestingasperthesamplingprocedurespecifiedinIS1879:
2010.
9.COMPRESSIONTEST.
Compressiontestshallbecarriedoutaspertheclause12ofIS1879:
2010.
10.SAMPLING.
MGLrepresentativeorThirdpartyinspectionagencyappointedbyMGLshallwitnessthetestsasperClause13ofIS1879:
2010.However,vendortoperform100%inspectionofvisual,dimensional&pressuretest.Vendorshallfurnishinternaltestcertificatesatthetimeoffinalinspection.
11.POWDERCOATING.
PurePolyesterPowdercoatinghastobedoneonGalvanizedfittingsasperprevailingMGLtechnicalspecificationsforPowderCoating(MGL/ENG/PE/SP11-R5).
12.MARKING.
Eachfittingshallbeembossedwithmanufacturer'snameortrade-mark,andthesizedesignationandMGLhologramshouldbeaffixedonallthefittings.
Eachpackingcontainingfittingsshallcarrythefollowing,stampedorwritteninindelibleink.
ØManufacturersnameortrade-mark,
ØDesignationoffittingsand,
ØLotnumber.
EachfittingconformingtothisstandardshallalsobemarkedwithBISstandardmark.
13.INSPECTION/DOCUMENTS.
1.InspectionshallbecarriedoutasperMGLTechnicalSpecification.
2.MGLrepresentativeand/orThirdPartyInspectionagencyappointedbyMGLshallcarryoutstagewiseinspectionduringmanufacturing/finalinspection.TheinspectionshallbeasperapprovedQAP/ITP,whichshallbeprepared/submittedforreview/approvalbyMGL/ThirdPartyInspection(TPI)agency.
3.Vendorshallfurnishallthematerialtestcertificatesproofofapproval/licensefromspecifiedauthorityasperspecifiedstandard,ifany,internaltest/inspectionreportsasperMGLTech.Spec.&specifiedcodefor100%material,atthetimeoffinalinspectionofeachsupplylotofmaterial.
4.Vendorshallincludedetailsofpacking/bundling/transport–quantityinonebundle,endprotection,etc.
Evenafterthirdpartyinspection,MGLreservestherightstoselectasampleoffittingsrandomlyfromeachmanufacturingbatch&havetheseindependentlytested.ShouldtheresultsofthesetestsfalloutsidethelimitsspecifiedinMGLtechnicalspecification,thenMahanagarGasLimited,reservestherightstorejectallproductionsuppliedfromthebatch
14.QAP
Sr.No.
Characteristics
TypeofCheck
QuantumofCheck
ReferenceDocument
AcceptanceNorms
FormatofRecords
Scope
Remarks
Vendor
TPIA
1
Chemicalcompositionofmaterialusedformanufacture
ChemicalAnalysis
Onesampleperlotforeachtypeoffittings
AsperIS1879
AsperMGLtechspecclauseno.3
MaterialTestCertificate
Review
Review
ReviewofMTCbyTPIA
2
Physicalverification
Dimensions
100%
AsperMGLtechspecclauseno.4&clauseno.5
Vendorinspectionreport
Perform
Perform
100%inspectionwillbecarriedoutbyvendor,TPIAtocarryout10%
Wallthickness
Threads
3
Visualcheck
Cracks
100%
AsperMGLtechspecclauseno.6
Vendorinspectionreport
Perform
Perform
100%inspectionwillbecarriedoutbyvendor,TPIAtocarryout10%
Surfacesmoothness
Chamferburr
Alignment
Chamfering
4
Galvanizing
Chemicalanalysis
AspersamplingplanmentionedinIS:
4759
AspertherequirementofMGLtechspec
AsperMGLtechspecclauseno.7
MaterialTestCertificate
Review
Review
TPIAhastoselectsamplefromlotandsendtoNABLapprovedlab,reviewthereportsofsame.
5
Compressiontest
Onesampleperlot
AsperIS1879
AsperMGLtechspecclauseno.9
Vendorinspectionreport
Perform
Perform
TPIAtoreviewthereport
6
Pressureprooftest
Pneumatic
100%
AsperMGLtechspecclauseno.8
Vendorinspectionreport
Perform
Perform
100%inspectionwillbecarriedoutbyvendor,TPIAtocarryout10%
7
Powdercoating
Thickness
100%
AsperMGLtechspecclauseno.11
Vendorinspectionreport
Perform
Perform
100%inspectionwillbecarriedoutbyvendor,TPIAtocarryout10%
R
E
M
A
R
K
S
1.Alldimensionsareinmmunlessotherwisespecified.
2.Allthemeasuringinstrumentsshallbedulycalibratedatthetimeofinspection
3.CalibrationcertificatesofallthemeasuringinstrumentsshallbereviewedbyTPIatthetimeofinspection,alongwiththeMastercalibrationcertificateofthemeasuringinstrumentsfromwhichtheinstrumentsiscalibrated.
4.Aftersatisfactoryinspection,theTPIagencytoapplytheirmark(stamp/sticker/embossing/etc.)oneachontheassemblyselectedfortesting.AlsoTPIhastoapplytheirmark(stamp/sticker/embossing/etc.)ontheouterpackingoftheassembly,afterverifyingtheinformationmentionedintheMGLtechnicalspecificationclauseNo.9.
16.TechnicalBidEvaluation
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