PP E 155 R4b Brass Tube Fittings.

NUCLEAR POWER CORPORATION OF INDIA LIMITED
TECHNICAL SPECIFICATION PAGE NO. 1 OF 11

FOR REV. NO. 4
BRASS COMPRESSION TYPE (FLARELESS)
TUBE FITTINGS

INDEX
SECTION DESCRIPTION PAGE
NO.

1.0 SCOPE ..................................................................... 2

2.0 APPLIICABLE SPECIFICATIONS & STANDARDS... 2

3.0 MATERIAL, PROCESS AND WORKMANSHIP ..... .. 3

4.0 REQUIREMENT.......................................................... 3

5.0 INSPECTION AND TESTING ............................. .. 5

6.0 IDENTIFICATION, PACKAGING AND SHIPPING... 8

7.0 GUARANTEE.................................................. .. 8

ANNEXURE-I SAMPLE QUALITY ASSURANCE PLAN ............ .. 9-I I

60615/PP-E-155 JULY,2009

FOR REV. NO. 4
TUBE FITTINGS

1.0 SCOPE

This Specication covers the general requirements for the manufacture, inspection,
testing and supply of Brass Compression type (Flareless) tube ttings for instrumentation
applications in all PHWRs.

2.0 APPLICABLE SPECIFICATIONS AND STANDERDS

2.1 The design, manufacture and performance assessment of the fittings shall conform to
Well established practices or codes.

The design, manufacture and performance assessment shall generally conform to the
following standard specications:

SAE J 514 : Hydraulic Tube Fittings

PP-M-1890 : Specication for Seamless Copper Tube,
Bright Annealed
ASTM-B-124 : Copper and copper alloy forging rod, bar and shapes
ASTM-B-16 : Free cutting brass rod, bar and shapes for use in
Screw machines
ANSI-B-20.1 : American Standard for Taper Pipe Threads
ANSl-B.1.1 : American standard for Unied Threads Class 2A
and 2B
IS 4218 : Indian standard for Metric Straight Pipe Threads

In the event of any conflict between the provisions of this specication and the
documents listed above, this specication shall govern. The contractor may propose
other equivalent material standards for the purchasers consideration and written
approval.

2.2 The manufacturer shall stipulate as part of the tender, the codes and the standards to
which the design, fabrication and performance assessment of the offered ttings conrm.

60615/PP-E-155 JULY,2009

FOR REV. NO. 4
TUBE FITTINGS

3.0 MATERIALS, PROCESS AND WORKMANSHIP

3.1 Materials, Processes and Parts
Materials, processes and standard parts shall be of good industrial quality and in
accordance with good practice pertinent to the manufacture of high quality ttings for
Nuclear Power Station.

3.2 Workmanship

Workmanship shall be in accordance with high grade commercial practice adequate to
ensure satisfactory operation and service life. Fittings shall be free from all burrs, loose
scale and sliver, which might get dislodged in usage and all other defects which might
affect the ttings serviceability. Also the ttings shall be free from internal fins or other
irregularities which might restrict the free flow of fluid, and shall be so designed that the
resistance to the ow of fluid through the ttings shall be reduced to a minimum. All
sealing surfaces must be smooth to 0.25 micron or better, except that annular tool marks
up to 2.5 microns maximum are permissible.

4.0 REQUIREMENTS

4.1 General

The ttings shall be capable of continuous satisfactory service over a long period with
minimum attention. Long term reliability under varying service conditions is of prime
importance and the use of high quality materials, components, tools, equipments etc. in
manufacturing and inspection of these ttings is therefore required.

4.2 Material Requirements

Straight bodies, nuts and ferrules shall be from brass conforming to ASTM-B-16 (SAB-
CA-360). Forgings shall conform to ASTM-B-124 (SAE-CA-377). These ttings shall
be suitable for use on copper tubing conforming to NPCIL Specification PP~I\/I-1890.
The barstock for the ttings shall have minimum RB-60 hardness.

4.3 Design and Construction

The design of the ttings shall be such that no preparation of the ends of the tube is
required other than that they are cut square. The joint is made by the compression of the
ferrule on to the outside wall of the tube. The design of these ttings shall be such as to
permit tube entry and tting make up without removal of the nut and ferrules. Fitting
shall be of heavy duty type.

60615/PP-E-155 JULY,2009

FOR REV. NO. 4
TUBE FITTINGS

4.3.1 The tube fittings when assembled with the recommended tubings shall be capable of
withstanding the following types of forces :

a) internal pressure
b) Tension of axial pull
c) Compression or axial push
d) Torque or twist
e) Vibration
f) Temperature variation
Any combination of some or all the above forces is possible.

4.3.2 Unless otherwise specified each socket shall be provided with an internal shoulder or stop
against which the inserted tube, cut square with its axis shall abut.

4.4 Designation of sizes and Tolerances

The size by which the fitting is designated shall be the outer diameter of the tube (in mm)
with which it is to be used.

4.5 Screw Threads

All fittings shall have American (National)Standard Taper Pipe Threads (NPT) as per
ANSl-B-1.20.1 and straight threads as per ANSI B 1.1 (Unified Threads CLASS 2A and
2B). Straight threads to other standards such as metric can also be proposed by the
contractor.

4.6 Pressure Rating

Fittings, when assembled in accordance with contractors instructions with NPCIL
specified tubing, shall be suitable for use at the maximum working pressure of 40
kg/cm (g) at normal atmospheric temperature. Hydrostatic and pneumatic tests shall be
carried out as specified in Sections 5.3.3 and 5.3.4 respectively.

4.7 Thickness

Unless otherwise specified the wall thickness at any point on the fitting shall conform to
SAE-J-514.

4.8 Hardness

The hardness of the ferrules shall not be less than Rockwell hardness RB-60.

60615/PP-E-155 JULY,2009

FOR REV. NO. 4
TUBE FITTINGS

4.9 Reassembly

The ttings shall be capable of having the joint broken and remade at least six times and
shall provide a sound joint on each occasion (Refer to Section 5.3.5).

4.10 Cleanliness

The ttings shall be free from any metal particles, contaminant and other forms of dirt.
Fittings in the made up condition shall be suitably sealed in polythene bags and shall be
stored in clean storage. Failure to meet this requirement shall either result in rejection or
call for clean-up of all the ttings at the discretion of the Purchaser.

4.11 Certicate of Compliance

4.12 Quality Control at Manufactures Work

The contractor shall submit as part of the tender, his incoming inspection procedures for
the raw materials to be used in the manufacture of his ttings. it is required that the
contractor shall formulate sound quality control procedures and also systematic
documentation. The contractor shall classify the tting according to the size and type of
component (nut, ferrule etc.) and submit his inspection plans for each of these for the
approval of Purchaser. The Contractor shall furnish copies of his inspection reports on
each batch of components ifso requested by the Purchaser.

5.0 INSPECTION AND TESTING

5.1 General

The contractor shall be responsible for, and perform all the inspection and testing
specied herein, in a manner satisfactory to and subject to the approval of the Purchaser.
The contractor shall supply all the materials required for testing. He shall supply and
prepare the necessary test pieces and provide the personnel and equipment for such
testing as may be carried out at his premises in accordance with this specication. In the
absence of such facilities at his works for conducting the tests, the contractor shall, at his
own expense, arrange for the tests to be carried out at any other suitable place acceptable
to the purchaser.
The Purchaser or his authorized representatives shall have access to the contractors and
his sub contractors premises at all reasonable times to the extent necessary to assess

60615/PP-E-155 JULY,2009

FOR REV. NO. 4
TUBE FITTINGS

compliance with the provisions of this specication. He shall be afforded all reasonable
facilities to satisfy himself that the ttings are being manufactured in accordance with
this specication. Immediately after receipt of Purchase Order the contractor shall
prepare a detailed dimensional drawing, a quality assurance plan and furnish in triplicate
for purchasers (NPCILs) approval. A sample QA plan is enclosed as Annexure A for
the reference.
The Purchaser shall also have the right to conduct at his own expense, any additional
inspection or testing deemed necessary by him.

5.2 Inspection

The ttings shall be inspected to determine conformance with all the provisions of this
Specication with respect to material, workmanship and cleanliness.

5.3 Tests

5.3.1 General

The Contractor shall notify the Purchaser, the date and location of the performance of
tests, giving sufficient notice to enable the Purchaser or his authorized representative to
be present.
The test procedures shall be proposed by the Contractor and approved by the Purchaser.
The Contractor shall provide all the test equipment required.
The purchaser or his authorized representative shall have access to the calibration
certicates ofthe test equipment used for these tests.
The samples shall be randomly selected from the lot by the purchasers representative as
per the NPCIL approved QA Plan. For the purpose of random sampling, identical size
and type of ttings may be classied as same batch/lot.

5.3.2 Dimensional Check

Pipe threads of all the ttings and ferrule ID & nut ID of 10% quantity of ttings
randomly selected from the lot of each size, shall be gauged with suitable measuring
instruments in presence of the purchasers representative. The gauges shall he in the
tolerance range specied by the contractor and approved by the purchaser. A tting with
any of its dimensions beyond tolerance limits shall be treated as defective tting.

60615/PP-E-155 JULY,2009
FOR REV. NO. 4
TUBE FITTINGS

5.3.3 Hydrostatic Test

1% quantity (or l0 no. whichever is more) of ttings randomly selected from the lot of
each size shall be subjected to hydrostatic test. The ttings and their component parts,
when assembled with copper tubing as per PP-M-1890 , shall be subjected to internal
hydro static test pressure of 60 kg/cm (g). The pressure shall be applied gradually and
maintained at the test pressure for not less than ten minutes. No deformation or visual
leakage shall be seen in any of the ttings.

5.3.4 Pneumatic Leak Test

All the ttings which have undergone hydrostatic test shall be subjected to pneumatic
leak test at a test pressure of 10 kg/cm (g). The pressure shall be maintained for a
minimum of IO minutes and there shall be no leakage as detected by soap solution.

5.3.5 Re-assembly Test

All the ttings which have undergone hydrostatic and pneumatic leak tests shall be
disassembled and reassembled six times. After the sixth assembly, the ttings shall be
pneumatically tested as per Section 5.3.4.

5.3.6 Hardness Test

The raw material to be used for manufacture of ttings shall be tested for hardness and
shall satisfy the requirements of Section 4.2. Three randomly selected ferrules from each
lot of each size shall be tested for hardness, and shall satisfy the requirements of Section
4.8. Contractor shall submit suitable test certicates to Purchaser to this effect.

5.3.7 Material Certication

Contractor shall submit original mill certicates for the raw material for the purchasers
review. Purchaser reserves the right to call for retest of any raw material.

5.4 Inspection and Test Failure

In the event of failure of ttings to fully meet inspection and test requirements specied
herein, the Contractor shall notify the Purchaser or his authorized representative.
The Contractor shall obtain permission from the Purchaser before carrying out any
repairs or modications to these rejected ttings or part. Appropriate re-inspection and
retesting shall be conducted after any repair or modication

60615/PP-E-155 JULY,2009
FOR REV. NO. 4
TUBE FITTINGS

.5.5 Reports and Procedures

Five (5) copies of test reports along with the details of test equipments used, test hook-
ups etc. shall be submitted to the Purchaser. All such reports shall be signed by the
contractor or his authorized representative. Contractor shall also give 5 copies of
assembly and reassembly procedures of tube ttings.

6.0 IDENTIFICATION, PACKAGING AND SHIPPING

The contractor shall make adequate provisions to protect the ttings supplied to this
specication to ensure that on arrival at the project site, the generating station or
elsewhere as may be advised by the purchaser and after storage, as may occur they will
not have suffered corrosion or damage of any sort. All openings shall be properly
plugged to avoid entry of moisture or dust. Fittings of different types and size shall be
packaged separately.

All the packages shall be clearly and legibly marked in a suitable permanent manner
with the following informations :

(a) Purchase Order No. of the Purchaser.
(b) Items No. of Purchase Order.
(0) Number and details ofpieces in the packages.

7.0 GUARANTEE

All the ttings shall be guaranteed by the contractor for the period mentioned in the
general condition of contract. During this period, any preventive &. breakdown
maintenance shall be clone by the contractor. All the faulty items shall be replaced free
of cost at site by the contractor.

60615/PP-E-155 JULY,2009
FOR REV. NO. 4
TUBE FITTINGS

ANNEXURE1
SAMPLE QUALITY ASSURANCE PLAN
Sr.
No.

1
COMPONENT
&
OPERATION
2
TEST
CHARACTER
ISTICS
3
TYPE
OF
CHECK
4
TEST
CLASSIFI
CATION
5
QUANT
UM OF
CHECK
6
REF.
DOCUMENTS

7
ACCEPTAN
CE NORM

8
FORl\/IAT
OF
RECORD
9
AGENCY
(P)(W)(V)

10
REMARKS

11
1.0 RAW MATERIAL
1.1 Material for
body, nut &
ferrules
Chemical
Composition
Chemical
Analysis
MA Sample
from each
heat
Applicable
standards
Applicable
standards
Test
Reports
3 2 1 To be
done in
NPCIL
Approved
Lab
Physical
properties
Tensile
Strength
Hardness
Test
MA Sample
from each
heat
Applicable
standards
Applicable
standards
Test
Reports
3 2 1 To be
done in
NPCIL
Approved
Lab
2.0 IN PROCES S/ROUTINE TEST
2.1 Body Threads Gauging MA 100% NPCIL
Approved
Document/
drawings
NPCIL
Approved
Document/
drawings
IQC
records
2 2 1

60615 / PP-E-155 JULY 2009

FOR REV. NO. 4
TUBE FITTINGS

Sr.
No.

1
COMPONENT/
OPERATION

2
CHARACT-
ERISTICS

3
TYPE
OF
CHECK
4
CLASSIF-
ICATION

5
QUANTUM
OF CHECK

6
REFERENCE
DOCUMENTS

7
ACCEPTANCE
NORM

8
FORl\/IAT
OF
RECORD
9
AGENCY
(P)(W)(V)

10
REMARKS

11
2.2 Body Dimensions Measurem
ent
MA 100% NPCIL
Approved
Document/
drawings
NPCIL
Approved
Document/
drawings
IQC
Records
2 2 1
2.3 Nut Dimensions Measurem
ent
MA 100% NPCIL
Approved
Document/
drawings
NPCIL
Approved
Document/
drawings
IQC
Records
2 2 1
2.4 Ferrule Dimensions Measurem
ent
MA 100% NPCIL
Approved
Document/
drawings
NPCIL
Approved
Document/
drawings
IQC
Records
2 2 1
3.0 FINISHED PRODUCT /ROUTINE TESTS
3.1 Fittings Dimensions
(overall)
ferrule ID,
nut ID and
nish
Measurem
ent
MA 100% NPCIL
Approved
Document/
drawings
NPCIL
Approved
Document/
drawings
Test
Report
2 1*
1
* 10% by
1.
3.2 Fittings NPT threads Gauging MA 100% NPCIL
Approved
Document/
drawings
NPCIL
Approved
Document/
drawings
Test
Report
2 1*
1
* 10% by
1.

60615 / PP-E-155 JULY 2009

FOR REV. NO. 4
TUBE FITTINGS

Sr.
No.

1
COMPONENT/
OPERATION

2
CHARACT-
ERISTICS

3
TYPE
OF
CHECK
4
CLASSIF-
ICATION

5
QUANTUM
OF CHECK
6
REFERENCE
DOCUMENTS

7
ACCEPTANCE
NORM

8
FORl\/IAT
OF
RECORD
9
AGENCY
(P)(W)(V)

10
REMARKS

11
3.3 Fittings Hydrostatic
Pressure
Test
Strength/
Material
Integrity
MA 1% of
randomly
selected
ttings
forming a
loop.
As per
NPCIL
approved test
procedures
AsperPP-E-1551 Test
report
2 1&2 1
3.4 Fittings Pneumatic
Leak Test
Leak
tightness
MA I% of
tting
formed as a
loop.
As per
NPCIL
Approved test
procedures
AsperPP-E-1551 Test
report
2 1&2 1
3.5 Fittings Re-
Assembly
Leak Test
Re-
assembly
MA Same loop
for re-
assemble.
As per
NPCIL
Approved test
procedures
AsperPP-E-1551 Test
report
2 1&2 1
4.0 Identication
And packing
Adequacy of
identication
and packing
Visual MA 100% As per
NPCIL
Approved test
procedures
Approved
procedure
-- 2 2 1

LEGEND:
P = Performed by 1. NPCIL
W = witness by 2. Manufacturer
V = verified by 3. Third party
MA = Major

60615 / PP-E-155 JULY 2009

PP E 155 R4b Brass Tube Fittings.

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NUCLEAR POWER CORPORATION OF INDIA LIMITED

TECHNICAL SPECIFICATION PAGE NO. 1 OF 11

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