v AA 101 52

CORPORATE PURCHASING SPECIFICATION Rev. No. 06

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STEEL TUBES - ELECTRIC RESISTANCE WELDED / SUBMERGED

ARC WELDED

1.0 GENERAL:

This specification governs the quality requirements of light, medium and heavy grades of
Electric Resistance Welded/Submerged Arc Welded steel tubes with plain ends in
ungalvanized and galvanized condition in the range of 60mm to 150mm NB.

2.0 APPLICATION:

For general purpose, suitable for bending, welding and screwing for flanges and fittings. Not
suitable for steam services.
3.0 CONDITION OF DELIVERY:

Tubes shall be supplied with plain ends.

The ends shall be cut cleanly and square with the axis of the tube.

Unless otherwise specified, tubes shall be supplied in ungalvanized condition.

4.0 COMPLIANCE WITH NATIONAL STANDARDS:

The material shall comply with the requirements of the following National standard and also
meet the requirements of this specification.

IS : 1239(part 1) - 2004: Steel Tubes, Tubular and other Wrought Steel Fittings
Gr: ERW .

5.0 DIMENSIONS AND TOLERANCES :

5.1 Sizes:

BHEL order shall clearly state the maximum outside diameter, and wall thickness of the tube.

5.2 Tolerances:
5.2.1 Thickness:

Light tubes + Not limited

- 8 percent
Medium and Heavy tubes + Not limited
- 10 percent

Revisions:
APPROVED:
INTERPLANT MATERIAL RATIONALISATION
Cl. 27.6.11 of MOM of MRC-S&GPS COMMITTEE-MRC (S&GPS)

Rev. No. 06 Amd.No. Reaffirmed Prepared Issued Dt. of 1st Issue

BHOPAL Corp. R&D JULY, 1976
Dt: 15.06.2005 Dt : Year :
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Rev. No. 06 CORPORATE PURCHASING SPECIFICATION

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5.2.2 Weight:
Single tube (light series) + 10 percent
- 8 percent

Single tube (medium and heavy series) 10 percent

For quantities per load of 10 tonnes, min (light series) + 7.5 percent
- 5 percent
For quantities per load of
10 tonnes, min (medium and heavy series) 7.5 percent

5.2.3 Internal Weld Fin:

Height of the internal weld fin shall not be greater than 60 percent of the specified thickness.
5.2.4 Length:

5.2.4.1 Random Length:

Tubes shall be supplied in random lengths of 4 to 7 metres, unless otherwise specified and in
the line with IS: 1239, Pt. 1.
5.2.4.2 Exact Length:
When exact lengths are called for, the tolerances shall be + 6mm, - 0 mm of the specified
length.

6.0 MANUFACTURE:
Tubes shall be made form tested quality steel manufactured by any approved process and shall
be fully killed.
Tubes shall not be manually welded.
7.0 FREEDOM FOR DEFECTS :
Tubes shall be cleanly finished and reasonably free from injurious defects. They shall be
reasonably straight. The ends shall be cut cleanly and reasonably square with the axis of the
tube.
8.0 CHEMICAL COMPOSITION :
The melt analysis of steel shall be as follows:
--------------------------------------------------------------------------------------------------------------------
Element Percent max. Permissible variation over speci ied limit max
--------------------------------------------------------------------------------------------------------------------
Carbon 0.20 0.02
Manganese 1.30 0.04
Sulphur 0.040 0.005
Phosphorus 0.040 0.005
-------------------------------------------------------------------------------------------------------
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9.0 GALVANIZING:
When galvanized tubes are ordered, the Zinc coating on the tubes shall be in accordance
with IS: 4736.
10.0 TEST SAMPLES:

All tubes bearing the same designation and manufactured under a single process shall be
grouped together to constitute a lot. Each lot shall be sampled separately in accordance with
IS: 4711.
11.0 MECHANICAL PROPERTIES :

11.1 Tensile:

The tensile strength of strips cut form selected tubes, when tested in accordance with IS:1608
shall be as follows:
Tensile strength : 320 N/mm2 , min.
Elongation on 5.65 So gauge length:
Upto and Incld. 25 mm NB : 12 percent, min.
Over 25 mm upto incld. 150 mm NB : 20 percent, min.

Note: 1. For welded tubes, the strip tensile test specimen shall not contain the weld.
2. For galvanized tubes, zinc coating may be removed by stripping prior to tensile test.

11.2 Bend Test (On tubes upto and including 50mm Nominal bore):

When tested in accordance with IS:2329, the tubes shall be capable of withstanding
the bend test without showing any signs of fracture or failure.
Tubes shall be bent with the weld at 900 to the plane of bending. The tubes shall not be filled
for this test.

Ungalvanised tubes shall be capable of being bent cold without cracking, through
1800 around a former having a radius at the bottom of groove in the plane of bending equal to
at least six times the outside diameter of the tube.

Galvanized tubes shall be capable of being bent cold without cracking of the steel, through
900 round a former having a radius at the bottom of the groove equal to at least eight times the
outside diameter of the tube.
11.3 Flattening Test (On tubes above 50mm Nominal bore):
Rings not less than 40mm in length, cut form the end of each selected tubes shall be
flattened between parallel plates with the weld at 900 (point of maximum bending) in
accordance with IS:2328. No opening shall occur by fracture in the weld until the distance
between the plates is less than 75 percent of the original outside diameter of the tube and no
cracks or breaks on the metal elsewhere than in the weld shall occur until the distance
between the plates is less than 60 percent of the original outside diameter.
Test rings may have the inner and outer edges rounded.
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11.4 Hydraulic Test/Eddy Current Test:

Each tube shall withstand a test pressure of 5 N/mm2 without showing leakage defects of
any kind. The pressure shall be applied and maintained for a minimum period of 30 seconds
for proof and inspection.
Note: Eddy current test may be done in place of Hydrostatic test as per the procedure in
Annexure-B of IS: 1239, Part-1.
12.0 TEST CERTIFICATES :

Three copies of test certificates shall be supplied, unless otherwise stated on the order.

In addition, to the above, the supplier shall ensure to enclose one copy of the test certificate
along with their dispatch documents to facilitate quick clearance of the material.
The test certificate shall bear the following information:
AA 101 52: Rev. No. 06: Steel tubes-ERW/SAW
BHEL order No,
Supplier's Reference :
Name
Identification No.
Melt No.
Results of Tests :
Results of Chemical, Mechanical tests and Hydraulic/Eddy Current test,
13.0 PROTECTIVE COATING

The shall be protected with a rust preventive coating of varnish, externally throughout the
length.

14.0 PACKING AND MARKING :

Each tube shall be plugged at both ends by means of tight fitting end caps.
The tubes shall be suitably packed in bundles/packages to prevent corrosion and damage
during transit.
Each bundle/package shall bear the following information:
AA 10152: Steel Tubes - ERW/SAW
BHEL Order No.
Consignment/Identification No.
Out side Diameter and Wall Thickness.
Supplier's Name

15.0 REFERRED STANDARDS (Latest Publications Including Amendments):

1. IS: 1239 2. IS : 1608 3. IS:2328 4. IS:2329
5. IS:4711 6. IS : 4736