Purchase Specification

Technical Quality Sulzer Pumps

Page: 1 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas 1.0 Scope

This purchase specification details the minimum inspection, testing and certification requirements for castings requiring certified material test reports, 100% surface examination using magnetic particle or liquid penetrant methods and radiographic examination of critical areas. Note:- Sulzer procedures referred to in this specification can be down loaded from www.sulzerpumps.com/spukstds

2.0 3.0
3.1

Materials
Material type specification and grade shall be as stated in the Sulzer Purchase Order.

Manufacturers Certification
The following documentation shall be provided as appropriate: a) Certified material test report (e.g. EN 10204 type 3.1) b) Heat treatment details including any post weld heat treatment c) NDE report on completion of surface examinations d) Location and size of major repair excavations e) NDE report of repair excavations f) NDE report on completion of a weld repair

3.2

All documentation shall be in the English language, legible and suitable for reproduction.

4.0
4.1 4.2

Inspection
Examinations shall be carried out on completion of heat treatment. Visual examination: a) Test Procedure Sulzer TP-0012 Visual examination of castings b) All surfaces of the casting shall be examined and shall be free of adhering sand, scale, cracks and hot tears. Other surface indications shall meet the requirements of MSS-SP55 c) Hydraulic surfaces are to be clean and free from obtrusions with a surface finish in the order of 25m (N11) / SCATA A1

4.3

Magnetic particle examination a) Test Procedure Sulzer TP-0002 Magnetic particle testing of ferromagnetic materials b) Areas to be examined 100% accessible surfaces c) Acceptance ASME VIII App 7 Para 7-3 (3)

4.4

Liquid penetrant examination: Note:- Liquid penetrant shall only be carried out when magnetic particle examination is not feasible due to casting configuration or metallurgy. a) Test Procedure Sulzer TP-0001 Liquid penetrant examination b) Areas to be examined 100% accessible surfaces c) Acceptance ASME VIII App 7 Para 7-3 (4)

4.5

Radiographic Examination: a) Test procedure Sulzer TP-0007 Radiographic examination of castings b) Area to be examined Areas to be examined are as shown in Appendix A. Where a suitable sketch is not shown then the supplier shall submit to Sulzer details of the proposed areas to be radiographed for approval c) Acceptance ASME App 7 clause 7.3 (1)

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

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3103

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Purchase Specification

Technical Quality Sulzer Pumps

Page: 2 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas
4.6

Sulzer and/or their clients representatives shall be afforded access and assistance at all reasonable times to carry out inspections at the manufacturers premises.

5.0
5.1 5.2 5.3

Repairs
Unacceptable surface imperfections shall be removed and blended into their surrounding surfaces to avoid any sharp contours. Iron castings shall not be weld repaired, without Sulzer's written agreement. Whenever an imperfection is to be weld repaired, the excavation shall be examined by the liquid penetrant method (clause 4.4) to verify that the imperfection has been removed or reduced to an acceptable size. All weld repairs shall be carried out using welding procedures and operators qualified in accordance with: a) ASTM A 488 / ASME IX or b) ISO EN 15614 / EN 287 Weld procedures and supporting qualifications shall be submitted to Sulzer for review prior to welding. Whenever impact testing is required by the purchase order or base material specifications then welding procedure qualifications shall include impact testing to the same test criteria. Definition of a major weld repair: a) Removal of more than 20% of the wall thickness or 25mm which ever is the smaller or b) Area of excavation exceeding 65cm

5.4

5.5 5.6 5.7

5.8

On completion of welding, repaired areas shall be blended into their surrounding surfaces to avoid any sharp contours and be examined by the liquid penetrant method (clause 4.4.) When subsequent heat treatment is required, examination shall be conducted after heat treatment.

6.0

Product Marking
To provide traceability between the material and the documentation, each piece of material/component shall be individually marked at a prominent location with the following: a. Casting melt/heat number b. Material grade and class c. Sulzer Purchase Order number, line item number and material number

7.0
7.1 7.2 7.3 7.4 7.5

General Notes
All certification and delivery advice documentation shall include the Sulzer Purchase Order number, line item number and material number. Certification shall be provided on or prior to delivery of the material. Acceptance of the material shall be on satisfactory compliance to the Purchase Order requirements. All standards referenced shall be current issues unless stated otherwise. Failure to comply with the above requirements could result in rejection or delayed payment of invoices.

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

PS

3103

Uncontrolled valid at time of printing

Purchase Specification

Technical Quality Sulzer Pumps

Page: 3 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas

Appendix A Radiographic Shooting Sketches

Application Description Inlet and outlet casing Inlet and outlet casing Weld neck flanges castings
Typical Pump Type Remarks

Reference Appendix 1 2 3

VCR JVCR VCR JVCR MSD HSB SM HPDM BBS BBT CD HZB OHH OHV ZE ZF

Critical casting areas Critical casting areas and weld preparations Suction tank weld preparations

Axial split casing castings

Axial split casing castings

Volute casing casting

Axial split casing castings

End suction pump casing

Axial split casing castings

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

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3103

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Purchase Specification

Technical Quality Sulzer Pumps

Page: 4 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas

Appendix A 1 Inlet and Outlet Casting

1. Radiographic shooting sketch for axial split casing casting that require radiographic examination of critical sections. 2. Areas to be radiographed are marked thus comprising one shot at each area location. 3. The largest practical film size shall be used to ensure adequate coverage of the areas indicated, but shall not be less than 150 mm x 100 mm.

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

PS

3103

Uncontrolled valid at time of printing

Purchase Specification

Technical Quality Sulzer Pumps

Page: 5 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas

Appendix A 2 Inlet and Outlet Casting with Weld Preparations

1. Radiographic shooting sketch for axial split casing casting that require radiographic examination of critical sections. 2. Areas to be radiographed are marked thus 3. The largest practical film size shall be used to ensure adequate coverage of the areas indicated, but shall not be less than 150 mm x 100 mm.

100% Coverage of weld preparation

One shot

One shot

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

PS

3103

Uncontrolled valid at time of printing

Purchase Specification

Technical Quality Sulzer Pumps

Page: 6 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas

Appendix A 3 Inlet and Outlet Casting

1. Radiographic shooting sketch for axial split casing casting that require radiographic examination of critical sections. 2. Areas to be radiographed are marked thus .

100mm min

100% Coverage of weld preparation

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

PS

3103

Uncontrolled valid at time of printing

Purchase Specification

Technical Quality Sulzer Pumps

Page: 7 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas

Appendix A 4 Axial Split Casing Casting

1. Radiographic shooting sketch for axial split casing casting that require radiographic examination of critical sections. 2. Areas to be radiographed are marked thus comprising one shot at each area location. 3. The largest practical film size shall be used to ensure adequate coverage of the areas indicated, but shall not be less than 150 mm x 100 mm.

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

PS

3103

Uncontrolled valid at time of printing

Purchase Specification

Technical Quality Sulzer Pumps

Page: 8 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas

Appendix A 5 Volute Casing Casting

1. Radiographic shooting sketch for axial split casing casting that require radiographic examination of critical sections. 2. Areas to be radiographed are marked thus comprising one shot at each area location. 3. The largest practical film size shall be used to ensure adequate coverage of the areas indicated, but shall not be less than 150 mm x 100 mm.

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

PS

3103

Uncontrolled valid at time of printing

Purchase Specification

Technical Quality Sulzer Pumps

Page: 9 of 9

Castings - Requiring certified material test reports, 100% surface examination (MP or DP) and radiographic examination of critical areas

Appendix - A 6 End Suction Pump Casing Casting

1. Radiographic shooting sketch for axial split casing casting that require radiographic examination of critical sections. 2. Areas to be radiographed are marked thus comprising one shot at each area location. 3. The largest practical film size shall be used to ensure adequate coverage of the areas indicated, but shall not be less than 150 mm x 100 mm.

Revision: 1 Date: 14-01-08 Amendment: RT sketches 5 and 6 added to appendices This document has been prepared & published under the authority of the Technical Quality Working Group

Doc No:

PS

3103

Uncontrolled valid at time of printing