Specifications for manufacture and supply of Eccentric shafts & Spiral Bevel Gears for Pilgermills

1. Scope of supply:
Manufacturing, material testing, inspection at Supplier’s work, antirust coating & packing,
forwarding, transportation, delivery at site of Gears & Shafts.

2. Application:
Gears & shafts are used in power transmission system of Pilger mills which used for production
of tubes of various grades. These tube reducing mill are reciprocating machine.

3. Applicable standards and drawings

a) Reference Drawing
b) Analysis
c) Grain Size
d) Mechanical Testing
e) Ultrasonic Testing
f) Magnetic Particle Examination
g) Liquid Penetrant Test
: AS per Indent/Tender
: ASTM A291/A 291M - 05(2010)
: ASTM E112
: ASTM A370
: ASTM A388/A388M - 11
: ASTM 275/A275M - 08(2013)
: ASTM E 165

4. Manufacturing
a) Gears & Shafts shall be manufactured to dimensions as per enclosed Drawing.
b) The original forging shall be subsequently brought to normalized condition through heat
treatment.
c) Sufficient discard shall be made in the ingot to secure freedom from piping and segregation.
Size of the forging shall be such that sufficient extra material is available for accommodating
all the test specimens including material for retests required if any.
d) The Gear & shaft grinding shall be carried out as per the attached drawings.
e) Final product surface shall be clean, smooth and free from injurious discontinuities like
scratches, tears, cracks, etc.

5. Inspection and Testing

a) The supplier shall submit a Quality Assurance Plan (QAP) before manufacturing for approval
of quality checks at each stage of manufacturing. The NFC reserves right to carry out
inspection at any stage of manufacturing and witness any test carried out by them.
b) Chemical composition of raw material: The supplier shall submit the chemical analysis from
govt. approved lab/NABL accredited lab with traceability national/ international standards.
Also one sample in the product shall be submitted to NFC engineers to test the same at NFC.
c) Visual and Dimensional Checks: Visual and Dimensional checks shall be carried out by the
manufacturer at every stage of operation for ensuring final dimensions within allowable
tolerances. The dimensions of the Gears & shaft shall be as per enclosed Drawings. However
the same checks would be carried out by NFC engineers during their stage-wise and final
inspections.
d) Non Destructive Testing
I. Hardness: The Gears & shaft shall be as per the drawings. The same will be verified
during visit of NFC engineers.
 II. Liquid Penetrant Test: All the surfaces shall be examined by a liquid penetrant
method as per the Recommended Practice ASTM E 165 and acceptance criteria as
per S19, ASTM A778/A778M - 14 (and shall be free from any surface defects).
Manufacturer shall carryout LPT at intermediate stages. Acceptance limits and no.
Of stages shall be as agreed upon by the manufacturer and the purchaser.
e) Ultrasonic Testing: The forging shall be subjected to Ultrasonic testing by Back reflection
Technique using normal beam & angle beam as per ASTM A388/A388M with acceptance
criteria 12.1.2.1 QA-1, ASTM A745/A745M – 12 (Angle beam reference acceptance shall be
based on a notch depth of 3 % of the thickness of the forging) at the time of examination.
Manufacturer shall submit UT procedure for approval which will be used for examination.
f) Magnetic Particle Examination: The magnetic particle examination of the gear & shaft shall
be done on completion of all machining operations. The examination shall be in accordance
with Test Method ASTM 275/A275M - 08(2013).
g) Metallography: The grain size of the forging following heat treatment shall be as per ASTM
5 or finer in accordance with Test Methods ASTM E112 -13. Manufacturer shall analyze the
grain size by an accredited laboratory. Also one sample shall be made available for NFC
engineers to test it from our side.
h) Mechanical Tests: The mechanical tests shall be carried out to meet the tensile
requirements mentioned in TABLE 2 Grade 4 Classes E .i.e. 795 Mpa minimum as per ASTM
A291/A 291M - 05(2010), . Tests shall be carried out after normalizing heat treatment of the
forging. For Gear & shaft, tension testing at the prolongation mid-radius position shall be
done.

i) Charpy Impact Testing: One set of three longitudinal Charpy V-notch specimens shall be
taken at the mid-radius position, for testing at room temperature. The notch shall be
oriented at right angles to the surface of the prolongation, that is, radially. The absorbed
energy shall be 35J minimum.

6. Acceptance criteria:
The Gears & shaft would be accepted after conducting all the above tests by the manufacturer
and NFC engineers at various stages as per QAP. All the test reports carried out at different
stages shall be submitted along with item.

7. Documents to be submitted
a) Along with offer
 Detailed technical offer complete in all respects as per this document
 Proof of experience in manufacturing & supply of Gears & Shafts of similar type.
 Details of Design, Production and Inspection Facilities available
 Any technical literature supporting their offer
b) Within 15 days from the placement of order
 Detailed manufacturing process with tentative schedule
 Quality Assurance Plan (QAP) for manufacturing, indicating different tests/inspections to
be carried out. Inspection will be carried out by purchaser/purchaser’s representative as
per QAP.
c) Along with supply
 3 sets of Original Fabricated drawing along with soft copy
  2 sets of Inspection reports as mentioned in #5.0
 Warranty

8. General Conditions
 Vendors are encouraged to visit the site before quoting. Before visiting with advance
intimation can be sent to either 040-27184439/4884 or by e mail to udbhav@nfc.gov.in,
along with details.

9. Qualification criteria
 Offers from Gear manufacturer will only be considered.
 Original manufacturer shall have experience of at least five years in manufacturing and
supply of Spiral bevel Gears as specified in this tender.

10. Warranty
Warranty for a period of eighteen months shall be provided after acceptance and receipt of the
Gears & Shafts at NFC Stores. Supplier shall undertake to replace failed Gears and shafts within
the warranty period within reasonable period mutually agreed by NFC and the vendor. The
supplier shall submit a performance Bank Guarantee for this period.