FOUNDRY DIVISION Date : 31/12/13 Description of Material : © EXOTHERMIC CUM INSULATING SLEEVES Anmual Quantity : 22000 Nos. Approx. Annual Value Rs, 1330000/- Pre-qualification criteria for supply of Exothermic Cum Insulating Sleeves 1 Supplier should be manufacturer/Agent of Exothermic Cum Insulating Sleeves and should be able to supply various sizes sleeves as per BHEL specification, Exothermic Cum Insulating Sleeves should be as per specification AAS36i8 Rev-O1. Party should have Monthly capacity of Minimum 10000 Nos. for supplying of Exothermic Cum Insulating Sleeves. ‘The party should have the experience of minimum three years of making and supplying Exothermic Cum Insulating Sleeves. Work order / P.O. to be submitted for proof. List of customers along with contact details to be furnished. Following must be acceptable to interested parties :~ + BHEL reserves the right to inspect the material at site before dispatch. ‘The supplier shall intimate in advance enclosing a copy of test certificate of the material offered for inspection. - If the material received is not found suitable to our requirements, it shall be replaced free of cost by supplier. - Final tests shall be carried out at BHEL and material will be accepted or rejected based on this result. L ego ‘Asst. Engineer (FYM)AA 53618, For Fn RPORATE Rev. No. OF rT co! PURCHASE SPECIFICATION =" (COPYRIGHT AND CONFIDENTIAL . ‘Te Information on this document isthe property of BHARAT HEAVY ELECTRICALS LIMITED Gp bed de or aie many wey desinertl othe ater fe 40 20 3.0 40 44 42 43 44 45 46 47 PAGE 1 OF 4 EXOTHERMIC AND /OR INSULATING SLEEVES AND FLEXIBLE BOARDS FOR USING IN FOUNDRY GENERAL: . This specification govems the requirement of riser fining material in the form of oyiindical oval sleeves, and rectanguar or square fexible boards, APPLICATION: ‘The material shal be used for riser lining in order to enhance riser efficiency in making castings. COMPLIANCE WITH NATIONAL STANDARDS: ‘There is no National standard in compliance with this specication. PROPERTIES: ‘The material shall be Exo-Is0 or insulatng in nature. Itcan be of duplex type also Le., ‘exothermic material in metal contact surface and insulating material on outer side, The Sleeves / hoards shal! be homogeneously bonded and shall have smooth and well finished surface, sfree from cracks, bow holes, cavity, patches. Edges and comers should be sharp’ and intact, Strength: The sleeve shal have strength to withstand the compressive pressure of femme muidng sand an! should re develop crack, scant dlaton (2% mex) or colapse, The compressive strength shall be 10-12 kglom™. When unpacked and taken out from the wrapper, moisture content shoud not exceed 49% in sleeve material “The buk density shall be In the range of 07 gm/oc to 0.8 grvce. Permeatitty shall be in the range of 120-150. The minimum Modulus Extension Factor (MEF) shall be as glen below but material with higher MEFS shall be preferred. Sleeve 4mm) Min MEF 2 Exoiso Tasulating ‘upto 150 mm 155 435 4180-225 mn. 145 130 250-300 mm 14 130 325 and above 13 42 Revisions + (C119.2 & 19.9.37 of MOM of MRC-EN RATIONALISATION COMMITTEE-MRC (FN) ‘APPROVED : - INTERPLANT MATERIAL, February, 1994 Rev.No.0t | Amd.No, Reaffirmed | Prepared Inwed Dt. of Ist Tasue De: 18.06.2005 | De: Years ‘BHOPAL Corp. R&DPAGE 48 49 50 60 70 For rr CORPORATE PURCHASE SPECIFICATION atta 2 OF 4 When the material is in cindrical form the thickness shall het 10% of the inlemat diameler. In case of eval shaped sleeves, thickness shell be 12.8% of minor axis length rounded off to nearest S mm oF as agreed between supplier and BHEL. Height shal be 28 agreed between supplier and BHEL in case of boards - flexible, square or rectangle thickness shall be as per agreement The tolerance on thickness shall be 410% or 22 mmm whichever is less. In case of boards - flexible, square or rectangular, thickness shall be as agreed between supplier and BHEL. ‘While the riser lining material is used, the covering powder and its quantity for the lined fiser shai be as agreed between customer and suppter, for which purpose a table is to bbe provided by the supplier TESTING: Random sampies shall be taken from each batch of the consignment for checking the Properties as per clause No. 4.0 (Except clause 4.7) The recommended MEF, volumetic effidency and extent of gas evolulin and entrapment shail be verified by BHEL representative at supplier's site, The method of verifcaton of MEF, volumetic efficiency and gas evolution and entrapment shal be as agreed behwsen customer and supplier Typical examples are given in annexures enclosed. TEST CERTIFICATES: Three copies of test certificates shall be supplied, unless otherwise slated on the order. in addition, the supplier shat ensure to enclose one copy of the tes! certcate along with their dispatch documents to factitate quick clearance of the mater ‘The test certificate shalt bear the foliowing information AA 536 18, Rev 01: Exothemmic and /or insulating sleeves and flexible boards for using in foundry BHEL order No ‘Specification No.: Exolso / insulating / duplex riser fining material ‘Supplier reference / bade mark Identification Nofbatch no. Properties as per Clause No.4.0 Any other specific information which the supplier would lke to convey. INSPECTION, DEVIATION AND REPLACEMENT: BHEL reserves the right to inspect material at site before despatch. The supplier shall inmate in advance enclosing a copy of test certiicate of the matenal offerad for ipspection. “However inspection at BHEL shall be final. The supplier shall olfer BHEL. representative af reasonebie facies witout charge to salisty the latter that the ‘material is being fumished in accordance with this specification. The supplier shall Prepare and provide necessary test specimens for testing tO be carried out at his premises. If feciiies are not available at his works, the supplier shail make necessary arrangements for camying out the prescsibed tests escwhore #1 the material received atCFFP is not found in accordance with the requirements, it shall bbe rejected an the supplier will have to replace it free of cast at the earliest. For any deviation from the specfication demanded by the supper, prior approval of BHEL must be obtained in writing,8.0 PACKING AND MARKING : ‘The material shall be sutably packed lo avoid damage, breakage and moisture pickup during transit and storage. Each consignment is to be legibly marked of labeled with the following information ‘AA. 536 49 ; Exothermic and /or insulating sioaves and flexible boards for using in foundry BHEL order No. ‘Specticaton No.: Exo-lso/ insulating / duplex riser fring material Manufacturers/Suppliers name and trace mark, f any, Batch No. Size and quantity surpled. Dateotranuiactare ‘Any rmaerial found broken, damaged, sol due to improper packing or mishanding dtinng transportation or otherwise shal be rejected and has to be replaced in equal quantity by the supper within 15 days of imation. 9.0 REFERRED STANDARDS (Latest Publications Including Amendments) DIN 1690, Pe IT ANNEXURE — Verification of Module Extension Factor (MEF) as recommenced by supplier. Testing shall be done on a cube casting provided with a circular fined! nee Mrirum feed safety margin to be considered 2s 20% af Ined riser ing height The contact surface of ser base to casting top shal be considered nor-co3ing, ‘After covering the riser top with recommended covering power, the coolng coefficient coftiser top shal be treated equa to side surfaces of ed nser The cooling coefficient of cube top which isnot in contact of riser base shal have the Value equal to other sies (a (2/)£¢")} for cube of side ‘a! andriser cierneter‘c) Riser shall be parted off from casting by sawing - not by gas culing. The rise then shal be splitted vertically lo physically observe stvinkage Pattern and measuring the ‘feed safety margin, ‘The cube casting shal be eubjected to UT as par DINT690 Patt Il Guslty level 1. The UT shal be done to check shrinkage only and not for any other defect &g., incision, segregation, crack, etc Iffelt necessary, the cube casting can be parted offin pieces by sawing and ventying {orshrinkagedefects Llu meta! shal be plain C stod (economic consideration) at 1565410°C, Moutding sand shal be ether sodium silicate bonded sand or phencl resin bonded sand, Nore pressurised gating system shall be at the rao of 12-3: 4.5 (from sprue to ingate) ‘The riser fop shell have prevision to accommodate the reccermended quantiy of ‘covering powder. Adkiion of covering powder shal be done inmedataly after pour Boling iondency of fas meta f any in the secve riser shal be noted tf cing coninues for more than 2 minutes, gas evolution in Seeve shall be considered ‘excessive and table for rejection,AA 536 18 Rev. No. OF CORPORATE PURCHASE SPECIFICATION PAGE 4 OF 4 Example: When recommended! MEF for 6250 sleeve is 1.4, fora sleeve rser of H=D. Maduhis © (25075) X 14= 70 oi 1 6250 lined riser is placed on a cube of 320 mm side, all § surfaces of cube shal have cooling coeficient of 7 and the top surface under riser shall ave cooing coefficient equivalent to (820 X 320 - 0.785 X 250 X 250] # (320 X 320) = 05208 Hence casting morhitss = 320 / (HO 82/1))= 57.97 mm Hence, ser modulusfeasting maduius = 1.2075 Hence 6250 HT.250 mm sleove, wih MEF 1.4, shal be suffcent io feed a cube of 320 mm, ANNEXURE7 \Verieation of Modus Extension Faclor (MEF) 28 recommended by surple Altemative method for finding cube size ‘Suppose the test cube has side 300 mm. A sand riser has been placed on CConsigering sand rss¢ covering the tolal top surkace of cube, ube modulus = 3005 760 mm, ‘The comesponding desivad iser modulus = 60 X 12 = 72 mm. Fer HED sand riser, the riser size shal be 72x5 = @360. Ifthe riser fring mater! (rcluding the covering powder) have MEF of 1.4, then the size of te fined ser shal bo (72)1.4)X- = 4280.14 approximates i 4250. Here the cooing effect of partion of cube not covered by riser has nol been donsidered. 7 nthés method for 300 mm cute size, §250 H=D riser with MEF = 4.4 shat work whereas, ‘Sccording to cther method the same rser shat feed 320 mm cube.