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Ref: RRCAT/ACDFS/IAS/KEF/2014 Date: 01 Jul 2014

Technical specifications of stainless steel Type 316L knife edge vacuum flanges

1. Scope: This document covers the technical specifications for the manufacture and supply of knife edge vacuum flanges made from AISI SS316L stainless steel plates conforming to ASTM standard A240M and additional requirements set herein. This document also serves as a Vendor Confirmation Form. Incomplete and ambiguous responses will lead to the rejection of the offer. Vendor response shall be duly signed by authorised signatory and stamped with the company seal.

2. Scope of tender: Procurement of material, testing, machining, inspection, packing and supply of finished knife edge flanges according to this specification. Acceptance tests/inspection reports and supply of test certificates for all the tests mentioned in this document in electronic and paper form. Safe packaging and transport to the purchaser’s site.

3. General Conditions. 3.1. Qualification Criteria for the bidder: Quality management system and essential facilities

mandatory for qualification of the Bidders are summarized in Table-1. Vendors shall carefully write their responses against each entry. The purchaser reserves the right to visit the vendor’s facilities to verify the bid responses and the bidder shall agree to show/demonstrate all the facilities required and considered for completing this work. Insufficient facilities shall be a cause of rejection of the bid. It is mandatory to propose names of material manufacturers planned for sourcing raw material for flanges with the relevant catalogue pages in the bid itself. The raw material manufacturers shall be reputed stainless steel manufacturers of the specified grade with ISO 9001 certification or shall have an equivalent internal standard for QA and QC requirements. Change of the raw material manufacturer shall not be permitted without submission of full data about the quality of the proposed manufacturer and the material to the purchaser and a written permission from the purchaser. The vendors shall submit details of their quality management system including material procurement, process qualification, process control, inspection and non-conformance handling procedures along with their offer. RRCAT may ask the bidders for making presentation of their offers at RRCAT. Bidder should meet the following criteria to qualify for bidding-

a) All CNC machines required for finish machining of finished flanges shall be available in-house with the bidder. These operations cannot be sub-contracted.

b) The inspection of PCD of holes and gasket locating diameter of knife edge flanges is to be carried out on CMM having volumetric accuracy better than 10 microns in 300 mm X300 mm X300 mm. The inspection on CMM may be sub-contracted. The bidder has to submit a written agreement with the sub-contractee along with the bid.

c) The repeatability of machines proposed for finish machining of the flanges should be better than or equal to 5 microns. Bidder shall submit valid calibration report along with bid.

d) The proposed machines should not be older than fifteen years. e) Bidder should have experience of manufacturing of precision components having similar sizes

and tolerances. f) All final machining work shall be carried out on CNC machines with process qualification and

periodic process control. g) All inspection reports have to be prepared & submitted in Excel sheets showing the deviations in

proper red fonts along with signed paper copies of the same. h) Bidder shall machine all components of the qualification test setup as shown in Drg. No.

RRCAT/IMA/G/074/R-0. The welding of test setup with the pre-series flanges manufactured by the bidder and its testing will be carried out at RRCAT. RRCAT may need to make minor dimensional adjustments in the tolerances of the flanges based on this test and bidder shall agree to accommodate these minor revisions, if any. These changes will not have any cost implications and requirement of adjustment, if any, can only be confirmed after testing of the pre-series.

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Table-1: Qualification of the bidder – Essential Conditions and bidder’s responses. Note: Bidder shall give full details of machines/equipments including make, model, year of make, repeatability. Sr. No.

Mandatory quality system and facilities

Mandatory Information Regarding Vendor’s Facility, QAP & Raw Material Source

3.1.1. Quality Management System: ISO 9001 (or Equivalent1)

Accreditation Agency

Certificate Number

Issue Date Expiry Date

Vendor’s Response →

3.1.2 In-house machining facility2

Machine-1 Machine-2 Machine-3 Machine-4

Vendor’s Response →

3.1.3. In-house/bidder’s Inspection Facility – bidder to specify

Equipment-1(CMM)

Equipment-2 Equipment-3 Equipment-4

Vendor’s Response →

3.1.4 QAP for incoming raw material

Material manufacturer qualification

Material Certificate

Verification Method

Qualification of the Inspector

Minimum requirements for final production stage

ISO 9001 manufacturer with proven capability for 316L

Mill Certificate Testing at NABL accredited labs

Should have one year experience

Vendor’s Proposal →

3.1.5 QAP for outgoing finished flanges

CMM Inspection Examination for burrs

Visual examination of knife edge quality

Inspection of packaging

Minimum requirements 100% 100% 100% 100% Vendor’s Proposal →

3.1.6 Proposed raw material manufactures(with catalogue pages)

Manufacturer-1 Manufacturer-2

Vendor’s Proposal →

3.2. Cost Comparison of Offers: The purchase order cannot be split on different vendors due to the in-depth and exhaustive technical requirements for evaluation and control of quality provisions of the ultra-high vacuum knife edge flanges. The cost comparison will be made on the basis of cost of the total quantity of all types of flanges. These requirements are necessary to ensure proper quality of these components which have very critical applications in the accelerators under development. The attention and efforts required for qualification of manufacturing, testing and acceptance on part of RRCAT will be significant and considering available resource constraints, this cannot be repeated for more than one manufacturer.

3.3. Delivery Period: Pre-series flanges shall be delivered within two months of the PO date and final delivery of all the flanges within six months of the PO date.

1A quality management system is equivalent to ISO-9001:2000 if documented and standardized practices are being followed. 2 Please only mention the relevant machines which are crucial for the job.

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4. TECHNICAL REQUIREMENTS

The purchaser may witness full production/inspection facilities/process and ask for repeating the inspection at vendor’s premises using the equipments and manpower provided by the vendor.

4.1. Primary Specification of the raw material: The material for knife edge flanges shall be SS316L. The material for these flanges should be procured in single lot directly from qualified manufacturers (Ref Clause 3.1). All plates should have “original” manufacturer’s marking having information about grade, size, manufacturer’s name, batch/ID number etc. These markings (their photographs) shall be verified from the manufacturer for their genuineness and confirmation shall be copied to RRCAT. Any indication of these being spurious markings by the manufacturer shall lead to rejection of the raw material.

4.2. Raw material samples required for testing specified in tender document shall be prepared and submitted for testing in presence of RRCAT representative. The material testing charges shall be borne by the bidder. All the test reports, in one bunch, as mentioned in Table - 2 shall be submitted to RRCAT for clearance before starting the machining work.

Table-2: Raw Material Specifications

SN ITEM TENDER SPECIFICATION VENDOR’S RESPONSE

4.2.1 Steel Grade Stainless Steel Type 316L or equivalent4 4.2.2 Material standard ASTM A 240M or equivalent4 4.2.4 Chemical analysis ASTM A 240M or equivalent4 4.2.5 Mechanical properties ASTM A 240M or equivalent4 4.2.6 Material condition Solution annealed 4.2.7 Material source, properties

and markings To be verified from the original material manufacturer.

4.2.8 Ultrasonic examination Ultrasonic examination as per ASTM A435M/A577M

4.2.9 ASTM grain size no. 3 or more as per ASTM E 112 4.2.10 Inclusion content 2.5 or less in A,B,C and D as per ASTM E

45

4.2.11 Brinnel Hardness No. 150 (min) 217 (max)

4.2.12 Inter Granular Corrosion Test

ASTM A 262

4.3. Manufacturing Requirement: The machining of face, step bore knife edge and drilling shall be done

on CNC machines after qualification of the process and with periodic process control through inspection. Grinding, polishing and buffing operations are not allowed.

The blanks should preferably be cut using water-jet cutting machine. A suggested manufacturing process is given below. The Vendor may decide to change the suggested manufacturing process if such changes would benefit the product performance.

__________________________ 4 Equivalent materials or standards may also be used but the responsibility of proving the equivalence lies with the vendor.

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Table – 3: Suggested manufacturing process

I II III IV V VI

Make blanks with thickness +1 mm & finalise the OD

→ Drill bolt holes and do deburring

→ Make leak testing groove

→ Take a clean cut on the other face of the flange

→ Make face, step bore and knife edge

→

Do deburring

4.4. Production Plan: The production of flanges shall be preceded by a two-step approval process. 4.4.1. Sample Flange Manufacturing: The vendor will make one DN100CF (OD=152 mm) fixed type

flange as per attached drawing and after packing the flange as specified in clause 3.3 of the specification, will submit the flange to the purchaser along with the details of employed manufacturing process and quality control records. It shall be noted that minimum requirements of QAP mentioned in Table-1 must be adhered to. The Purchaser will carry out inspections to ensure compliance with the technical requirements as specified in this specification. If the flange fails to qualify the tests, then another flange will be submitted after incorporating the changes in the manufacturing process required for mitigation of the causes of disqualification. The process will continue till the vendor is able to establish manufacturing process capable of producing flange as per this specification.

4.4.2. Pre-Production Manufacturing: After approval of the sample flange, the vendor will submit a set of four flanges of each designation and each type as mentioned in the Table-5 along with the manufacturing process and quality control records. If any of the flanges fails to qualify the tests, then another set of flanges of the same type and design will be submitted after incorporating the changes in the manufacturing process required for mitigation of the causes of disqualification. The process will continue till the vendor is able to establish manufacturing process capable of producing flange as per this specification. Once the process is finalized and documented it will not be changed for subsequent production.

4.4.3. Final Production: The vendor will manufacture the flanges as per the dimensions mentioned in drawing and quantities mentioned in Table-5.

4.4.4. Marking: Each flange shall be marked preferably by laser/etching for material, type of flange and serial number e.g. RRCAT-SS316L - DN160CF - F/R #1-Year on the outer cylindrical surface as shown in the drawing. The same number shall also appear on the QC records to be supplied in excel sheets.

4.4.5. Cleaning and Packing: The flanges have special features which may be damaged unless handled carefully. All handling shall be done such that there is no possibility of denting the flanges. Flanges shall be cleaned and dried before packing. The knife edge shall be protected by an aluminium grade AA1100 knife edge protector and the same shall be placed in a 100 μm thick clean and transparent polythene bag. This packet shall be kept in a specially manufactured and properly fitting polypropylene flange cover and inserted in a properly fitting PE foam pre-from. The duly packed flanges shall be put in a wooden box. The wooden box shall provide adequate protection against shocks, vibrations, and handling forces. Please refer to attached drawing numbers RRCAT/IMA/G/076/R-0 & RRCAT/IMA/G/075/R-0 for details of packing (PE foam is to be used for filling and not thermocol).

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4.5. Quantity:

Table-4: Dimension and quantity of knife edge flanges Sr. Flange Name Drg. No. Quantity ( Nos.)

Pre-production

Production

4.5.1. Knife edge flange DN 40 CF RRCAT/IMA/G/077/R-0, dated 28-04-2014 2 198 4.5.2. Rotatable knife edge flange DN 40 CF RRCAT/IMA/G/078/R-0, dated 28-04-2014 2 38 4.5.3. Knife edge flange DN 63CF RRCAT/IMA/G/077/R-0, dated 28-04-2014 2 98 4.5.4. Rotatable knife edge flange DN 63 CF RRCAT/IMA/G/078/R-0, dated 28-04-2014 2 38 4.5.5. Knife edge flange DN 100 CF RRCAT/IMA/G/077/R-0, dated 28-04-2014 2 98 4.5.6. Rotatable knife edge flange DN 100 CF RRCAT/IMA/G/078/R-0, dated 28-04-2014 2 28 4.5.7. Knife edge flange DN 160 CF RRCAT/IMA/G/077/R-0, dated 28-04-2014 2 98 4.5.8. Rotatable knife edge flange DN 160 CF RRCAT/IMA/G/078/R-0, dated 28-04-2014 2 28 4.5.9. Adopter knife edge flange

DN 63 CF to DN 40 CF RRCAT/IMA/G/079/R-0, dated 28-04-2014

2 18

4.5.10. Adopter knife edge flange DN 100 CF to DN 63CF

RRCAT/IMA/G/080/R-0, dated 28-04-2014

2 18

4.5.11. Adopter knife edge flange DN 100 CF to DN 40 CF 2 18

Total 22 678

4.5.1 Quantity of raw material required: The estimated quantity of raw material required for manufacturing

of knife edge flange will be 5000 kg (approximate). Note – Minor changes in the tolerances of the flanges shall be accepted by the bidder after testing of the pre-series flanges. These changes will not have any cost implications.

4.6. Testing and acceptance In general all inspection, testing and documentation is the responsibility of the bidder. RRCAT will be free to carry out stage inspection and pre-dispatch inspection of materials, processes and flanges. Bidder shall arrange the manpower, tools, and access and recording facilities for RRCAT’s inspection/repeat inspection. All inspection reports have to be prepared & submitted in Excel format in soft copies and signed hard copies showing the deviations in red fonts with proper, numbered referencing to the jobs and tests. Test reports, digital photographs and process documentation shall be supplied by bidder to RRCAT.

4.6.1. Testing of raw material and inspection of flanges by bidder:

a) Testing of raw material as specified in Table -2 and Clause 4.1 of this specification. b) 100% inspection of knife edges and packaging of the flanges. c) All flanges have to be inspected on CMM for dimensional and geometrical accuracies

specified on the drawings. d) Certification of conformance to the specification by the suppliers. e) Packaging, transportation, inspection report and digital photographs to be submitted.

4.6.2. Acceptance: The Purchaser will accept the flanges on the basis of -

a) Quality control record of each flange prepared by the manufacturer and/or independent inspection by RRCAT. RRCAT may ask for repeating inspection of the flanges for verification and the manufacturer shall agree to do this.

b) Safe receipt of flanges meeting the requirements of this specification and supplied in the specified packing with inspection/testing documentation shall be accepted.

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Annexure –I Technical data sheet

Bidder shall furnish all relevant data of this form. Numerical values shall be clearly specified where given. Merely writing the generic terms such as YES or Agrees or OK shall be termed hiding of information. S. No. Description Specification Bidder’s offer

1. CNC machines In -house 2. CMM In –house or sub-contracted 3. CNC machines’ repeatability 05 µ 4. CMM’s volumetric accuracy in

300 mm X 300 mm X 300 mm 10 µ

5. Pre-production flanges To be made 6. Quality management system ISO 9000 or equivalent 7. Packing PP cover 8. Raw material Type 316L or equivalent 9. Machining process Process qualification and process

control

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X

DETAIL-X

DESCRIPTION DRN./DATE

1000

ANGULAR DIMNS:- ±0° 15'DIAMETRICAL DIMS:-

ALL DIMENSIONS ARE IN mmREMOVE SHARP CORNERS, EDGES BY CHAM. 1X45°

APPD.

LINEAR DIMNS:-IS : 2101-1980

SURFACE FINISH: 1.6

30 ± 0.3- 120

HOLE H11 & SHAFT h11

-1000-2000

- 315 315120

± 0.8± 1.2

± 0.5

0.5 - 66 - 30

± 0.1± 0.2

DGN

DRN

DO NOT SCALE THE DRAWING, IF DOUBT ASK

NOTES:

S.NO.

SIGN/DATESIGN/DATE NAMENAME

APPD

CHKD

GOVERNMENT OF INDIA

INDUSTRIAL ACCELERATOR SECTION

DEPARTMENT OF ATOMIC ENERGY

S DUTTA/SGG

C P VERMA 28-04-2014

P KUMAR

J DWIVEDI

BILL OF MATERIALMATERIALDESCRIPTION

SHT.

SCALE:-

QTY.

OF

1:1 A3

REMARKS

KNIFE EDGE FLANGES

DRG. NO. :- RRCAT/IMA/G/077/ R-01 1

ACAD REF : Knife Edge Flanges 28-04-2014.dwg

VIEW FROM 'Q'

Q

S.NO. ØAREMARKS

BØC ØD H N Ød

1. 70.0 58.7 48.35 42.0 13 6 Nos 6.6

2. 114.0 92.1 82.65 77.0 18 8 Nos 8.5

3. 152.0 130.2 120.75 115.3 21 16 Nos 8.5

+0.05 +0.1 +0.1(FLANGE OD) (PCD)

KNIFE EDGE

DN 40 CF

DN 63 CF

DN 100 CF

4. 202.5 181.0 171.55 166.1 22.3 20 Nos 8.5DN 160 CF

DN 40 CF, DN 63 CF, DN 100 CF & DN 160 CF

BLANK FLANGE

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VIEW FROM 'Q'

SCALE 10:1FEMALE PART

MALE PART

Q

DETAIL AT-`X'

KNIFE EDGE DETAILS

S.NO.

ØA

REMARKS

BØC1 H H1 N Ød

1. 70.0 58.7 48.35 13 7.7 6 NOs 6.6

2. 114.0 92.1 82.65 18 12.8 8 NOs 8.5

3. 152.0 130.2 120.75 21 14.4 16 NOs 8.5

FEMALE PART MALE PART

ØC2

48.3

82.6

120.7

42.0

77.0

115.3

7

12.1

13.7

ØD H2(PCD)

+0.05 -0.05 +0.1 +0.1 +0.05

-0.15-0.20

-0.15-0.20

-0.20-0.25

(FLANGE OD)

ASSY OF ROTATABLE FLANGE

ROTATABLE KNIFE EDGE FLANGES

DRG. NO. :- RRCAT/IMA/G/078/R0

KNIFE EDGE BLANK FLANGE

DN 40 CF

DN 63 CF

DN 100 CF

ROTATABLE

DN40CF, DN63CF, DN100CF & DN160CF

GOVERNMENT OF INDIA

INDUSTRIAL ACCELERATOR SECTION

DEPARTMENT OF ATOMIC ENERGY

4. 202.5 181.0 171.55 22.3 15.9 20 NOs 8.5 171.5 166.1 15.2

-0.20-0.25

DN 160 CF

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S NO.ØA ØB C

'A'ENLARGED VIEW AT 'A'

FLANGE COVERMATERIAL - POLY PROPELENE

DESCRIPTION DRN./DATE

1000

ANGULAR DIMNS:- ±0° 15'DIAMETRICAL DIMS:-

ALL DIMENSIONS ARE IN mmREMOVE SHARP CORNERS, EDGES BY CHAM. 1X45°

APPD.

LINEAR DIMNS:-IS : 2101-1980

SURFACE FINISH: 1.6

30 ± 0.3- 120

HOLE H11 & SHAFT h11

-1000-2000

- 315 315120

± 0.8± 1.2

± 0.5

0.5 - 66 - 30

± 0.1± 0.2

DGN

DRN

DO NOT SCALE THE DRAWING, IF DOUBT ASK

ACAD REF : Knife Edeg Flange Covers 28-04-2014.dwg

NOTES:

S.NO.

SIGN/DATESIGN/DATE NAMENAME

APPD

CHKD

GOVERNMENT OF INDIA

INDUSTRIAL ACCELERATOR SECTION

DEPARTMENT OF ATOMIC ENERGY

BILL OF MATERIALMATERIALDESCRIPTION

SHT.

SCALE:-

QTY.

OF

1:1 A3

REMARKS

COVER DETAILS FOR KNIFE EDGE FLANGESDN40CF, DN63CF, DN100CF & DN160CF

S DUTTA/SGG

C P VERMA 14-02-2014

P. KUMAR

J DWIVEDI

1 1DRG. NO. :- RRCAT/IMA/G/076/R0

PACKING DETAILS

+0.6+0.4

+0.6+0.4

KNIFE EDGE PROTECTOR(OD x ID x THK)

1. POLY PROPELENEFLANGE COVER SEE

2. ALUMINUMKNIFE EDGE PROTECTOR

DETAILS

SEETABLE

SCALE 5:1SECTION - XX

X X

REMARKS

3

2

1

DN 100 CF

DN 63 CF

DN 40 CF

152

114

70

98

60

33

22

19

14 48.15 x 36 x 1.6

82.4 x 63 x 1.6

120.5 x 101 x 1.6

FLANGE COVERDESIGNATION

KNIFE EDGE FLANGE

4 DN 160 CF 202.5 150 23.5 171.3 x152 x 1.6

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DRG. NO. :- RRCAT/IMA/G/075/R-0