Specification 1 4

IN-SITU ORBITAL TUBE BEVELING SYSTEM

Portable Orbital tube Beveling system – Part B Page 1/5

PART - B

SPECIFICATION FOR IN-SITU ORBITAL TUBE BEVELING SYSTEM Sl.No Particulars and BHEL specification Bidder’s offer

(With complete Technical Details)

1.0 PURPOSE

1.1

In-situ orbital beveling and chamfering system with single point cutting tool for facing, compound beveling of tubes (diameter range 33.0 to 76.1 mm) with wall thickness (4.0 to 12.5 mm).

The system should be suitable for beveling of OD controlled tubes of above diameter range.

The machine should be robust, portable and suitable for site application.

Ratcheting hinge mechanism should be provided to allow the heavy duty split frame to easily install on the OD of large diameter tubes to reduce the time & increases the productivity.

Vendor to Specify

2.0 TUBE SIZES

2.1 Tube diameters (OD) in mm Tube wall thickness (mm) Qty

Tube diameters to be handled: 33.0, 38.1, 44.5, 51.0, 47.6, 54.0, 63.5, 76.1 mm OD.

4.0 to 12.5 mm

3.0 MATERIAL SPECIFICATION

3.1 a. Carbon Steel: SA 210 GrA1, SA 210 Gr.C, SA106Gr.C

b. Alloy steels: SA213 T11, SA213 T22, SA213 T91

c. Stainless Steel: TP 347H, TP304

4.0 EDGE PREPARATION

4.1 Edge Preparation

Single V

J-groove

Square butt

ID taper boring on higher thickness tubes.

Vendor to Specify

5.0 MACHINE OUTPUT / PRODUCTIVITY

5.1 VENDOR should specify the minimum possible output of machined edges from one workstation, for tubes with the following dimeters, in a single shift of 8 hrs:

Vendor to Specify


Expected productivity is as follows: Tube Size:

(Gr C) 38.1 mm (OD) x 5.0 mm & 12.5 mm

76.1 mm (OD) x 5.0 mm & 12.5 mm

(T-22) 47.6 mm (OD) x 5.6 mm

(T-91) 54 mm (OD) x 7.1 mm

(Gr A1) 38.0 mm (OD) x 5.3 mm

(T11) 63.5 mm (OD) x 4.0 mm

(TP-347H) 76.0 mm (OD) x 7.1 mm

6.0 SCOPE OF SUPPLY

6.1 Design features

1. To cover a range of 30 to 80 mm diameter tubes.

2. Sufficient interior frame clearance should be provided to accommodate obstructions and deformed tube.

3. Roller bearing should be provided (rather than bushing) on load surfaces for durability and stability.

4. Bearings and drive gears should be fully enclosed for safety and durability.

5. Corrosion resistant finishes on all components to withstand harsh environments.

6. Mounts to O.D. with drive motor and slides installed, ready to operate.

7. Hydraulic and Pneumatic drive.

8. Standard ratcheting hinge mechanism should be provided to enable quick opening and closing of frame.

9. Built in lifting eyes for vertical and horizontal mounting.

Vendor to specify

6.2 Specifications

System Function: Split Frame type machine should be suitable for parting, beveling and facing of large wall thickness tubes.

Vendor to specify

System Capacity: Should be able to accommodate the following: Tube diameters to be handled: 33.0, 38.1, 44.5, 51.0, 47.6, 54.0, 63.5, 76.1 mm OD. Wall thickness: 4.0 to 12.5 mm

Vendor to specify

Cutting Tool Surface Speed: Vendor to specify Vendor to specify

Drive Options: Hydraulic and Pneumatic Vendor to specify

Power Requirements: 740 W @ 6 bar

Operating pressure : 6 to 7 bar

Vendor to specify

Feed Method: Positive mechanical starwheel Vendor to specify


Feed Rate: Vendor to specify Vendor to specify

Construction: Should be of hardened alloy steel components, sufficient section thickness, high capacity bearings, heavy duty pinion housing, corrosion resistant finish and ratcheting hinge mechanism.

Vendor to specify

6.3 STANDARD EQUIPMENT

1. Hydraulic or Pneumatic Drive Motor

2. Auto Resetting Single Trip Assembly

3. Lifting Hooks for Vertical or Horizontal Mounting

4. Ratcheting Hinge Mechanism for Scissoring Open and Closed

5. Self Squaring Mounting System with Adjustable Clamping Legs

6. Heavy Duty Storage Case

7. Operating Hand Tools

8. Operation Manual

Vendor to specify

7.0 Safety measures

7.1 All the tubes, cables etc. on the machine should be well supported and protected. These should not create any hindrance to machine operator's movement for effective use of machine.

Vendor to Confirm

8.0 Other features

8.1 The equipment should be portable

Vendor to specify

8.2 Normal life of the Spares and consumables (such as guide rings, loaded springs, Hex nuts, rollers, wheels, etc,.) to be specified, for a set of beveling conditions and environment.

Vendor to specify

8.3 Warranty period for any free service and replacement is min. 2 years

Vendor to specify

9.0 Installation, Commissioning and training

9.1 Inspection of the complete system by BHEL engineers at vendors place

9.2 Carrying out trials on a mock-up job at vendor’s works before dispatch.

Tube Material Outside diameter,

mm

Thickness of tube,

mm

No. of Joints to

be beveled

SA210GrC 63.5 7.1 2

SA213T11 44.5 4.0 2

SA213 347H 51.0 5.6 2

Vendor to Confirm

9.3 Installation, commissioning of the system at BHEL site


9.4 (minimum 10 joints to be beveled for meeting BHEL quality requirements)

Tube Material Outside diameter, mm

Thickness of tube, mm

No. of Joints to be beveled

SA106 GrC 76.1 12.5 5

SA213 T91 54.0 7.0 5

SA213 347H 76.0 7.1 5

Vendor to Confirm

9.5 Training of 4 operators at site for operating the machine after commissioning. Duration of training 2 days

10.0 Documentation

10.1 Three sets of following documents in tear proof hard copy and soft copy (CD)

Vendor to specify

10.2 Machine Operation manuals:

Operating manuals of Machine & system with machine specifications, detailed operating instructions for machine operation, setting of machine parameters, precautions, and machine safety details.

Vendor to specify

10.3 Maintenance and trouble shooting manuals:

Maintenance, Interface & commissioning manuals for system & drives

Catalogues, O&M Manuals of all bought out items including drawings, wherever applicable.

Detailed specification of all wear items and hydraulic / lube fittings

The vendor shall submit complete Master List of parts used in the machine.

Vendor to specify

11.0 Spares and Consumables

11.1 Itemized break-up of mechanical, hydraulic, electrical and electronic spares and consumable wear parts used in the machine in sufficient quantity as per recommendation of Vendor for 2 years of trouble free operation on three shifts continuous running basis shall be offered by vendor. The list is to include following, in addition to other recommended spares: (Unit Price for each item of spare shall be offered)

Vendor to specify

11.2 The Vendor shall bring special tools and equipment required for erection of the machine. Necessary tools like Torque Wrench, Spanners, Keys, grease guns etc. for operation and maintenance of the machine should be supplied. List of such tools should be submitted with offer

Vendor to confirm

11.3 Any Test mandrel required for checking & alignment of the machine components etc. should be supplied

Vendor to confirm

11.4 Vendor to confirm that complete list of spares for machine and accessories, along with item part no / specification / type /

Vendor to confirm


model, and name & address of the spare supplier shall be furnished along with documentation to be supplied with the machine

12.0 MACHINE PACKING

12.1 Sea worthy & rigid packing for all items of complete machine, control system, all accessories and other supplied items to avoid any damage/loss in transit. When machine is dispatched in containers, all small loose items shall be suitably packed in boxes

Vendor to confirm

13.0 GUARANTEE TERMS

13.1 Performance Guarantee for a minimum period of 24 months (for the machine in total and sub-systems or bought-out items in particular) from the date of acceptance of the machine.

Vendor to confirm

14.0 Power supply

14.1 Input Power supply- 220 V, 50 Hz Vendor to confirm

15.0 General Points

15.1 Make and Model of the machine to be mentioned. Detailed catalogs of the machine to be sent with the offer.

Vendor to specify

15.2 Complete description of all systems & sub-systems shall form part of the technical bid

Vendor to confirm

15.3 A schematic diagram showing the layout of the machine & associated systems with salient dimensions shall be submitted along with the offer.

Vendor to confirm

15.4 The operating sequence of the machine with broad outline of various operations involved should be furnished with the offer.

Vendor to confirm

15.5 Total weight of the Machine & Sub-Systems. Weight of the heaviest part of the machine

Vendor to specify

15.6 Total connected load KVA Vendor to specify

15.7 Warranty period for the total system will be two years from the date of commissioning of the system at BHEL

Vendor to confirm

• •

Hiland Oilfield Services Pvt. Ltd. 423, Somdutt Chambers-II, 9, Bhikaji Cama Place, New Delhi - 110066, Ii'JDIA Phone: +91-11-26197740 Fax: +91-11-26197739 E-mail: [email protected] Website: www.hos-into.com

• I .

No. HOSjDjQUTj2011j050 8th Aug, 2011

Bharat Heavy Electricals Limited Tiruchirapalli - 620 014

Kind Attn: Dr. A. Raja {AGM/WRIl

Sub: Specification For Orbital Tube Beveling System &. Orbital Pipe Cutting &. Beveling System.

In accordance with your requirement, we have worked out a proposal to deploy Wachs Orbital Tube Beveling System & Orbital Pipe Cutting & Beveling System.

We are enclosing herewith our proposal for deploying the said machine as Annexure tto Annexure -5. The proposal provides the schedule of prices and terms and conditions. We shall be pleased to promptly provide any clarification, confirmation and details, should, you require the s

in you and hoping to arrive at a workable agreement soon.

IELO SERVICES PVT. LTD.

~ ~

Annexure -1

S.NO. PART NO. DESCRIPTION QTY. UNIT PRICE (USDl

TOTAL PRICE (USD)

1. 16-000-01 Wachs Air Powered SDB103/3 Portable Pipe & Tube Prepping Machine for facing beveling, compound beveling and counterboring 1" - 4" diameter pipe, complete with Heavy Duty Air Drive with Speed Control Valve, Standard Mandrel (1.16" - 4.18 I.D.).7 sets of Leg Extensions, Operating Hand Tools, Watertight Storage Case and Manual.

1 1\10. 6,020.00 6.020.00

2. 26-410-02 Facing Tool (non-Wedgelock) 1.16" to 3" I.D. 1 1\10. 70.00 70.00

3. 26-411-01 37-1/2 Degree Bevel Tool (non-Wedgelock) 1.16" to 3.0" I.D.

1 No. 95.00 95.00

~ ~

S.NO. PART NO.

1. 80-4000-10

2. 80-4000-20

3. 80-4000-30

4. 80-7001-02

5.

-.

52-710-03

Annexure -2

DESCRIPTION

Wachs 1" Small Diameter Split Frame Machine, complete with 1" Frame, Pinion Housing, Storage Case, Spare Fastener Kit, Hand Tools & Manual.

Wachs 2" Small Diameter Split Frame I"lachine, complete with 2" Frame, Pinion Housing, Storage Case, Spare Fastener Kit, Hand Tools & Manual.

Wachs 3" Small Diameter Split Frame Machine, complete with 3" Frame, Pinion Housing, Storage Case, Spare Fastener Kit, Hand Tools & Manual.

Parting Tool, 1/8" X Y2", 2.13" length Standard.

37-1/2 Degree Bevel Tool, 3/8" X Y2", 2.63" length - Extended Reach.

QTY. UNIT PRICE (USD)

TOTAL PRICE (USD)

1 1\10. 6,020.00 6,020.00

1 1\10. 6,195.00 6,195.00

1 No. 6,375.00 6,375.00

1 No. 120.00 120.00

1 No. 135.00 135.00

~ ANNEXURE - 3 ~

S. NO. PART NO. DESCRIPTION

1. 60-HYD-06 Wachs Hydraulic Powered SF206/3 Portable Low clearance Split Frame Machine for cutting and / or beveling 2" - 6" diameter pipe, complete with 206 Rotating Ring Set, 4 Jaw self -Squaring Chucking System (1) Set of four each Y2", 1", 1-1/2" and 2" Extension Legs, (l)Extended parting Tool Slide, (1) Extended Beveling tool Slide, Star wheel Feed Mechanism, Heavy Duty Right Angle Hydraulic Drive, Operating Hand Tools, Storage Case and Manual.

QTY.

1 No.

UNIT PRICE (USD)

13,980.00

TOTAL PRICE (USD)

13,980.00

2.

3.

4.

60-HYD-12 Wachs Hydraulic Powered SF612/3 Portable Low clearance Split Frame Machine for cutting and / or beveling 6" - 12" diameter pipe, complete with 612 Rotating Ring Set, 4 Jaw self -Squaring Chucking System (1) Set of four each 1", 2" and 3" Extension Legs, (l)Extended parting Tool Slide, (1) Extended Beveling tool Slide, Star wheel Feed Mechanism, Heavy Duty Right Angle Hydraulic Drive, Operating Hand Tools, Storage Case and Manual.

60-HYD-20 Wachs Hydraulic Powered SF1420/3 Portable Low clearance Split Frame Machine for cutting and / or beveling 14" - 20" diameter pipe, complete with 1420 Rotating Ring Set, 4 Jaw self -Squaring Chucking System (1) Set of four each 1", 2" and 3" Extension Legs, (l)Extended parting Tool Slide, (1) Extended Beveling tool Slide, Star wheel Feed Mechanism, Heavy Duty Right Angle Hydraulic Drive, Operating Hand Tools, Storage Case and Manual.

60-HYD-28 Wachs Hydraulic Powered SF2228/3 Portable Low clearance Split Frame Machine for cutting and / or beveling 22" - 28" diameter pipe, complete with 2228 Rotating Ring Set, 8 Jaw self -Squaring Chucking System (1) Set of eight each 1", 2" and 3" Extension Legs, (1) Super Extended parting Tool Slide, (1) Super Extended Beveling tool Slide, Star wheel Feed IViechanism, Heavv Dutv Rlqht Anqle

1 No.

1 No.

1 No.

21,030,00

32,998.00

41,638.00

21,030.00

32,998.00

41,638.00

Hydraulic Drive, Operating Hand Tools, Storage Case and Manual.

53,535.00 53,535.00 Portable Low clearance Split Frame Machine for cutting and j or beveling 30" - 36" diameter pipe, complete with 3036 Rotating Ring Set, 8 Jaw self -Squaring Chucking System

1 No. 60-HYD-36 Wachs Hydraulic Powered SF3036/35.

(1) Set of eight each 1", 2" and 3" Extension Legs, (1) Super Extended parting Tool Slide, (1) Super Extended Beveling tool Slide, Star wheel Feed l\1echanism, Heavy Duty Right Angle Hydraulic Drive, Operating Hand Tools, Storage Case and l\1anual.

62,315.001 No. 62,315.00 Portable Low clearance Split Frame Machine for cutting and j or beveling 36" - 42" diameter pipe, complete with 3642 Rotating Ring Set, 8 Jaw self -Squaring Chucking System

60-HYD-42 Wachs Hydraulic Powered SF3642/36.

(1) Set of eight each 1", 2" and 3" Extension Legs, (1) Super Extended parting Tool Slide, (1) Super Extended Beveling tool Slide, Star wheel Feed Mechanism, Heavy Duty Right Angle Hydraulic Drive, Operating Hand Tools, Storage Case and Manual.

Bridge Slide for Beveling above 1" wall thickness

7. 60-428-20

8. 60-428-28

9. 60-428-36

10. 60-428-48

Bridge Slide for single point beveling applications over 1" wall and counterboring for Wachs Models SF612j3 - SF1420j3.

Bridge Slide for single point beveling applications over 1" wall and counterboring for Wachs Models SF1824j3 and SF2228j3.

Bridge Slide for single point beveling applications over 1" wall and counterboring for Wachs l\1odels SF2632j3 and SF3036j3.

Bridge Slide for single point beveling applications over 1" wall and counterboring for Wachs Models SF3642j3 - SF4248j3.

Power Unit

1 No. 10,620.00 10,620.00

1 No. 10,835.00 10,835.00

1 No. 11,040.00 11,040.00

1 No. 11,295.00 11,295.00

11. 14-000-03 Wachs HCM-3E-50, 15 H.P. 415-440 Volt 50 Hz 3-Phase Electric Motor Driven Hydraulic Cart Mounted Power Unit, with Electric Motor Starter, Spark Arrestor, and oil Cooler. Fixed Volume of 15 GPM at 1500 PSI. Shipped without Hydraulic Oil.

6 Nos. 13,900.00 83,400.00

TOOLINGS

12. 05 20 Degree Bridge Slide Template

10 Degree X 37-1/2 Degree Bridge Slide Template

13. 11

60-234-00 Tool Holder for Bridge Slide 14.

52-701-0115. Standard 3/8" X 3/8" HSS Tool Bit for Single Point Facing Beveling, & Flange Facing.

43-711-01 3/16" Wide H.S.S. Parting Blade (5" Long).16.

1 No.

1 No.

260.00

260.00

1 No.

1 No.

180.00

90.00

1 No. 145.00

260.00

260.00

180.00

90.00

145.00

.~ ~

ANNEXURE - 4

S.NO. PART NO. DESCRIPTION QTY. UNIT PRICE (USD)

TOTAL PRICE (USD)

1. 60-HYD-06 Wachs Hydraulic Powered SF206/3 Portable Low clearance Split Frame Machine for cutting and / or beveling 2" - 6" diameter pipe, complete with 206 Rotating Ring Set, 4 Jaw self Squaring Chucking System (1) Set of four each 112", i", 1-1/2" and 2" Extension Legs, (l)Extended parting Tool Slide, (1) Extended Beveling tool Slide, Star wheel Feed Mechanism, Heavy Duty Right Angle Hydraulic Drive, Operating Hand Tools, Storage Case and l"1anual.

1 No. 13,980.00 13,980.00

2. 60-HYD-12 Wachs Hydraulic Powered SF612/3 Portable Low clearance Split Frame Machine for cutting and / or beveling 6" - 12" diameter pipe, complete with 612 Rotating Ring Set, 4 Jaw self Squaring Chucking System (1) Set of four each i", 2" and 3" Extension Legs, (l)Extended parting Tool Slide, (1) Extended Beveling tool Slide, Star wheel Feed Mechanism, Heavy Duty Right Angle Hydraulic Drive, Operating Hand Tools, Storage Case and Manual.

1 No. 21,030,00 21,030.00

3. P03-010-424 HDSF 1224/1 Heavy Duty Split Frame for cutting and/or beveling pipe range of 12" to 24" OD. Includes mechanical hinged rotating and stationary steel ring frames, with pneumatic or hydraulic drive motor, Set of two (2) O.D. tracking tool slides, single trip assembly, lifting hooks, one set of four (4) rnountlno feet to cover pipe ranee.

1 1\10. 62,935.00 62,935.00

~ ~

Operating hand tools, shipping container, and manual.

76,475.0076,475.001 No. P03-010-436 HDSF 2436/1 Heavy Duty Split Frame4. for cutting and/or beveling pipe range of 24" to 36" 00. Includes mechanical hinged rotating and stationary steel ring frames with pneumatic or hydraulic drive motor, Set of two(2) 0.0. tracking tool slides, single trip assembly, lifting hooks, one set of four (4) mounting feet

, to cover pipe range.

90,020.00 90,020.001 No. P03-010-448 HDSF3648/1 Heavy Duty Split Frame5. for cutting and/or beveling pipe range

, of 36" to 48" 00. Includes mechanical hinged rotating and stationary steel ring frames, with a pneumatic or hydraulic drive motor, Set of two (2) 0.0. tracking tool slides, single trip assembly, lifting hooks, one set of eight (8) mounting feet to cover pipe range. Operating hand tools, shipping container, and manual.

Bridge Slide for Beveling above 1" wall thickness

1 No. 10,620.00 10,620.0060-428-20 Bridge Slide for single point beveling6. applications over 1" wall and , counterboring for Wachs Models SF612/3 - SF1420/3 .

.15,000.00 15,000.0011\10.7. Bridge Slide for Model HDSF 1224/1-

- 15,000.00 15,000.00Bridge Slide for Model HDSF 2436/1 1 No. 8.

1 No. 15,000.00 15,000.00Bridge Slide for Model HDSF 3648/19. -

Power Unit 13,900.00 69,500.0014-000-03 Wachs HCM-3E-50, 15 H.P. 415-440 5 Nos. 10.

Volt 50 Hz 3-Phase Electric Motor Driven Hydraulic Cart Mounted Power Unit, with Electric Motor Starter, Spark Arrestor, and oil Cooler. Fixed Volume of 15 GPM at 1500 PSI. Shipped without Hydraulic Oil.

~ ~

TOOi..INGS 11. 52-701-01 Standard 3/8" X 3/8" HSS Tool Bit for

Single Point Facing Beveling, & Flange Facing.

3/16" Wide H.S.S. Parting Blade (5" Long).

1 No. 90.00 90.00

12. 43-711-01 1 No. 145.00 145.00

..~

ANNEXURE -5

COMMERCIAL TERMS AND CONDITIONS:

PRICES Above prices in US Dollars.

VALIDITY This offer is valid for 120 days.

SERVICE TAX Inclusive (10.3%)

TIMING To be mutually agreed.

PAYMENT Against L/e

Hope to receive your valued order.

o I you need any information/ clarification, please feel free to contact us.

You, ND OILFIELD SERVICES PVT. LTD.

ORBITAL GTAW TUBE WELDING SYSTEM

Orbital Tube Welding System – Part B Page 1/7

PART - B

Specification for Orbital GTAW Tube Welding System

Sl. No Particulars and BHEL specification Bidder’s offer (with Complete Technical

Details)

1.0 PURPOSE

1.1

Orbital TIG welding system with filler wire addition for in-situ welding of boiler tube butt joints at power plant erection site to result in higher productivity and quality.

The orbital TIG welding system shall be capable of following:

The system, should able to weld the OD controlled tubes having diameter range of 40 to 130 mm and wall thickness range of 6 to 18 mm. The joint may be of V or J groove.

Orbital tube welding with multiple passes involving multiple runs of the welding head around the tube.

Welding in 2G, 5G & 6G positions for carbon steel and alloy steel material of wall thicknesses ranging from 6 to 15 mm and outer diameters from 50 to 130 mm.

The system should be robust and suitable for site welding condition.

The system should be able to weld tubes requiring multi passes with weaving, torch movement, etc.

System should be suitable welding on preheated tubes. Preheat temperature range 120 to 220 °C.

The joints should be of radiographic quality as per ASME Sec IX and leak proof.

Confirmed

2.0 TUBE SIZES

OD controlled tubes of diameter range of 40 to 130 mm and thickness range of 6 to 18 mm.

Confirmed

3.0 TUBE MATERIALS

3.1 1. Carbon Steel

2. Alloy Steel

3. Stainless Steel

Confirmed equipment can weld all materials as specified.


4.0 WELD JOINT DETAILS

4.1 1. Edge Preparation

Single V equipment can be used with all specified details.

J groove

2. Pipe End Condition.

Machined in automatic end preparation equipment.


5.1 VENDOR has to indicate the minimum output of welded joints, possible from the workstation, for the tubes with the following dimensions/details, in a single shift of 8 hrs:

Yes confirmed.

Tube diameter Tube thickness Number of joints

63.0

66.0

127.0

7.0

8.0

12.5

Vendor to specify

6.0 SCOPE OF SUPPLY

Open welding Head equipped with wire feeder, oscillation unit and AVC control.

Power source.

Controller.

Remote operator pendant.

Water cooling unit.

Sub System

1. Torch gas control with flow meter with low flow detection

2. Ground cable.

3. PC laptop window keyboard/touch screen in English

4. Gas hoses.

5. Pressure regulator.

6. Adapter for connection standard power source

7. Recommended spares for power source and welding head.

8. Additional accessories

Confirmed

Confirmed

Confirmed

Confirmed

Confirmed

Confirmed

Confirmed

Confirmed

Confirmed

Confirmed

Confirmed

Confirmed

7.0 Orbital welding head


7.1 Orbital open type TIG welding head.

Radial clearance 50 mm or less.

TIG Cold wire feeder with spool holder.

Encoder for position based control of the welding program

Provision for constant or pulsed welding speed.

Precise and constant torch rotation by means of planetary drive.

Welding torch with ceramic nozzle and gas lens for laminar gas protection.

Motorised Arc Voltage control (AVC) and Torch Oscillation control (OSC) for multi pass welding of heavy wall tubes

Two interchangeable clamping system, i.e., clamp for fixed OD for precise and strong clamping, for heavy duty production, with water cooling for preheated tubes.

Motion controls

1. Torch rotation: Constant or pulsed

2. Wire feeding: Constant or pulsed/automatic wire retract

Welding torch cooling: Built in closed loop water cooling system with flow safety valve.

Confirmed

50 mm.

Yes

Yes

Yes

Yes

Yes

Yes Available

Yes

Confirmed

Confirmed

Yes Available

8.0 Power source

8.1 High precision invertor power source, compact design with integrated water cooling system

Input power: 230 V +/- 10%, 50/60 Hz

Max. Open circuit voltage: 80 V DC

Welding current range 2-425 A

Welding current precision +/-1%

Duty Cycle 100% by 275 A

Type of cooling – Wing Tunnel – Forced air.

Power source cooling: Forced Ventilation

Yes Confirmed

8.2 Controller

8.2.1 Controller integrated with weld head and power source.

Confirmed


Remote pendant for operation.

Rotation axis with electronic brake

8.2.2 Functions controlled

Wire feed speed: 1.0 to 25 m/min

Weld head rotation: 0 to 2 m/min adjustable

Weld head electronic cross-seam adjustment:

Remote cross seam adjustment:

Arc length control: Remote arc length adjustment

Pre-programmes for carbon steel & alloy steel in standard & pulsed mode for 0.8, 1.2 & 1.6 for solid, metal cored wires.

Confirmed

8.2.3 Wire feeder:

Drive type: four roll drive (with various groove geometries)

Wire diameter: 0.8 , 1.0 mm

Confirmed

0.8mm , 1.0mm

8.2.4 Gas hose with end fittings – Gas cylinder to power source Length to suit long travel on cable festoon

Confirmed

8.2.5 PC with the following features

a. Setting of all welding parameters,

b. Data logging with 0.1 sec frequency or 0.1 deg rotation

c. Trouble shooting for welding program software.

d. USB memory stick.

e. Internal PC memory.

f. Display, recording of real values during welding: Arc voltage, welding current, electrode position, angular degree, rotation and wire speed.

Confirmed

8.2.6 Each weld program for a unique combination should allow multiple pass welding each with unique/different parameters.

6 programmable levels per passes,plus upslope/down slope.

8.2.7 Different Parameter Values for each sector within a pass of 360° should be programmable enabling sector vise programming for each pass.

6 programmable levels per pass.

8.2.8 Front Panel Display (in English) ENGLISH

8.2.9 Contact K type temperature measuring digital sensor unit 1 no


Temperature measurement accuracy = ± 0.1⁰C Confirmed

9.0 Safety measures

9.1 Interlocks:

The system should trip in the event of:

Stoppage of shielding gas flow

Stoppage of cooling water flow

Stoppage of wire feeding

Stoppage of movement head around pipe.

Provided

9.2 All the pipes, cables etc. on the machine should be well supported and protected. These should not create any hindrance to machine operator’s movement for effective use of machine.

Confirmed

10.0 Other features

10.1 Post sequence Printing capability of all the weld parameters used (including overrides) and actual peak/min/average values for every pass to pass welding.

Confirmed

10.2 Orbital welding head radial Clearance of 50 mm or less. 50mm

10.3 Large color touch screen with multilingual, graphically assisted welding software

Confirmed

10.4 Extension cable (15 m) Confirmed

10.5 Gas hose Confirmed

10.6 Pressure regulator Confirmed

10.7 Normal life of the Spares and consumables (such as contact tips, guide rings, loaded springs, Hex nuts, rollers, wheels, etc,.) to be specified, for a set of welding conditions and environment.

Vendor to specify

10.8 Built in printer for perfect monitoring and traceability Confirmed

10.9 Full function remote control Confirmed

10.10 Expert help menu for procedure optimization Confirmed

10.11 Warranty period for 2 years any free service and replacement 12 Months

11.0 Services:

Installation, Commissioning and training

11.1 Inspection of the complete system by BHEL engineers at vendors place by carrying out trial welding on tubes of higher thickness to meet the quality requirements.

Confirmed

11.2 Carrying out welding trials on a mock-up job at vendor’s works before dispatch.

Confirmed


Tube diameter Tube thickness

63.0

66.0

127.0

7.0

8.0

12.5

The acceptance criteria for weld quality shall be passing Radiography as stipulated in ASME Sec IX, ANSI B31.1, and B31.3 for welding high- pressure piping in power plant

For trials BHEL will only provide only the pipe material.

Welding will be done by vendors (including welding consumable)

Testing at vendor’s works

Confirmed

11.3 Installation, commissioning of the system at BHEL site Confirmed

11.4 Carrying out welding trials on the following material combination of pipes at BHEL site satisfactorily meeting the quality requirements as per ASME SEC IX for welding high pressure tubes in power plant (minimum 4 joints to be welded in succession for meeting quality requirements as per ASME SEC IX & ANSI B31.1, and B31.3 ) on the following sizes.

Tube diameter Tube thickness

63.0

66.0

127.0

7.0

8.0

12.5

Subsequent to qualification of tubes, actual jobs in in-situ condition has ot be done by vendor.

Vendor to confirm

For trials BHEL will only provide only the pipe material.

Welding will be done by vendors (including welding consumable)

Confirmed

11.5 Training of operators at site for operating the machine in in-situ condition after completing the commissioning. Duration of training 3 days (without any charge)

Confirmed

12.0 Documentation

12.1 Three sets of following documents in tear proof hard copy and soft copy (CD)

Machine operation manuals

Maintenance and troubleshooting manuals

Troubleshooting procedures for different error codes and problems must be addressed in the manuals.

Confirmed

12.2 Machine Operation manuals: Vendor to specify


Operating manuals of Machine & system with machine specifications, detailed operating instructions for machine operation, setting of machine parameters, precautions, and machine safety details.

Programming Manuals of Machine & system

12.3 Maintenance and troubleshooting manuals:

Maintenance, Interface & commissioning manuals for system & drives

Catalogues, O&M Manuals of all bought out items including drawings, wherever applicable.

Detailed specification of all wear items and hydraulic / lube fittings.

The vendor shall submit complete Master List of parts used in the machine.

On line fault diagnostic system

Confirmed


13.1 Should cover gas cups, ceramic torch insulators, gas diffusers, washers, Wire feeder drive wheels for 1.2mm wire dia., Tapered Welding Tips, Bullet tips for water cooled torch (for 1.2mm wire dia.) etc

Confirmed

13.2 Itemized break-up of mechanical (nuts, bolts, tension springs, cams, etc) , hydraulic, electrical electronic spares (All types of Printed Circuit Boards, Proximity Switches, Push Buttons, Spares for PLC System, Servo Motors for Feed Drives, Power Module & Control Cards for Drives etc) and consumable wear parts used in the machine in sufficient quantity as per recommendation of Vendor for 10 years of trouble free operation on three shifts continuous running basis shall be offered by vendor. The list is to include following, in addition to other recommended spares: (Unit Price for each item of spare shall be offered)

Confirmed

13.3 The Vendor shall bring special tools and equipment required for erection of the machine.

Necessary tools like Torque Wrench, Spanners, Keys, grease guns etc. for operation and maintenance of the machine should be supplied. List of such tools should be submitted with offer

Confirmed

13.4 Vendor to confirm that complete list of spares for machine and accessories, along with item part no / specification / type / model, and name & address of the spare supplier shall be

Confirmed


furnished along with documentation to be supplied with the machine


14.1 Sea worthy & rigid packing for all items of complete machine, control system, all accessories and other supplied items to avoid any damage/loss in transit. When machine is dispatched in containers, all small loose items shall be suitably packed in boxes

Confirmed


15.1 Performance Guarantee for a minimum period of 24 months (for the machine in total and sub-systems or bought-out items in particular) from the date of acceptance of the machine.

Warranty period 12 Months

17.0 General Points

17.1 Make and Model of the machine to be mentioned. Detailed catalogs of the machine to be sent with the offer.

Confirmed

17.2 Complete description of all systems & sub-systems shall form part of the technical bid

Confirmed

17.3 A schematic diagram showing the layout of the machine & associated systems with salient dimensions shall be submitted along with the offer.

Confirmed

17.5 Total weight of the Machine & Sub-Systems.

Weight of the heaviest part of the machine

60 KG

17.6 Warranty period for the total system will be two years from the date of commissioning of the system at BHEL

12 Months

I N T E R N A T I O N A L B V

be Amer 24 P.O. Box 348 Phone (+31) 321 386677 8253 RC bronten 8250 AH bronten Fax (+31) 321 314165 The Netherlands The Netherlands [email protected] VAT reg. No. NL8182.71.541B01 Ch. Of C. reg. No. 39100085

QUOTATION TO: GOVERNMENT OF INDIA

ACCOUNT: BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPALLI – 620014 TAMIL NADU, INDIA

Quotation date : 05-08-2011 Quotation no : 110708 Subject :Orbital GTAW TUBE WELDING SYSTEM

Dear Sir,

Please find enclosed offer for Orbital Tube welding machines.

1 MODEL D-HEAD FOR WELDING 1” UP TO 14” € 35,945.00

Torch rotation (max surface speed is 10”/min)

Filler wire feeder (max wire speed is 100”/min)

Standard 1kg spools (D100) For 0.8 – 1.0mm wire sizes

Torch oscillation (max oscillation stroke 16mm)

Adjustment range 19mm

Speed max. 152mm/min

Electronic arc gap control functions Stroke 13mm

Standard 8.0 m length torch cable assy. (water-cooled)

Radial clearance minimal 64 standard profile

Toolkit Protector/shipping case

2 PROGRAMMABLE PENDANT ASSY. € 8,947.00

Suitable for 516 Model Power Source & D-Head model 420

New heat resistant pendant with sunlight readable display

PENDANT CABLE ASSEMBLY INCLUDED

Suitable for 516 Model Power Source & D-head model 420



Quotation date : 05-08-2011 Quotation no : 110708 Subject : Orbital GTAW TUBE WELDING SYSTEM :

3. PIPEMASTER MODEL 516 DIGITAL CONTROLLER/ € 48,880.00 POWER SOURCE INCL. MODEL 905 WATER-COOLER.

Output: 2 – 425 Amp.

Input power requirement: 230/480 VAC, 1 or 3 phase.

Duty cycle 100% by 275 Amp Automatic weld head calibration Auto-tack program creates tacking program automatically

Built in high frequency arc starter

Continuous or pulsed current with slope between each level.

Control of arc voltage, rotation and oscillation Digital power source with digital programming

Auto-programming feature, easy for operators 100 weld program on-board memory

Extended signals for arc monitoring system.

Each program allowing up to 100 parameters levels

Copy functions allow individual parameter levels or entire weld programs to be copied

Large colour display

Printer (free standing)

USB digital “Data Key” storage/program transfer device

Integrated water cooler

Printer paper rolls (10)

Magnatech torch coolant (3)

4. TORCH & CABLE ASSY. € 4,034.00 Suitable for 516 Model Power Source &

D-head model 420

Recommended Spare parts for D-Head € 15,000.00

PC € 1,500.00

TOTAL NET VALUE IN EURO € 114,306.00



Quotation date : 05-08-2011 Quotation no : 110708 Subject : Orbital GTAW TUBE WELDING SYSTEM

GENERAL TERMS AND CONDITIONS:

Port of shipment : FOB AMSTERDAM AIRPORT Terms of payment : 80% value of the goods will be paid immediately against dispatch

documents negotiated through bank. Balance 20% will be paid within immediately from the date of acceptance / commissioning of goods against submission of supplementary invoice and also against submission of PBG for 10% of Order value

with required validity. Delivery schedule : 12 weeks after LOI Offer validity : 120 days from offer issuing date

Country of Origin : USA origin Agent commission : not applicable

GUARANTEE:

The liability of the seller (Magnatech-International BV) shall be 12 months from date of Commissioning or 14 month from date of dispatch whichever is earlier under

warranty obligations.

With best regards, MAGNATECH INTERNATIONAL BV

Ralph Wijnholds Managing Director

ORBITAL GMAW/FCAW PIPE WELDING SYSTEM

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PART - B

Specification of orbital GMAW/FCAW pipe welding system for in-situ welding of large

diameter and heavy wall thickness carbon steel, alloy steel pipe joints

at power plant erection site.

Sl. No Particulars and BHEL specification Bidder’s offer (with

Complete Technical

Details)

1.0 Purpose

1.1

Orbital GMAW/FCAW pipe welding system for in-situ welding of

large diameter (125 to 965 mm) heavy wall thickness (16 to 130

mm) carbon steel, alloy steel pipe joints at power plant erection

site. The system should be able to weld root pass and all fill passes

to produce a complete pipe weld joint.

The joints should meet the RT quality requirements of ASME Sec.

IX.

The orbital pipe welding system should be capable of:

Welding pipe joints in 2G, 5G & 6G positions of carbon steel and

alloy steel material grades with OD ranging from 125 to 965

mm and wall thicknesses ranging from 6 to 130 mm.

The weld joints should meet Radiographic & Mechanical test

requirements as per ASME SEC IX.

The system should be robust and suitable for site welding

condition.

External clamping device should be provided so as to perform

welding from root pass.

The system should able withstand preheat temperatures up to

250 °C and accommodate the preheating coils for local pre

heating while welding.

The wire spool should be mounted on the welding head

preferably.

Vendor to confirm

2.0 PIPE SIZES TO BE WELDED

2.1 Pipe diameters (OD) in mm Pipe wall thickness

(mm)

Qty

125, 127, 133, 141, 141.3, 150, 159, 168.3,

177.8, 219.1, 244.5, 273, 273.1, 323.9,

355.6, 368, 406.4, 444.5, 457, 457.2, 508,

558.8, 559, 559.9, 609.6, 610, 660, 660.4,

711, 762, 812.8, 863.6, 864, 914, 964, 965

6 to 130 mm

Vendor to confirm

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pipes are to be welded.

Suitable guide rings should be provided.

3.0 PIPE MATERIALS TO BE WELDED

Vendor to confirm

3.1 a. Carbon Steel: IS 1239, SA106 GrB,SA106GrC

b. Alloy steels: SA335 P12, SA335 P22, SA 335 P91

c. Stainless Steel: TP 304 H, TP 316, TP 316L, TP 321, TP 321H

4.0 WELD JOINT DETAILS

4.1 1. Edge

Preparation

Single V Up to 18 mm Vendor to confirm

Compound V 19 and above

J groove Above 50 mm

2. Pipe End

Condition

Machined in automatic edge preparation

line. ID of the pipes should be matched

properly.

3. Weld Joint

Location

Length of straight portion on either side

of weld joint will be 300 mm max.

4. Preheating

Temperature

Upto 250 °C by local preheating

arrangement for a width of 75 mm to 250

mm on either side of the joint using pads.

5. Weld Joint

Soundness

Tests

100% Radiography and / or Ultrasonic

Testing as well proof testing by hydraulic

test.

6. Weld Quality

Appraisal

As per ASME Section IX, V and VIII (Division

1 & 2) for Radiography Test & Mechanical

tests.

ANSI B31.1, B31.3 for power and process

piping


5.1 VENDOR should specify the minimum output of welded joints,

possible from one workstation, for the pipes with the following

dimensions, in a single shift of 8 hrs:

Expected productivity is as follows:

Pipe Size:

(Gr C) 368 mm (OD) x 56 mm (wall thickness)– xx Joints

Vendor to Specify

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(P22) 508 mm (OD) x 90 mm (wall thickness)– xx Joints

(P91) 406 mm (OD) x 65 mm (wall thickness)– xx Joints

(Gr C) 323.9 mm (OD) x 36 mm (wall thickness) – xx Joints

(P22) 273 mm (OD) x 28 mm (wall thickness) -- xx Joints

6.0 Orbital GMAW Pipe Welding System – Scope of Supply of

equipment

6.1 Orbital weld head:

a. Axial length:

b. Radial clearance:

c. Width of head:

d. Weight of head:

(weight without wire spool)

Vendor to Specify

6.2 Linear oscillation

a. Oscillation stroke amplitude: 50.8 mm

b. Oscillation speed: 0-350 cm/min

c. Oscillation dwell: 0-10 sec independently adjustable (with

0.01s increments) Oscillation dwell left and right

independent adjustment controls

d. Oscillation methods/modes selection options

e. Cross seam adjustment: ± 60 mm (60 mm left & right of

center)

Vendor to specify

6.3 Pendular oscillation

a. Oscillation angular stroke: 0˚ to 15˚

b. Oscillation speed: 3 Hz (max)

c. Oscillation dwell: 0-1.0 secs

d. Cross seam adjustment: 25.4mm

Vendor to specify

6.4 Torch vertical motion (motorized)

a. Stroke: 100 mm

b. Speed: 100 cm/min

Vendor to specify

6.5 Motorized tractor

a. Tractor speed range: 0-1.5 m/min (welding speed)

b. Forward / reverse facility. Programmable

Vendor to specify

(the variation should

be with in some

specified range only)

6.6 Wire Feeder

The wire feeder should able to feed

a. Carbon & alloy steel. Solid & flux cored wires of

Vendor to specify

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diameter – 1.2 and 1.6 mm

b. Wire feeder mounted on welding head must accommodate

5 kg or 15 kg wire spool.

6.7 Water cooled torch

Water cooled torch rated at 400 @ 100% duty cycle

Vendor to specify

6.8 Torch adjustment capability

a. Torch lead/lag adjustment: ± 15 degrees.

b. Torch tilt adjustment: ±25 degrees

c. Angle bracket: 360˚ manual

Vendor to specify

6.9 Sensor tracking device for automatic adjustment of welding torch

for groove center & contact tip to work distance

Vendor to specify

6.10 Proportional Gas Mixing Unit for mixing Argon and CO2 gases.

Gas mixing accuracy:

Vendor to specify

7.0 Power source specifications

7.1 Inverter type Synergic GMAW/FCAW Power source

Vendor to specify

7.2 Functions controlled

a. Welding mode: Modified Short circuit Root pass process

(such as STT, RMD, WISE ROOT) , Standard and Pulsed

GMAW option, FCAW, Metal cored Process (Root pass for

P91)

b. Electrode feed speed: 1.0 to 25 m/min

c. Weld head rotation: 0-2 m/min adjustable

d. Weld head torch oscillation: 0 to 60 mm

e. Weld head electronic cross-seam adjustment: remote cross

seam adjustment

f. Arc length control: Remote arc length adjustment

g. Pre-programmes for carbon steel & alloy steel in standard

& pulsed synergic mode for 0.8, 1.2 & 1.6 for solid & flux

cored wires, metal cored wire

Vendor to specify

7.3 Power source details

a. Output rating: 400A @ 44 V DC @ 100% duty cycle

b. Max. Open circuit voltage: 80 V DC

Vendor to specify

7.4 Weld head controller

Pendant cable length: 12 m

Vendor to specify

7.5 Wire feeder Vendor to specify

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a. Wire feeder mounted on head

b. Drive type: four roll drive (with various groove geometries)

c. Wire diameter: 0.8 to 2.4 mm

7.6 Water Cooling Unit

Built-in water circulation unit of suitable capacity for the weld

head and torch.

Shall cool the torch while welding Pipes with 250 °C preheat

involving more than 20 continuous passes.

Vendor to provide

details.

7.7 Gas hose with end fittings – Gas cylinder to power source Length

to suit long travel on cable festoon

Vendor to specify

7.8 Self aligning clamps to align pipe edges (OD Controlled pipes) to be

welded.

8.0 Main Controller

8.1 Controller integrated with weld head.

Remote operator pendant for online monitoring and control of

the welding process.

Vendor to specify

8.2 Data logger:

a. Setting of all welding parameters

b. Data logging with 0.01 sec frequency or 0.1 deg rotation

c. Trouble shooting for welding program software

Vendor to specify

8.3 Welding Data Entry: Through a ‘dust & moisture proof’ Membrane

Key Pad – Rugged Type that is adequately cooled to ensure

problem free operation.

Vendor to specify

8.4 External Memory: Does equipment have provision to store welding

programs in Pen drive (Memory stick)?

Vendor to specify

8.5 Each weld program for a unique combination should allow multiple

pass welding each with unique/different parameters.

Vendor to specify

the Max. No of

passes that can be

written in a program.

8.6 Different Parameter Values for each sector within a pass of 360 °

should be programmable enabling sector vise programming for

each pass.

Vendor to specify

the Maximum No of

sectors that can be

programmed per

pass of 360.

8.7 Front Panel Display (in English) Vendor to describe

8.8 Contact K type temperature measuring digital sensor unit

Temperature measurement accuracy = ± 0.1⁰C

1 no

Vendor to specify

9.0 Safety measures

of 11

9.1 Interlocks

The system should trip in the event of:

Stoppage of shielding gas flow

Stoppage of cooling water flow

Stoppage of wire feeding

Arc start failure

Stoppage of movement head around pipe

Vendor to specify

9.2 All the pipes, cables etc. on the machine should be well supported

and protected. These should not create any hindrance to machine

operator’s movement for effective use of machine.

Vendor to Confirm

10.0 Other features

10.1 The equipment should be portable

Length between the power source and the welding head:15 meters

Vendor to specify

10.3 Post sequence Printing capability of all the weld parameters used

(including overrides) and actual peak/min/average values for every

pass to pass welding.

Vendor to specify

10.4 Orbital welding head must accommodate the radial Clearance

between pipes of 300 mm

Vendor to specify

10.5 Orbital welding head must have provision for preheating coil to be

mounted on the pipes during welding

Vendor to specify

10.6 Extended arm facility has to be provided to accommodate

preheating coils.

The spacing between the inside edge of guide ring to the groove

center is to be 350 mm length. The radial clearance of 100 mm is

required to accommodate heating coil.

Vendor to specify

10.9 Normal life of the Spares and consumables (such as contact tips,

guide rings, loaded springs, Hex nuts, rollers, wheels, etc,.) to be

specified, for a set of welding conditions and environment.

Vendor to specify

10.10 Warranty period for any free service and replacement Vendor to specify

11.0 Services:

Installation, Commissioning and training

11.1 Inspection of the complete system by BHEL engineers at vendors

place

Vendor to confirm

11.2 Carrying out welding trials on a mock-up job at vendor’s works

before dispatch.

Pipe Material Outside

diameter, mm

Thickness of

pipe, mm

No. of

Joints to be

welded

Vendor to confirm

For trials BHEL will

only provide only

the pipe material.

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SA106GrC + GrC

(with 90/10 gas

combination)

368 56 2

SA335P22 + P22

(with 90/10 gas

combination) 508 90

2

SA335P91 + P91

(with 95/05 gas

combination) 406.4 65

2

The acceptance criteria for weld quality shall be passing

Radiography as stipulated in ASME Sec IX, ANSI B31.1, and B31.3

for welding high- pressure piping in power plant

The one set with full GMAW solid wire welding & one set with root

solid wire, fill passes with Flux cored wire welding

Welding will be

done by vendors

(including welding

consumable)

Testing can be done

by BHEL if required

11.3 Installation, commissioning of the system at BHEL sites Vendor to confirm

11.4 Carrying out welding trials on the following material combination

of pipes at one BHEL site in India satisfactorily meeting the quality

requirements as per ASME SEC IX for welding high pressure piping

in power plant (minimum 4 joints to be welded in succession for

meeting quality requirements as per ASME SEC IX & ANSI B31.1,

and B31.3)

The two sets with full GMAW solid wire welding & two sets with

root solid wire, fill passes with Flux cored wire welding


diameter, mm

Thickness of

pipe, mm

No. of

Joints to

be

welded

SA106GrC + GrC

(with 90/10 gas

combination)

368 56 4

SA335P22 + P22

(with 90/10 gas

combination) 508 90

4

SA335P91 + P91

(with 95/05 gas


4

Vendor to confirm

For trials BHEL will

only provide only

the pipe material.

Welding will be

done by vendors

(including welding

consumable)

Testing can be done

by BHEL if required

of 11

11.5 Welding of actual jobs at site to prove out the orbital welding

technology for power piping within one month from the date of

commissioning of the system at WRI, BHEL, Tiruchy.

(minimum 5 joints to be welded in succession for meeting quality

requirements as per ASME SEC IX, ANSI B31.1, AND B31.3 )


diameter, mm

Thickness of

pipe, mm

No. of

Joints to be

welded

SA106GrC + GrC

(with 80/20 gas

combination)

368 56 5

SA335P22 + P22

(with 80/20 gas

combination) 508 90

5

SA335P91 + P91

(with 80/20 gas


5

Vendor to confirm

11.7 Training of a minimum of 15 operators at site for operating the

machine after completing the commissioning. Duration of training

7 days (without any charge)

Vendor to confirm

12.0 Documentation

12.1 Three sets of following documents in tear proof hard copy and soft

copy (CD)



Troubleshooting procedures for different error codes and

problems must be addressed in the manuals.

Vendor to specify


Operating manuals of Machine & system with machine

specifications, detailed operating instructions for machine

operation, setting of machine parameters, precautions, and

machine safety details.


Vendor to specify

12.3 Maintenance and troubleshooting manuals:

Detailed Maintenance manual of machine with all drawings

of machine assemblies/sub-assemblies/parts, Hydraulic,

Electrical circuit diagrams. All Assembly/ Sub Assembly

Vendor to specify

of 11

Drawings shall be supplied with the part list also

Maintenance, Interface & commissioning manuals for

system & drives

Manufacturing drawings for all supplied holders, adapters,

sleeves, fixtures etc if any.

Catalogues, O&M Manuals of all bought out items including

drawings, wherever applicable.

Detailed specification of all wear items and hydraulic / lube

fittings

PLC program printouts with comments in English.

PLC program on CD, NC data & PLC data on CD

Complete back up of hard disk on CD and clear written

Instructions to take back up and reloading of a new hard

disk.

The vendor shall submit complete Master List of parts used

in the machine.

One additional set of all the above documentation on CD



13.1 Should cover gas cups, ceramic torch insulators, gas diffusers,

washers, Wire feeder drive wheels for 1.2mm wire dia., Tapered

Welding Tips, Bullet tips for water cooled torch (for 1.2mm wire

dia.) etc

Vendor to specify

13.2 Itemized break-up of mechanical (nuts, bolts, tension springs,

cams, etc) , hydraulic, electrical electronic spares (All types of

Printed Circuit Boards, Proximity Switches, Push Buttons, Spares

for PLC System, Servo Motors for Feed Drives, Power Module &

Control Cards for Drives etc) and consumable wear parts used in

the machine in sufficient quantity as per recommendation of

Vendor for 2 years of trouble free operation on three shifts

continuous running basis shall be offered by vendor. The list is to

include following, in addition to other recommended spares: (Unit

Price for each item of spare shall be offered)

Vendor to specify

13.3 The Vendor shall bring special tools and equipment required for

erection of the machine.

Necessary tools like Torque Wrench, Spanners, Keys, grease guns

etc. for operation and maintenance of the machine should be

supplied. List of such tools should be submitted with offer

Vendor to confirm

13.4 Any Test mandrel required for checking & alignment of the Vendor to confirm

of 11

machine components etc. should be supplied

13.5 Vendor to confirm that complete list of spares for machine and

accessories, along with item part no / specification / type / model,

and name & address of the spare supplier shall be furnished along

with documentation to be supplied with the machine

Vendor to confirm


14.1 Sea worthy & rigid packing for all items of complete machine,

control system, all accessories and other supplied items to avoid

any damage/loss in transit. When machine is dispatched in

containers, all small loose items shall be suitably packed in boxes

Vendor to confirm


15.1 Performance Guarantee for a minimum period of 24 months (for

the machine in total and sub-systems or bought-out items in

particular) from the date of acceptance of the machine.

Vendor to confirm

16.0 Power supply

16.1 Input Power supply- 415 V/ 50 Hz Vendor to specify

16.2 All electronic controls for controller / drives that need stabilized

supply shall be provided with suitable voltage stabilizer

Vendor to specify

17.0 General Points

17.1 Make and Model of the machine to be mentioned. Detailed

catalogs of the machine to be sent with the offer.

Vendor to specify

17.2 Complete description of all systems & sub-systems shall form part

of the technical bid

Vendor to confirm

17.3 A schematic diagram showing the layout of the machine &

associated systems with salient dimensions shall be submitted

along with the offer.

Vendor to confirm

17.4 The operating sequence of the machine with broad outline of

various operations involved should be furnished with the offer.

Vendor to confirm

17.5 Standards for Design, Manufacture and testing of the machine

shall be in accordance with internationally accepted standards.

Vendor to confirm



Vendor to specify


17.8 Colour of the system to be mentioned by the vendor. Vendor to specify

17.9 Floor area required (Length x width x height) for complete machine

and accessories

Vendor to specify

17.10 Warranty period for the total system will be Two years from the

date of commissioning of the system at BHEL

Vendor to confirm

Bharat Heavy Electricals Ltd.Quotation No. AMIQ20098Welding Research Institute

Tiruchirapalli, 620 014INDIA

Date 5/2/2011

Sales Rep. Tom Stancikas

5/2/2011Attention: Mr. Dhanesh Kant Verma

Tel: Fax:

EMail: [email protected]

Re:

Dear Mr. Verma,Per your request, Arc Machines, Inc. is pleased to provide this budgetary price quotation for orbitalpipe welding equipment.

US$ US$

Item Qty U/M Part No. / Description Unit Price Ext. Price

1 1 $55,800.00 $55,800.00EA 13D150100-06

MODEL 415B POWER SUPPLY TOP ASSY200-575VAC AXIOMTEK CPU

Model 415 computer controlled programmable power supply, with 400 ampereDC welding current output. Includes M-415 operator pendant with AMI headsup display (HUD), 50-ft. M-415 pendant extension, reusable wooden shippingcontainer,40-ft. M-415 weld head service adapter cable,40-ft. M-415 weldhead control adapter cable,25-ft. gas inlet hose, operation maintenancemanual and electrical drawings package. The M-415 requires three-phaseinput power,200 to 575 VAC, 50/60 Hz. Windows XP (TM) Operating System

2 1 $37,704.00 $37,704.00EA 13150136-02

MODEL 15-415 WELD HEAD TOP ASSYWITH -C- TORCH & DUAL W.F.

3

Note: your request is from 300mm to1000mm diameters. Following guide ringsare for reference and offers an idea of theprice range for guide rings. Shown are thesmallest and largest in your requested sizerequirements.

4 1 $3,420.00 $3,420.00EA 131509105-1254GUIDE RING 12.539 (318.5MM)

5 1 $12,480.00 $12,480.00EA 131509105-4000

GUIDE RING 40.000 (1016MM)

To: Page 1Bharat Heavy Electricals Ltd.

Arc Machines, Inc. Quotation No. AMIQ20098

US$ US$

Item Qty U/M Part No. / Description Unit Price Ext. Price

Delivery: Please consult factory at time of order.

All shipments are: Ex-works, Pacoima (Los Angeles), California, U.S.A.

Payment Terms: Payment in advance. See attached Payment Terms.

Validity: This quotation is valid for a period of ninety (90) days from this date.

We appreciate your interest in Arc Machines, Inc products and thank you for this opportunity ofsubmitting this quotation. Should you have any questions regarding this quotation or need anyadditional information, please contact us at your earliest convenience.

Very truly yours,

Tom Stancikas

Arc Machines, Inc.

Tel: 818-896-9556 Ext. 258

Tel: House Account

To: Page 2Bharat Heavy Electricals Ltd.

Arc Machines, Inc. Quotation No. AMIQ20098

Customer: Bharat Heavy Electricals Ltd.

Ref: Quotation No. AMIQ20098

Date: 5/2/2011

Days Allowed: 4

TRAINING, INSTALLATION & SERVICE

Training or Installation Service – No Labor ChargeA.Arc Machines, Inc. (Seller) shall provide the services of a qualified representative at Customer’s facility, for thepurpose of training operators or of assisting with installation, check-out or acceptance testing of Equipmentdelivered per above reference, for the period of time specified above in “Days Allowed”, free of charge for therepresentative’s labor. Other charges apply – see “B”, “C” and “D” below.

All Other Service – Labor ChargeB.If, after the first installation or training period per “A” above additional assistance with installation, training, orchecking-out of equipment at Customer’s facility is requested by Customer, the charge for labor for each dayor any fraction thereof shall be US$800.00, and such charge shall apply for the entire time that the Seller’srepresentative either is at the Customer’s facility or is available to perform the above-listed duties at theCustomer’s convenience. Labor is not charged for travel time. Additional other charges apply – see “C”, “D”and “E” below.

Other Charges – Travel and Transportation ExpensesC.In connection with any and all service at Customer’s facility, the Customer shall pay all actual travel andtransportation expenses incurred by Seller’s representative. Additional other charges apply – see “D” and “E”below.

Other Charges – Living and Incidental ExpensesD.The charge for living and incidental expenses shall apply for the entire time the representative is outside of LosAngeles County, California.

U.S.A. Domestic: In connection with all service at Customer’s facility, (outside of Los Angeles County),Customer shall pay either the Seller’s representative’s actual living and incidental expenses, or US$225.00 per

day or any fraction thereof, in addition to actual travel and transportation expenses.

Foreign: In connection with all service at Customer’s facility, Customer shall pay the Seller’s representative’sactual living and incidental expenses (if pre-paid not less than US$225.00 per day or fraction thereof) inaddition to actual travel and transportation expenses. Estimated travel, transportation and living expenses andservice charges, if any, shall be paid to Arc Machines, Inc., prior to departure.

Other Charges – Service in Factory (located in Pacoima – near Los Angeles, California, USA)E.In lieu of installation Service at Customer’s Facility (“A” above), Customer may, at their option, send a limitednumber (maximum 5) of their personnel to Seller’s factory for acceptance, operator training, check-out ortesting of equipment delivered per above reference, at Customer’s cost. Seller shall charge CustomerUS$400.00 per day for each work day or fraction thereof that Customer’s personnel are in Seller’s factory inexcess of the period of time per “Days Allowed” specified above.

F. Notice: All above rates and “Days Allowed” apply only to such purchase as is included in the above“Reference.” Number of installation and training “Days Allowed” for multiple systems purchased are to be

negotiated prior to placing Purchase Order. Please note that this schedule of labor rates and charges doesnot apply to Project Site Support, or to Maintenance Training or to Warranty or other repair or other after-saleservices. All services not expressly provided herein are to be quoted and priced separately.

QAF 3.2.4 Rev 10/29/02 Page 1 of 1



Date: 5/2/2011 Revised: 12 April 2000

WARRANTY (India)

Arc Machines, Inc. (Seller) warrants to the original Buyer that the equipment, excluding consumables,delivered herewith or subject to delivery at a future date, will be free from defects in workmanship ormaterial for a period of eighteen (18) months from date of shipment or one (1) year from date ofcommissioning at Buyer’s location, whichever first occurs. This warranty shall apply only to such itemsas are manufactured by Seller. This warranty specifically excludes such items as may be attached to orinstalled into Seller’s equipment at the request of the Buyer. This warranty shall terminate and becomevoid if equipment shipped by Seller is either (i) altered, modified or repaired by anyone other than Selleror Seller’s authorized repair personnel, or (ii) connected to or used with items manufactured by anyoneother than Seller (excepting only test equipment approved by Seller).

Seller’s sole liability and Buyer’s sole remedy for breach of warranty shall be the replacement, repair oradjustment, at Seller’s option, F.C.A. place of manufacture or authorized repair station, of warrantedequipment with respect to which Buyer claims a breach of warranty by written notice to Seller received bySeller within one (1) year from date of commissioning at Buyer’s location, or within a period of eighteen(18) months from the date of shipment of such equipment, whichever first occurs. All equipment or partsclaimed to be in breach of this warranty must be returned by Buyer to place of manufacture or authorizedrepair station, transportation prepaid, and will be returned to Buyer, transportation charges collect.

IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIALDAMAGES, WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OFSELLER. THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESCRIBED HEREIN;AND NO WARRANTIES BY SELLER SHALL BE IMPLIED OR OTHERWISE CREATED, INCLUDINGBUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE, WHICH WARRANTIES ARE HEREBY DISCLAIMED.



Date: 5/2/2011

LETTER OF CREDIT INSTRUCTIONS

To avoid any delays or additional costs and charges in connection with Letter of Credit payments, pleaseprepare you irrevocable L/C in accordance with these instructions.

BENEFICIARY: Arc Machines, Inc. Tel: USA 818-896-9556(SELLER) 10500 Orbital Way Fax: USA 818-890-3724

Pacoima, CA 91331 USA

ADVISING BANK: State Bank of India Swift: SBINUS66Los Angeles Agency Telex: 18819707 Wilshire BoulevardLos Angeles, CA 90017, USA

PAYMENT TERMS: The Letter of Credit must be payable at the counters of State Bank of India(SBI) Los Angeles, on sight of documents.

PAYMENT: To be effected in US DOLLARS only for the full contract amount.

DRAFTS: To be drawn at sight. In case of time drafts, all charges are for the accountof the applicant.

PRICES ARE: Ex-Works Factory, Pacoima, California, USA.

SHIPMENT TERMS: FCA Los Angeles (LAX) airport (per INCOTERMS 1990), by Air Freightonly. Freight and insurance costs to the account of the applicant.

FRT. FORWARDER: To be located only in the Los Angeles area.

BANK CHARGES: Only the charges imposed by SBI, Los Angeles, are to the account of theBeneficiary. Bank charges imposed by any other bank are to the account ofthe applicant.

L/C OPENING: To be issued and received by Beneficiary at same time as Purchase Orderor Contract is issued.

L/C EXPIRATION: To be no less than fourteen (14) days after the shipment. Shipment datewill be notified to Buyer upon request, prior to issue of L/C.

NOTES: Failure to comply with these instructions may cause rejection or amendment of the L/C, at applicant’s expense. L/Cmust be in English language. Only Seller’s warranty applies. Performance bonds, bank guarantees, customs drawbacks andsimilar are not acceptable.

ORBITAL PIPE CUTTING AND BEVELING SYSTEM

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PART - B SPECIFICATION FOR ORBITAL PIPE CUTTING AND BEVELING SYSTEM

Sl. No Particulars and BHEL specification

Bidder’s offer (With

complete Technical

Details)

1.0 PURPOSE

1.1

Split Frame type cutting and beveling machine with single point

cutting on OD controlled heavy wall pipes generating compound

bevels, counter bore and flange facing.

The machine should be Robust and suitable for in-situ beveling

condition.

Ratcheting hinge mechanism to allow the heavy duty split frame

to easily install on the OD of large diameter pipes.

1 Set

Vendor to confirm

2.0 PIPE SIZES to be Machined

2.1 Pipe diameters (OD) in mm Pipe wall thickness

(mm)

80, 88.9, 100, 108, 114.3, 125, 127,

133, 141, 141.3, 150, 159, 168.3, 177.8,

219.1, 244.5, 273, 273.1, 323.9, 355.6,

368, 406.4, 444.5, 457, 457.2, 508,

558.8, 559, 559.9, 609.6, 610, 660,

660.4, 711, 762, 812.8, 863.6, 864, 914,

964, 965 pipes are to be edge prepared

6 to 130 mm

Vendor to specify the

ranges of the systems

available

3.0 MATERIAL SPECIFICATION

Carbon steel, Low Alloy steel, P 11, P12, P22, P91 and Stainless

steel

3.1 a. Carbon Steel: API5L Gr.B, IS 1239, SA106 Gr.B, SA106Gr.C

b. Alloy steels: SA335 P12, SA335 P22, SA 335 P91

c. Stainless Steel: TP 304 H, TP 316, TP 316L, TP 321, TP 321H

4.0 Edge Preparation Details

4.1 1. Edge Preparation

Single V (Bevel angle ) (up to 19

mm wall thickness)

Compound V ( Angles ) (greater

than 19 mm to 130 mm)

J groove (for P 91 material grade)

Vendor to confirm

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2. Surface finish 12.5 microns

3. Quality Appraisal


5.1 VENDOR has to indicate the minimum output of machined

joints, possible from a single workstation, for the pipes with the

following dimensions/details, in a single shift of 8 hrs:

Expected productivity of typical pipes is as follows:

Pipe Size:

(Gr C) 368 mm (OD) x 56 mm (wall thickness) – xx Joints

(P 22) 508 mm (OD) x 90 mm (wall thickness) – xx Joints

(P 91) 406 mm (OD) x 65 mm (wall thickness) – xx Joints

(Gr C) 323.9 mm (OD) x 36 mm (wall thickness) – xx Joints

(P 91) 914 mm (OD) x 32 mm (wall thickness -- xx Joints

Vendor to Specify

6.0 Scope of Supply of equipment

6.1 Heavy Duty Split Frame type portable pipe cutting, edge

chamfering equipment.

1. Pipe diameter range to cover 80 to 1200 mm O.D.

2. Larger interior frame clearance to accommodate

obstructions and deformed pipe.

3. Roller bearing for all load bearing surfaces for durability

and stability.

4. Bearings and drive gears should be fully enclosed for

safety and durability.

5. Positive mechanical star wheel feed.

6. Corrosion resistant coating on all components to

withstand harsh environments.

7. Equipment should mounts to O.D. of pipe.

8. Heavy duty Out of Round tracking slides should be

included to compensate for out-of-round pipe common

in larger diameters.

9. Built in lifting eyes for vertical and horizontal mounting.

10. Ratcheting hinge mechanism to open and close frame

quickly.

11. Pneumatic drive.

12. The compound bevels and lands produced should be

Vendor to Specify

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precise and consistent.

13. Setup, cutting and preparation times should be faster.

Cutting Tool Surface Speed:

Surface speed in meters per minute.

Vendor to specify

Drive Options: Hydraulic and Pneumatic Vendor to specify

Power Requirements:

Hydraulic requirement 38 LPM @ 103 bar pressure.

Air requirement: 2.7 Cubic Meters per Minute @ 6.2 bar.

Vendor to specify

Feed Method: Positive mechanical star wheel Vendor to specify

Feed Rate: Fixed trip rate: Vendor to specify

Construction: Select hardened alloy steel components, large 6”

(152.4 mm) cross section, high capacity bearings, heavy duty

pinion housing, corrosion resistant finish and ratcheting hinge

mechanism.

Vendor to specify

6.6 OPTIONAL EQUIPMENT

1. Dual Pinion Drives

2. Cantilever Tool Slide

3. Interchangeable Tooling Mounts

4. Genuine supplier Tooling

Vendor to specify

6.7 Sensor tracking device for automatic adjustment of cutting tool

for groove center

Vendor to specify

7.0 Main Controller

7.1 Integrated controller Vendor to specify

8.0 Safety measures

8.1 All the pipes, cables etc. on the machine should be well

supported and protected. These should not create any

hindrance to machine operator's movement for effective use of

machine.

Vendor to Confirm

9.0 Other features

9.1 The equipment should be portable Vendor to specify

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9.2 Normal life of the Spares and consumables (such as guide rings,

loaded springs, Hex nuts, rollers, wheels, etc,.) to be specified,

for a set of beveling conditions and environment.

Vendor to specify

9.3 Warranty period for any free service and replacement Vendor to specify

10.0 Services:

Installation, Commissioning and training at BHEL construction

sites

10.1 Inspection of the complete system by BHEL engineers at vendors

place

10.2 Carrying out trials on a mock-up job at vendor’s works before

despatch.


diameter,

mm

Thickness

of pipe,

mm

No. of

Joints to

be

beveled

SA106GrC 368 56 2

SA335P22 508 90 2

SA335P91 406.4 65 2

The acceptance criteria for quality shall be passing as stipulated

in ASME high pressure piping in power plant.

10.3 Installation, commissioning of the system at WRI, BHEL

10.4 Actual jobs at site to prove out the orbital pipe beveling

technology for power piping

(minimum 5 joints to be beveled in succession for meeting

quality requirements as per ASME)


diameter,

mm

Thickness of

pipe, mm

No. of

Joints to

be

beveled

SA106GrC 368 56 5

SA335P22 508 90 5

SA335P91 406.4 65 5

10.5 Training of 4 operators at site for operating the machine after

completing the commissioning. Duration of training 5 days

11.0 Documentation

11.1 Three sets of following documents in tear proof hard copy and

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soft copy (CD)



Troubleshooting procedures for different error codes and

problems must be addressed in the manuals.


Operating manuals of Machine & system with machine

specifications, detailed operating instructions for

machine operation, setting of machine parameters,

precautions, and machine safety details.


11.3 Maintenance and trouble shooting manuals:

Detailed Maintenance manual of machine with all

drawings of machine assemblies/sub-assemblies/parts,

Hydraulic, Electrical circuit diagrams. All Assembly/ Sub

Assembly Drawings shall be supplied with the part list

also

Maintenance, Interface & commissioning manuals for

system & drives

Manufacturing drawings for all supplied holders,

adapters, sleeves, fixtures etc if any.

Catalogues, O&M Manuals of all bought out items

including drawings, wherever applicable.

Detailed specification of all wear items and hydraulic /

lube fittings

PLC program printouts with comments in English.

PLC program on CD, NC data & PLC data on CD

Complete back up of hard disk on CD and clear written

Instructions to take back up and reloading of a new hard

disk.

The vendor shall submit complete Master List of parts

used in the machine.

One additional set of all the above documentation on CD


Soft copy of all software in the system.


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12.1 Itemized break-up of mechanical (nuts, bolts, springs, slides,

cams) , hydraulic, electrical electronic spares (All types of

Printed Circuit Boards, Proximity Switches, Push Buttons, Spares

for PLC System, Servo Motors for Feed Drives, Power Module &

Control Cards for Drives etc) and consumable wear parts used in

the machine in sufficient quantity as per recommendation of

Vendor for 2 year of trouble free operation on three shifts

continuous running basis shall be offered by vendor. The list is

to include following, in addition to other recommended spares:

(Unit Price for each item of spare shall be offered)

Vendor to specify

12.2 The Vendor shall bring special tools and equipment required for

erection of the machine.

Necessary tools like Torque Wrench, Spanners, Keys, grease

guns etc. for operation and maintenance of the machine should

be supplied. List of such tools should be submitted with offer

Vendor to confirm

12.3 Any Test mandrel required for checking & alignment of the

machine components etc. should be supplied

Vendor to confirm

12.4 Vendor to confirm that complete list of spares for machine and

accessories, along with item part no / specification / type /

model, and name & address of the spare supplier shall be

furnished along with documentation to be supplied with the

machine

Vendor to confirm


13.1 Sea worthy & rigid packing for all items of complete machine,

control system, all accessories and other supplied items to avoid

any damage/loss in transit. When machine is dispatched in

containers, all small loose items shall be suitably packed in

boxes

Vendor to confirm


14.1 Performance Guarantee for a minimum period of 24 months (for

the machine in total and sub-systems or bought-out items in

particular) from the date of acceptance of the machine.

Vendor to confirm

15.0 Power supply

15.1 Input Power supply- 415 V +_ 10% / 50 Hz / 3 Phase AC (or ) 220

V / 50 HZ / Single Phase AC

Vendor to specify

15.2 All electronic controls for controller / drives that need stabilized

supply shall be provided with suitable voltage stabilizer

Vendor to specify

16.0 General Points

16.1 Make and Model of the machine to be mentioned. Detailed Vendor to specify

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catalogs of the machine to be sent with the offer.

16.2 Complete description of all systems & sub-systems shall form

part of the technical bid

Vendor to confirm

16.3 A schematic diagram showing the layout of the machine &

associated systems with salient dimensions shall be submitted

along with the offer.

Vendor to confirm

16.4 The operating sequence of the machine with broad outline of

various operations involved should be furnished with the offer.

Vendor to confirm

16.5 Standards for Design, Manufacture and testing of the machine

shall be in accordance with internationally accepted standards.

Vendor to confirm



Vendor to specify


16.8 Colour of the system to be mentioned by the vendor. Vendor to specify

16.10 Warranty period for the total system will be two years from the

date of commissioning of the system at BHEL

Vendor to confirm

``````

Bharat heavy electricals limited 08-07-2011

Tiruchirapalli

Sub: Budgetary offer for portable pipe beveling equipment

Kind Attn: Dr.A Raja Addl GM/ Mr. N Rajasekaran

Dear sir,

We thank you very much for the courtesy extended to me during the visit to your Kolkata office and to show case our

pipe bevelling products .Following the discussions we had, please find below the budgetary offer for the different

machines as discussed.these machines are specially designed fo all super critical boiler applications in tube thickness

up to 15 mm,

1) MF 4 range 38mm OD -133mmOD(air motor/ electric motor) Euros 10500.00

(for OD controlled pipes with OD clamping and heavy thickness tubes)

2) MF 3-35 Range 20 mm OD – 63.5 mm OD(air motor/electric motor) Euros 8500.00

(for od controlled pipes with OD clamping and heavy thickness tubes)

3) MF 2-25 range 20mmOD-38mm OD( air motor/electric ) Euros 8500.00

(for OD controlled pipes od clamping and heavy thickness tubes)

All prices ex works germany in euros

Terms:

Delivery within 4 weeks of order and LC

Cif charges,custom duty and other levies if applicable in india to your account

Looking forward to hear from you

Thanking you

Yours truly

K Venkatesh

Sales director india

Dwt gmbh

9321027313

Email:[email protected]

[email protected]

Specification 1 4

Documents

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