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IN-SITU ORBITAL TUBE BEVELING SYSTEM

PART - B

SPECIFICATION FOR IN-SITU ORBITAL TUBE BEVELING SYSTEM


Sl.No

Particulars and BHEL specification

Bidders offer (With complete Technical Details)

1.0 1.1

PURPOSE
In-situ orbital beveling and chamfering system with single Vendor to point cutting tool for facing, compound beveling of tubes Specify (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.

2.0 2.1

TUBE SIZES Tube diameters (OD) in mm Tube wall thickness (mm) Tube diameters to be 4.0 to 12.5 mm handled: 33.0, 38.1, 44.5, 51.0, 47.6, 54.0, 63.5, 76.1 mm OD. MATERIAL SPECIFICATION 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 EDGE PREPARATION Edge Preparation Single V J-groove Square butt ID taper boring on higher thickness tubes. MACHINE OUTPUT / PRODUCTIVITY

Qty

3.0 3.1

4.0 4.1

Vendor to Specify

5.0 5.1

VENDOR should specify the minimum possible output of Vendor to machined edges from one workstation, for tubes with the Specify following dimeters, in a single shift of 8 hrs:
Page 1/5

Portable Orbital tube Beveling system Part B

Expected productivity is as follows: Tube Size: (Gr C) (T-22) (T-91) (Gr A1) (T11) (TP-347H) 6.0 6.1 38.1 mm (OD) x 5.0 mm & 12.5 mm 76.1 mm (OD) x 5.0 mm & 12.5 mm 47.6 mm (OD) x 5.6 mm 54 mm (OD) x 7.1 mm 38.0 mm (OD) x 5.3 mm 63.5 mm (OD) x 4.0 mm

76.0 mm (OD) x 7.1 mm SCOPE OF SUPPLY Design features To cover a range of 30 to 80 mm diameter tubes. 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. Specifications System Function: Split Frame type machine should be suitable for parting, beveling and facing of large wall thickness tubes. 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 Cutting Tool Surface Speed: Vendor to specify Drive Options: Hydraulic and Pneumatic Power Requirements: 740 W @ 6 bar Operating pressure : 6 to 7 bar Feed Method: Positive mechanical starwheel 1. 2. Vendor to specify

6.2

Vendor to specify Vendor to specify

Vendor to specify Vendor to specify Vendor to specify Vendor to specify


Page 2/5

Portable Orbital tube Beveling system Part B

Feed Rate: Vendor to specify

Vendor to specify Construction: Should be of hardened alloy steel components, Vendor to sufficient section thickness, high capacity bearings, heavy duty specify pinion housing, corrosion resistant finish and ratcheting hinge mechanism. 6.3 STANDARD EQUIPMENT 1. 2. 3. 4. 5. 6. 7. 8. 7.0 7.1 Hydraulic or Pneumatic Drive Motor Vendor to specify Auto Resetting Single Trip Assembly Lifting Hooks for Vertical or Horizontal Mounting Ratcheting Hinge Mechanism for Scissoring Open and Closed Self Squaring Mounting System with Adjustable Clamping Legs Heavy Duty Storage Case Operating Hand Tools Operation Manual

8.0 8.1 8.2

8.3 9.0 9.1 9.2

Safety measures All the tubes, cables etc. on the machine should be well Vendor to supported and protected. These should not create any Confirm hindrance to machine operator's movement for effective use of machine. Other features The equipment should be portable Vendor to specify Normal life of the Spares and consumables (such as guide rings, Vendor to loaded springs, Hex nuts, rollers, wheels, etc,.) to be specified, specify for a set of beveling conditions and environment. Warranty period for any free service and replacement is min. 2 Vendor to years specify Installation, Commissioning and training Inspection of the complete system by BHEL engineers at vendors place Carrying out trials on a mock-up job at vendors works before Vendor to dispatch. Confirm 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 Installation, commissioning of the system at BHEL site
Page 3/5

Tube Material

Outside diameter, mm

Thickness of tube, mm

9.3

Portable Orbital tube Beveling system Part B

9.4

(minimum 10 joints to be beveled for meeting BHEL quality Vendor to requirements) Confirm Tube Material Outside diameter, mm 76.1 54.0 76.0 Thickness of tube, mm 12.5 7.0 7.1 No. of Joints to be beveled 5 5 5

SA106 GrC SA213 T91 SA213 347H 9.5 10.0 10.1 10.2

10.3

11.0 11.1

11.2

11.3 11.4

Training of 4 operators at site for operating the machine after commissioning. Duration of training 2 days Documentation Three sets of following documents in tear proof hard copy and soft copy (CD) 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. 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. Spares and Consumables 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) 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 Any Test mandrel required for checking & alignment of the machine components etc. should be supplied Vendor to confirm that complete list of spares for machine and accessories, along with item part no / specification / type /

Vendor to specify Vendor to specify

Vendor to specify

Vendor to specify

Vendor to confirm

Vendor to confirm Vendor to confirm


Page 4/5

Portable Orbital tube Beveling system Part B

12.0 12.1

13.0 13.1

14.0 14.1 15.0 15.1 15.2 15.3

15.4 15.5 15.6 15.7

model, and name & address of the spare supplier shall be furnished along with documentation to be supplied with the machine MACHINE PACKING 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 GUARANTEE TERMS 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. Power supply Input Power supply- 220 V, 50 Hz General Points Make and Model of the machine to be mentioned. Detailed catalogs of the machine to be sent with the offer. Complete description of all systems & sub-systems shall form part of the technical bid A schematic diagram showing the layout of the machine & associated systems with salient dimensions shall be submitted along with the offer. The operating sequence of the machine with broad outline of various operations involved should be furnished with the offer. Total weight of the Machine & Sub-Systems. Weight of the heaviest part of the machine Total connected load KVA

Vendor to confirm

Vendor to confirm

Vendor to confirm

Vendor to specify Vendor to confirm Vendor to confirm

Vendor to confirm Vendor to specify Vendor to specify Warranty period for the total system will be two years from the Vendor to date of commissioning of the system at BHEL confirm

Portable Orbital tube Beveling system Part B

Page 5/5

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: mail@hos-into.com Website: www.hos-into.com

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.

1.

16-000-01

Wachs Air Powered SDB103/3 Portable Pipe & Tube Prepping Machine for facing beveling, compound beveling and 4" diameter pipe, counterboring 1" 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.

UNIT PRICE (USDl 6,020.00

TOTAL PRICE (USD) 6.020.00

2. 3.

26-410-02 26-411-01

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

1 1\10. 1 No.

70.00 95.00

70.00 95.00

Annexure -2
S.NO. PART NO. DESCRIPTION QTY. UNIT PRICE (USD) 6,020.00 TOTAL PRICE (USD)

1.

80-4000-10

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

1 1\10.

6,020.00

2.

80-4000-20

1 1\10.

6,195.00

6,195.00

3.

80-4000-30

1 No.

6,375.00

6,375.00

4.

80-7001-02

1 No.

120.00

120.00

5.
-.

52-710-03

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

1 No.

135.00

135.00

~
S. NO. PART NO.

ANNEXURE - 3

DESCRIPTION

QTY.

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. 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. 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. 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.

UNIT PRICE (USD) 13,980.00

TOTAL PRICE (USD) 13,980.00

2.

60-HYD-12

1 No.

21,030,00

21,030.00

3.

60-HYD-20

1 No.

32,998.00

32,998.00

4.

60-HYD-28

1 No.

41,638.00

41,638.00

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

5.

60-HYD-36

Wachs Hydraulic Powered SF3036/3 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) 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. Wachs Hydraulic Powered SF3642/3 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 (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.

1 No.

53,535.00

53,535.00

6.

60-HYD-42

1 No.

62,315.00

62,315.00

Bridge Slide for Beveling above 1" wall thickness

7.

60-428-20

Bridge single beveling Slide for point applications over 1" wall and counterboring for Wachs Models SF612j3 - SF1420j3. Bridge single beveling Slide point for applications over 1" wall and counterboring for Wachs Models SF1824j3 and SF2228j3. for single point beveling Bridge Slide applications over 1" wall and counterboring for Wachs l\1odels SF2632j3 and SF3036j3. single beveling Bridge Slide for point applications over 1" wall and counterboring for Wachs Models SF3642j3 - SF4248j3.

1 No.

10,620.00

10,620.00

8.

60-428-28

1 No.

10,835.00

10,835.00

9.

60-428-36

1 No.

11,040.00

11,040.00

10.

60-428-48

1 No.

11,295.00

11,295.00

Power Unit 14-000-03 11.

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. 13.

05 11

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

1 No. 1 No.

260.00 260.00

260.00 260.00

14. 15.

60-234-00 52-701-01

Tool Holder for Bridge Slide 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. 1 No.

180.00 90.00

180.00 90.00

16.

43-711-01

1 No.

145.00

145.00

.~

ANNEXURE - 4 S.NO. PART NO. DESCRIPTION QTY. UNIT PRICE (USD) TOTAL PRICE (USD) 13,980.00

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. 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.
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 No.

13,980.00

2.

60-HYD-12

1 No.

21,030,00

21,030.00

3.

P03-010-424

1 1\10.

62,935.00

62,935.00

hand tools, Operating container, and manual. 4. P03-010-436 shipping

HDSF 2436/1 Heavy Duty Split Frame 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. HDSF3648/1 Heavy Duty Split Frame 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. trip tracking tool slides, single assembly, lifting hooks, one set of eight (8) mounting feet to cover pipe range. Operating hand tools, shipping container, and manual.

1 No.

76,475.00

76,475.00

5.
,

P03-010-448

1 No.

90,020.00

90,020.00

Bridge Slide for Beveling above 1" wall thickness


6.
,

60-428-20

Bridge Slide for single point beveling applications over wall and 1" counterboring for Wachs Models SF612/3 - SF1420/3 . Bridge Slide for Model HDSF 1224/1 Bridge Slide for Model HDSF 2436/1 Bridge Slide for Model HDSF 3648/1

1 No.

10,620.00

10,620.00

7. 8. 9.

11\10. 1 No. 1 No.

15,000.00 15,000.00 15,000.00

15,000.00 15,000.00 15,000.00

14-000-03

Power Unit
10. 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. 5 Nos. 13,900.00

69,500.00

TOOi..INGS 52-701-01 11.


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

..
PRICES

ANNEXURE -5 COMMERCIAL TERMS AND CONDITIONS:

Above prices in US Dollars. This offer is valid for 120 days. Inclusive (10.3%) To be mutually agreed. Against L/e

VALIDITY SERVICE TAX TIMING PAYMENT

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

PART - B

Specification for Orbital GTAW Tube Welding System

Sl. No

Particulars and BHEL specification

Bidders offer (with Complete Technical Details)

1.0 1.1

PURPOSE 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 Confirmed thickness range of 6 to 18 mm.

3.0 3.1

TUBE MATERIALS 1. Carbon Steel 2. Alloy Steel 3. Stainless Steel Confirmed equipment can weld all materials as specified.
Page 1/7

Orbital Tube Welding System Part B

4.0 4.1

WELD JOINT DETAILS 1. Edge Preparation 2. Pipe Condition. End Single V J groove end equipment can be used with all specified details.

Machined in automatic preparation equipment.

5.0 5.1

MACHINE OUTPUT / PRODUCTIVITY VENDOR has to indicate the minimum output of welded Yes confirmed. joints, possible from the workstation, for the tubes with the following dimensions/details, in a single shift of 8 hrs: Tube diameter 63.0 66.0 127.0 Tube thickness 7.0 8.0 12.5 Open welding Head equipped with wire feeder, Confirmed 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 Confirmed detection Confirmed 2. Ground cable. 3. PC laptop window keyboard/touch screen in Confirmed English Confirmed 4. Gas hoses. Confirmed 5. Pressure regulator. Confirmed 6. Adapter for connection standard power source Confirmed 7. Recommended spares for power source and welding head. 8. Additional accessories Confirmed Confirmed Confirmed Confirmed Vendor to specify Number of joints

6.0

SCOPE OF SUPPLY

7.0

Orbital welding head

Orbital Tube Welding System Part B

Page 2/7

7.1

Orbital open type TIG welding head. Radial clearance 50 mm or less. TIG Cold wire feeder with spool holder.

Confirmed 50 mm. Yes

Encoder for position based control of the welding Yes program Provision for constant or pulsed welding speed. Yes

Precise and constant torch rotation by means of Yes planetary drive. Welding torch with ceramic nozzle and gas lens for Yes laminar gas protection. Motorised Arc Voltage control (AVC) and Torch Oscillation control (OSC) for multi pass welding of Yes Available heavy wall tubes Two interchangeable clamping system, i.e., clamp for Yes 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 pulsed/automatic wire retract Confirmed or Confirmed

8.0 8.1

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

Power source High precision invertor power source, compact design Yes Confirmed 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

8.2 8.2.1

Controller Controller integrated with weld head and power Confirmed source.
Page 3/7

Orbital Tube Welding System Part B

8.2.2

Remote pendant for operation. Rotation axis with electronic brake Confirmed

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

0.8mm , 1.0mm

8.2.4 8.2.5

Gas hose with end fittings Gas cylinder to power source Confirmed Length to suit long travel on cable festoon 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 6 programmable multiple pass welding each with unique/different levels per parameters. passes,plus upslope/down slope. Different Parameter Values for each sector within a pass of 6 programmable 360 should be programmable enabling sector vise levels per pass. programming for each pass. Front Panel Display (in English) Contact K type temperature measuring digital sensor unit ENGLISH 1 no
Page 4/7

8.2.7

8.2.8 8.2.9

Orbital Tube Welding System Part B

Temperature measurement accuracy = 0.1C 9.0 9.1 Safety measures Interlocks: The system should trip in the event of: 9.2 Stoppage of shielding gas flow Stoppage of cooling water flow Stoppage of wire feeding Stoppage of movement head around pipe.

Confirmed

Provided

All the pipes, cables etc. on the machine should be well Confirmed supported and protected. These should not create any hindrance to machine operators movement for effective use of machine. Other features Post sequence Printing capability of all the weld parameters Confirmed used (including overrides) and actual peak/min/average values for every pass to pass welding. Orbital welding head radial Clearance of 50 mm or less. 50mm

10.0 10.1

10.2 10.3 10.4 10.5 10.6 10.7

Large color touch screen with multilingual, graphically Confirmed assisted welding software Extension cable (15 m) Gas hose Pressure regulator Confirmed Confirmed Confirmed

Normal life of the Spares and consumables (such as contact Vendor to specify tips, guide rings, loaded springs, Hex nuts, rollers, wheels, etc,.) to be specified, for a set of welding conditions and environment. Built in printer for perfect monitoring and traceability Full function remote control Expert help menu for procedure optimization Confirmed Confirmed Confirmed

10.8 10.9 10.10 10.11 11.0 11.1

Warranty period for 2 years any free service and replacement 12 Months Services: Installation, Commissioning and training Inspection of the complete system by BHEL engineers at Confirmed vendors place by carrying out trial welding on tubes of higher thickness to meet the quality requirements. Carrying out welding trials on a mock-up job at vendors Confirmed works before dispatch.
Page 5/7

11.2

Orbital Tube Welding System Part B

Tube diameter 63.0 66.0 127.0

Tube thickness 7.0 8.0 12.5

For trials BHEL will only provide only the pipe material. Welding will be done by vendors (including welding consumable)

Testing at vendors The acceptance criteria for weld quality shall be passing works Radiography as stipulated in ASME Sec IX, ANSI B31.1, and B31.3 for welding high- pressure piping in power plant Confirmed 11.3 11.4 Installation, commissioning of the system at BHEL site 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 7.0 8.0 12.5 Confirmed Vendor to confirm For trials BHEL will only provide only the pipe material. Welding will be done by vendors (including welding consumable) Confirmed

63.0 66.0 127.0

Subsequent to qualification of tubes, actual jobs in in-situ condition has ot be done by vendor. 11.5 Training of operators at site for operating the machine in in- Confirmed situ condition after completing the commissioning. Duration of training 3 days (without any charge) Documentation Three sets of following documents in tear proof hard copy Confirmed 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. 12.2 Machine Operation manuals: Vendor to specify
Page 6/7

12.0 12.1

Orbital Tube Welding System Part B

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 Confirmed

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

13.0 13.1

Spares and Consumables Should cover gas cups, ceramic torch insulators, gas diffusers, Confirmed 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 Itemized break-up of mechanical (nuts, bolts, tension springs, Confirmed 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) The Vendor shall bring special tools and equipment required Confirmed 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

13.2

13.3

13.4

Vendor to confirm that complete list of spares for machine Confirmed and accessories, along with item part no / specification / type / model, and name & address of the spare supplier shall be
Page 7/7

Orbital Tube Welding System Part B

furnished along with documentation to be supplied with the machine 14.0 14.1 MACHINE PACKING Sea worthy & rigid packing for all items of complete machine, Confirmed 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 GUARANTEE TERMS Performance Guarantee for a minimum period of 24 months Warranty period 12 (for the machine in total and sub-systems or bought-out Months items in particular) from the date of acceptance of the machine. General Points Make and Model of the machine to be mentioned. Detailed Confirmed catalogs of the machine to be sent with the offer. Complete description of all systems & sub-systems shall form Confirmed part of the technical bid A schematic diagram showing the layout of the machine & Confirmed associated systems with salient dimensions shall be submitted along with the offer. Total weight of the Machine & Sub-Systems. Weight of the heaviest part of the machine 17.6 Warranty period for the total system will be two years from 12 Months the date of commissioning of the system at BHEL 60 KG

15.0 15.1

17.0 17.1 17.2 17.3

17.5

Orbital Tube Welding System Part B

Page 8/7

INTERNATIONAL

QUOTATION TO:

GOVERNMENT OF INDIA ACCOUNT: BHARAT HEAVY ELECTRICALS LIMITED TIRUCHIRAPALLI 620014 TAMIL NADU, INDIA

Quotation date Quotation no Subject Dear Sir,

: 05-08-2011 : 110708 :Orbital GTAW TUBE WELDING SYSTEM

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

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

be Amer 24 P.O. Box 348 8253 RC bronten 8250 AH bronten The Netherlands The Netherlands VAT reg. No. NL8182.71.541B01

Phone (+31) 321 386677 Fax (+31) 321 314165 info@magnatech-international.com Ch. Of C. reg. No. 39100085

INTERNATIONAL

Quotation date Quotation no Subject

: 05-08-2011 : 110708 : Orbital GTAW TUBE WELDING SYSTEM :

3.

PIPEMASTER MODEL 516 DIGITAL CONTROLLER/ POWER SOURCE INCL. MODEL 905 WATER-COOLER.

48,880.00


4.

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)
4,034.00

TORCH & CABLE ASSY.

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

Recommended Spare parts for D-Head


PC

15,000.00 1,500.00

TOTAL NET VALUE IN EURO


be Amer 24 8253 RC bronten The Netherlands VAT reg. No. NL8182.71.541B01 P.O. Box 348 8250 AH bronten The Netherlands

114,306.00

Phone (+31) 321 386677 Fax (+31) 321 314165 info@magnatech-international.com Ch. Of C. reg. No. 39100085

INTERNATIONAL

Quotation date Quotation no Subject

: 05-08-2011 : 110708 : Orbital GTAW TUBE WELDING SYSTEM

GENERAL TERMS AND CONDITIONS:

Port of shipment Terms of payment

Delivery schedule Offer validity Country of Origin Agent commission

: FOB AMSTERDAM AIRPORT : 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. : 12 weeks after LOI : 120 days from offer issuing date : USA origin : 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

be Amer 24 8253 RC bronten The Netherlands VAT reg. No. NL8182.71.541B01

P.O. Box 348 8250 AH bronten The Netherlands

Phone (+31) 321 386677 Fax (+31) 321 314165 info@magnatech-international.com Ch. Of C. reg. No. 39100085

ORBITAL GMAW/FCAW PIPE WELDING SYSTEM

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

Bidders offer (with Complete Technical Details)

1.0 1.1

Purpose 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. Vendor to confirm 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.

2.0 2.1

PIPE SIZES TO BE WELDED Pipe diameters (OD) in mm 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 Pipe wall thickness (mm) 6 to 130 mm Qty

Vendor to confirm
Page 1 of 11

pipes are to be welded. Suitable guide rings should be provided.

3.0 3.1

PIPE MATERIALS TO BE WELDED 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 Vendor to confirm

4.0 4.1

WELD JOINT DETAILS 1. Edge Preparation 2. Pipe End Condition Weld Joint Location Preheating Temperature Weld Joint Soundness Tests Weld Quality Appraisal Single V Compound V J groove Up to 18 mm 19 and above Above 50 mm Vendor to confirm

Machined in automatic edge preparation line. ID of the pipes should be matched properly. Length of straight portion on either side of weld joint will be 300 mm max. Upto 250 C by local preheating arrangement for a width of 75 mm to 250 mm on either side of the joint using pads. 100% Radiography and / or Ultrasonic Testing as well proof testing by hydraulic test. 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

3. 4.

5.

6.

5.0 5.1

MACHINE OUTPUT / PRODUCTIVITY VENDOR should specify the minimum output of welded joints, Vendor to Specify 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

Page 2 of 11

(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 6.1 Orbital GMAW Pipe Welding System Scope of Supply of equipment Orbital weld head: a. Axial length: b. Radial clearance: c. Width of head: d. Weight of head: (weight without wire spool) 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) 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 6.4 Torch vertical motion (motorized) a. Stroke: 100 mm b. Speed: 100 cm/min 6.5 Motorized tractor a. Tractor speed range: 0-1.5 m/min (welding speed) b. Forward / reverse facility. Programmable 6.6 Wire Feeder The wire feeder should able to feed a. Carbon & alloy steel. Solid & flux cored wires of
Page 3 of 11

Vendor to Specify

Vendor to specify

Vendor to specify

Vendor to specify

Vendor to specify (the variation should be with in some specified range only) Vendor to specify

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 6.8 Water cooled torch Water cooled torch rated at 400 @ 100% duty cycle Torch adjustment capability a. Torch lead/lag adjustment: 15 degrees. b. Torch tilt adjustment: 25 degrees c. Angle bracket: 360 manual 6.9 6.10 7.0 7.1 7.2 Sensor tracking device for automatic adjustment of welding torch Vendor to specify for groove center & contact tip to work distance Proportional Gas Mixing Unit for mixing Argon and CO2 gases. Gas mixing accuracy: Power source specifications Inverter type Synergic GMAW/FCAW Power source 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 7.3 Power source details a. Output rating: 400A @ 44 V DC @ 100% duty cycle b. Max. Open circuit voltage: 80 V DC 7.4 7.5 Weld head controller Pendant cable length: 12 m Wire feeder Vendor to specify
Page 4 of 11

Vendor to specify Vendor to specify

Vendor to specify Vendor to specify Vendor to specify

Vendor to specify

Vendor to specify

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 Vendor to provide Built-in water circulation unit of suitable capacity for the weld details. head and torch. Shall cool the torch while welding Pipes with 250 C preheat involving more than 20 continuous passes. 7.7 7.8 8.0 8.1 Gas hose with end fittings Gas cylinder to power source Length Vendor to specify to suit long travel on cable festoon Self aligning clamps to align pipe edges (OD Controlled pipes) to be welded. Main Controller Controller integrated with weld head. Remote operator pendant for online monitoring and control of the welding process. 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 8.3 Welding Data Entry: Through a dust & moisture proof Membrane Vendor to specify Key Pad Rugged Type that is adequately cooled to ensure problem free operation. External Memory: Does equipment have provision to store welding Vendor to specify programs in Pen drive (Memory stick)? Each weld program for a unique combination should allow multiple Vendor to specify pass welding each with unique/different parameters. the Max. No of passes that can be written in a program. Different Parameter Values for each sector within a pass of 360 Vendor to specify should be programmable enabling sector vise programming for the Maximum No of each pass. sectors that can be programmed per pass of 360. Front Panel Display (in English) Contact K type temperature measuring digital sensor unit Temperature measurement accuracy = 0.1C 9.0 Safety measures
Page 5 of 11

Vendor to specify

Vendor to specify

8.4 8.5

8.6

8.7 8.8

Vendor to describe 1 no Vendor to specify

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 Vendor to Confirm and protected. These should not create any hindrance to machine operators movement for effective use of machine. Other features The equipment should be portable Length between the power source and the welding head:15 meters Vendor to specify

10.0 10.1 10.3

Post sequence Printing capability of all the weld parameters used Vendor to specify (including overrides) and actual peak/min/average values for every pass to pass welding. Orbital welding head must accommodate the radial Clearance Vendor to specify between pipes of 300 mm Orbital welding head must have provision for preheating coil to be Vendor to specify mounted on the pipes during welding Extended arm facility has to be provided to accommodate Vendor to specify 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.

10.4 10.5 10.6

10.9

Normal life of the Spares and consumables (such as contact tips, Vendor to specify guide rings, loaded springs, Hex nuts, rollers, wheels, etc,.) to be specified, for a set of welding conditions and environment. Warranty period for any free service and replacement Services: Installation, Commissioning and training Inspection of the complete system by BHEL engineers at vendors Vendor to confirm place Carrying out welding trials on a mock-up job at vendors works Vendor to confirm before dispatch. For trials BHEL will Pipe Material Outside Thickness of No. of only provide only diameter, mm pipe, mm Joints to be the pipe material.
welded
Page 6 of 11

10.10 11.0 11.1 11.2

Vendor to specify

SA106GrC + GrC (with 90/10 gas combination) SA335P22 + P22

368

56

2 90 2 65

Welding will be done by vendors (including welding consumable) Testing can be done by BHEL if required

(with 90/10 gas combination) 508 SA335P91 + P91 (with 95/05 gas combination) 406.4

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 11.3 11.4 Installation, commissioning of the system at BHEL sites 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) Vendor to confirm Vendor to confirm For trials BHEL will only provide only the pipe material.

Welding will be The two sets with full GMAW solid wire welding & two sets with done by vendors root solid wire, fill passes with Flux cored wire welding (including welding consumable)
Pipe Material Outside diameter, mm Thickness of No. of pipe, mm Joints to be welded 56 4

Testing can be done by BHEL if required

SA106GrC + GrC (with 90/10 gas combination) SA335P22 + P22

368

4 90 4 65

(with 90/10 gas combination) 508 SA335P91 + P91 (with 95/05 gas combination) 406.4

Page 7 of 11

11.5

Welding of actual jobs at site to prove out the orbital welding Vendor to confirm 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 )
Pipe Material Outside diameter, mm 368 Thickness of No. of pipe, mm Joints to be welded 56 5

SA106GrC + GrC (with 80/20 gas combination) SA335P22 + P22

5 90 5 65

(with 80/20 gas combination) 508 SA335P91 + P91 (with 80/20 gas combination) 406.4

11.7

Training of a minimum of 15 operators at site for operating the Vendor to confirm machine after completing the commissioning. Duration of training 7 days (without any charge) Documentation Three sets of following documents in tear proof hard copy and soft Vendor to specify copy (CD) Machine operation manuals Maintenance and troubleshooting manuals Troubleshooting procedures for different error codes and problems must be addressed in the manuals.

12.0 12.1

12.2

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. Programming Manuals of Machine & system

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

Page 8 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 On line fault diagnostic system

13.0 13.1

Spares and Consumables Should cover gas cups, ceramic torch insulators, gas diffusers, Vendor to specify 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 Itemized break-up of mechanical (nuts, bolts, tension springs, Vendor to specify 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) The Vendor shall bring special tools and equipment required for Vendor to confirm 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

13.2

13.3

13.4

Any Test mandrel required for checking & alignment of the Vendor to confirm
Page 9 of 11

machine components etc. should be supplied 13.5 Vendor to confirm that complete list of spares for machine and Vendor to confirm 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 MACHINE PACKING Sea worthy & rigid packing for all items of complete machine, Vendor to confirm 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 GUARANTEE TERMS Performance Guarantee for a minimum period of 24 months (for Vendor to confirm the machine in total and sub-systems or bought-out items in particular) from the date of acceptance of the machine. Power supply Input Power supply- 415 V/ 50 Hz Vendor to specify All electronic controls for controller / drives that need stabilized Vendor to specify supply shall be provided with suitable voltage stabilizer General Points Make and Model of the machine to be mentioned. Detailed Vendor to specify catalogs of the machine to be sent with the offer. Complete description of all systems & sub-systems shall form part Vendor to confirm of the technical bid A schematic diagram showing the layout of the machine & Vendor to confirm associated systems with salient dimensions shall be submitted along with the offer. The operating sequence of the machine with broad outline of Vendor to confirm various operations involved should be furnished with the offer. Standards for Design, Manufacture and testing of the machine Vendor to confirm shall be in accordance with internationally accepted standards. Total weight of the Machine & Sub-Systems. Weight of the heaviest part of the machine 17.7 17.8 17.9 Total connected load KVA Colour of the system to be mentioned by the vendor. Vendor to specify Vendor to specify Vendor to specify

14.0 14.1

15.0 15.1

16.0 16.1 16.2 17.0 17.1 17.2 17.3

17.4 17.5 17.6

Floor area required (Length x width x height) for complete machine Vendor to specify and accessories

17.10 Warranty period for the total system will be Two years from the Vendor to confirm date of commissioning of the system at BHEL
Page 10 of 11

Page 11 of 11

Bharat Heavy Electricals Ltd. Welding Research Institute Tiruchirapalli, 620 014 INDIA

Quotation No. AMIQ20098


Date 5/2/2011 Sales Rep. Tom Stancikas

Attention: Mr. Dhanesh Kant Verma Tel: EMail: dkverma@bheltry.co.in Re:

5/2/2011 Fax:

Dear Mr. Verma, Per your request, Arc Machines, Inc. is pleased to provide this budgetary price quotation for orbital pipe welding equipment. US$ US$ Part No. / Description Unit Price Ext. Price 13D150100-06 $55,800.00 $55,800.00 MODEL 415B POWER SUPPLY TOP ASSY 200-575VAC AXIOMTEK CPU Model 415 computer controlled programmable power supply, with 400 ampere DC welding current output. Includes M-415 operator pendant with AMI heads up display (HUD), 50-ft. M-415 pendant extension, reusable wooden shipping container,40-ft. M-415 weld head service adapter cable,40-ft. M-415 weld head control adapter cable,25-ft. gas inlet hose, operation maintenance manual and electrical drawings package. The M-415 requires three-phase input power,200 to 575 VAC, 50/60 Hz. Windows XP (TM) Operating System 13150136-02 $37,704.00 $37,704.00 MODEL 15-415 WELD HEAD TOP ASSY WITH -C- TORCH & DUAL W.F.

Item 1

Qty 1

U/M EA

EA

3 Note: your request is from 300mm to 1000mm diameters. Following guide rings are for reference and offers an idea of the price range for guide rings. Shown are the smallest and largest in your requested size requirements. 4 1 EA 131509105-1254 GUIDE RING 12.539 (318.5MM) 131509105-4000 GUIDE RING 40.000 (1016MM) $3,420.00 $3,420.00

EA

$12,480.00

$12,480.00

To: Bharat Heavy Electricals Ltd. Arc Machines, Inc. Quotation No. AMIQ20098

Page

Item

Qty

U/M

Part No. / Description

US$ Unit Price

US$ Ext. Price

Delivery:

Please consult factory at time of order.

All shipments are: Ex-works, Pacoima (Los Angeles), California, U.S.A. Payment Terms: Validity: Payment in advance. See attached Payment Terms. 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 of submitting this quotation. Should you have any questions regarding this quotation or need any additional 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: Bharat Heavy Electricals Ltd. Arc Machines, Inc. Quotation No. AMIQ20098

Page

Customer: Ref: Date: Days Allowed:

Bharat Heavy Electricals Ltd. Quotation No. AMIQ20098 5/2/2011 4 TRAINING, INSTALLATION & SERVICE

A.

Training or Installation Service No Labor Charge Arc Machines, Inc. (Seller) shall provide the services of a qualified representative at Customers facility, for the purpose of training operators or of assisting with installation, check-out or acceptance testing of Equipment delivered per above reference, for the period of time specified above in Days Allowed, free of charge for the representatives labor. Other charges apply see B, C and D below. All Other Service Labor Charge If, after the first installation or training period per A above additional assistance with installation, training, or checking-out of equipment at Customers facility is requested by Customer, the charge for labor for each day or any fraction thereof shall be US$800.00, and such charge shall apply for the entire time that the Sellers representative either is at the Customers facility or is available to perform the above-listed duties at the Customers convenience. Labor is not charged for travel time. Additional other charges apply see C, D and E below. Other Charges Travel and Transportation Expenses In connection with any and all service at Customers facility, the Customer shall pay all actual travel and transportation expenses incurred by Sellers representative. Additional other charges apply see D and E below. Other Charges Living and Incidental Expenses The charge for living and incidental expenses shall apply for the entire time the representative is outside of Los Angeles County, California. U.S.A. Domestic: In connection with all service at Customers facility, (outside of Los Angeles County), Customer shall pay either the Sellers representatives 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 Customers facility, Customer shall pay the Sellers representatives actual living and incidental expenses (if pre-paid not less than US$225.00 per day or fraction thereof) in addition to actual travel and transportation expenses. Estimated travel, transportation and living expenses and service charges, if any, shall be paid to Arc Machines, Inc., prior to departure.

B.

C.

D.

E.

Other Charges Service in Factory (located in Pacoima near Los Angeles, California, USA) In lieu of installation Service at Customers Facility (A above), Customer may, at their option, send a limited number (maximum 5) of their personnel to Sellers factory for acceptance, operator training, check-out or testing of equipment delivered per above reference, at Customers cost. Seller shall charge Customer US$400.00 per day for each work day or fraction thereof that Customers personnel are in Sellers factory in excess of the period of time per Days Allowed specified above. 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 does not apply to Project Site Support, or to Maintenance Training or to Warranty or other repair or other after-sale services. 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

F.

Customer: Ref: Date:

Bharat Heavy Electricals Ltd. Quotation No. AMIQ20098 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 or material for a period of eighteen (18) months from date of shipment or one (1) year from date of commissioning at Buyers location, whichever first occurs. This warranty shall apply only to such items as are manufactured by Seller. This warranty specifically excludes such items as may be attached to or installed into Sellers equipment at the request of the Buyer. This warranty shall terminate and become void if equipment shipped by Seller is either (i) altered, modified or repaired by anyone other than Seller or Sellers authorized repair personnel, or (ii) connected to or used with items manufactured by anyone other than Seller (excepting only test equipment approved by Seller). Sellers sole liability and Buyers sole remedy for breach of warranty shall be the replacement, repair or adjustment, at Sellers option, F.C.A. place of manufacture or authorized repair station, of warranted equipment with respect to which Buyer claims a breach of warranty by written notice to Seller received by Seller within one (1) year from date of commissioning at Buyers location, or within a period of eighteen (18) months from the date of shipment of such equipment, whichever first occurs. All equipment or parts claimed to be in breach of this warranty must be returned by Buyer to place of manufacture or authorized repair station, transportation prepaid, and will be returned to Buyer, transportation charges collect. IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SELLER. THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESCRIBED HEREIN; AND NO WARRANTIES BY SELLER SHALL BE IMPLIED OR OTHERWISE CREATED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH WARRANTIES ARE HEREBY DISCLAIMED.

Customer: Ref: Date:

Bharat Heavy Electricals Ltd. Quotation No. AMIQ20098 5/2/2011

LETTER OF CREDIT INSTRUCTIONS


To avoid any delays or additional costs and charges in connection with Letter of Credit payments, please prepare you irrevocable L/C in accordance with these instructions. BENEFICIARY: (SELLER) Arc Machines, Inc. 10500 Orbital Way Pacoima, CA 91331 USA State Bank of India Los Angeles Agency 707 Wilshire Boulevard Los Angeles, CA 90017, USA Tel: USA 818-896-9556 Fax: USA 818-890-3724

ADVISING BANK:

Swift: SBINUS66 Telex: 18819

PAYMENT TERMS:

The Letter of Credit must be payable at the counters of State Bank of India (SBI) Los Angeles, on sight of documents. To be effected in US DOLLARS only for the full contract amount. To be drawn at sight. In case of time drafts, all charges are for the account of the applicant. Ex-Works Factory, Pacoima, California, USA. FCA Los Angeles (LAX) airport (per INCOTERMS 1990), by Air Freight only. Freight and insurance costs to the account of the applicant. To be located only in the Los Angeles area. Only the charges imposed by SBI, Los Angeles, are to the account of the Beneficiary. Bank charges imposed by any other bank are to the account of the applicant. To be issued and received by Beneficiary at same time as Purchase Order or Contract is issued. To be no less than fourteen (14) days after the shipment. Shipment date will be notified to Buyer upon request, prior to issue of L/C.

PAYMENT: DRAFTS:

PRICES ARE: SHIPMENT TERMS:

FRT. FORWARDER: BANK CHARGES:

L/C OPENING:

L/C EXPIRATION:

NOTES: Failure to comply with these instructions may cause rejection or amendment of the L/C, at applicants expense. L/C must be in English language. Only Sellers warranty applies. Performance bonds, bank guarantees, customs drawbacks and similar are not acceptable.

ORBITAL PIPE CUTTING AND BEVELING SYSTEM

PART - B SPECIFICATION FOR ORBITAL PIPE CUTTING AND BEVELING SYSTEM


Sl. No 1.0 1.1 Particulars and BHEL specification PURPOSE Split Frame type cutting and beveling machine with single point 1 Set cutting on OD controlled heavy wall pipes generating compound bevels, counter bore and flange facing. Vendor to confirm 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. 2.0 2.1 PIPE SIZES to be Machined Pipe diameters (OD) in mm Pipe wall thickness (mm) Vendor to specify the ranges of the systems available Bidders offer (With complete Technical Details)

80, 88.9, 100, 108, 114.3, 125, 127, 133, 141, 141.3, 150, 159, 168.3, 177.8, 6 to 130 mm 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 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 4.1 Edge Preparation Details 1. Edge Preparation

Single V (Bevel angle ) (up to 19 Vendor to confirm mm wall thickness) Compound V ( Angles ) (greater than 19 mm to 130 mm) J groove (for P 91 material grade)

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2. Surface finish 3. Quality Appraisal 5.0 5.1

12.5 microns

MACHINE OUTPUT / PRODUCTIVITY VENDOR has to indicate the minimum output of machined Vendor to Specify 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) (P 22) 508 mm (OD) x 90 mm (wall thickness) (P 91) 406 mm (OD) x 65 mm (wall thickness) (Gr C) 323.9 mm (OD) x 36 mm (wall thickness) (P 91) 914 mm (OD) x 32 mm (wall thickness xx Joints xx Joints xx Joints xx Joints -- xx Joints

6.0 6.1

Scope of Supply of equipment 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
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Vendor to Specify

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

Cutting Tool Surface Speed: Surface speed in meters per minute. Drive Options: Hydraulic and Pneumatic Power Requirements: Hydraulic requirement 38 LPM @ 103 bar pressure. Air requirement: 2.7 Cubic Meters per Minute @ 6.2 bar. Feed Method: Positive mechanical star wheel Feed Rate: Fixed trip rate:

Vendor to specify

Vendor to specify Vendor to specify

Vendor to specify Vendor to specify

Construction: Select hardened alloy steel components, large 6 Vendor to specify (152.4 mm) cross section, high capacity bearings, heavy duty pinion housing, corrosion resistant finish and ratcheting hinge mechanism.

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 7.0 7.1 8.0 8.1

Sensor tracking device for automatic adjustment of cutting tool Vendor to specify for groove center Main Controller Integrated controller Safety measures All the pipes, cables etc. on the machine should be well Vendor to Confirm supported and protected. These should not create any hindrance to machine operator's movement for effective use of machine. Other features The equipment should be portable Vendor to specify Vendor to specify

9.0 9.1

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9.2

Normal life of the Spares and consumables (such as guide rings, Vendor to specify loaded springs, Hex nuts, rollers, wheels, etc,.) to be specified, for a set of beveling conditions and environment. Warranty period for any free service and replacement Services: Installation, Commissioning and training at BHEL construction sites Vendor to specify

9.3 10.0

10.1 10.2

Inspection of the complete system by BHEL engineers at vendors place Carrying out trials on a mock-up job at vendors works before despatch. Pipe Material Outside diameter, mm 368 508 406.4 Thickness No. of of pipe, Joints to mm be beveled 56 90 65 2 2 2

SA106GrC SA335P22 SA335P91

The acceptance criteria for quality shall be passing as stipulated in ASME high pressure piping in power plant. 10.3 10.4 Installation, commissioning of the system at WRI, BHEL 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) Pipe Material Outside diameter, mm 368 508 406.4 Thickness of No. of pipe, mm Joints to be beveled 56 90 65 5 5 5

SA106GrC SA335P22 SA335P91 10.5 11.0 11.1

Training of 4 operators at site for operating the machine after completing the commissioning. Duration of training 5 days Documentation Three sets of following documents in tear proof hard copy and
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soft copy (CD) Machine operation manuals Maintenance and troubleshooting manuals Troubleshooting procedures for different error codes and problems must be addressed in the manuals. 11.2 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. Programming Manuals of Machine & system

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 On line fault diagnostic system Soft copy of all software in the system.

12.0

Spares and Consumables


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12.1

Itemized break-up of mechanical (nuts, bolts, springs, slides, Vendor to specify 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) 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

12.2

12.3 12.4

Any Test mandrel required for checking & alignment of the Vendor to confirm machine components etc. should be supplied Vendor to confirm that complete list of spares for machine and Vendor to confirm 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 MACHINE PACKING Sea worthy & rigid packing for all items of complete machine, Vendor to confirm 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 GUARANTEE TERMS Performance Guarantee for a minimum period of 24 months (for Vendor to confirm the machine in total and sub-systems or bought-out items in particular) from the date of acceptance of the machine. Power supply Input Power supply- 415 V +_ 10% / 50 Hz / 3 Phase AC (or ) 220 Vendor to specify V / 50 HZ / Single Phase AC All electronic controls for controller / drives that need stabilized Vendor to specify supply shall be provided with suitable voltage stabilizer General Points Make and Model of the machine to be mentioned. Detailed Vendor to specify
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13.0 13.1

14.0 14.1

15.0 15.1 15.2 16.0 16.1

catalogs of the machine to be sent with the offer. 16.2 16.3 Complete description of all systems & sub-systems shall form Vendor to confirm part of the technical bid A schematic diagram showing the layout of the machine & Vendor to confirm associated systems with salient dimensions shall be submitted along with the offer. The operating sequence of the machine with broad outline of Vendor to confirm various operations involved should be furnished with the offer. Standards for Design, Manufacture and testing of the machine Vendor to confirm shall be in accordance with internationally accepted standards. Total weight of the Machine & Sub-Systems. Weight of the heaviest part of the machine 16.7 16.8 16.10 Total connected load KVA Colour of the system to be mentioned by the vendor. Vendor to specify Vendor to specify Vendor to specify

16.4 16.5 16.6

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

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Bharat heavy electricals limited Tiruchirapalli

08-07-2011

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) (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) (for od controlled pipes with OD clamping and heavy thickness tubes) 3) MF 2-25 range 20mmOD-38mm OD( air motor/electric ) (for OD controlled pipes od clamping and heavy thickness tubes)

Euros 10500.00

Euros 8500.00

Euros 8500.00

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:venkatesh68@gmail.com k.venkatesh@dwt-gmbh.de