Name : B50HES1030 Rev : - Release : 2020/12/06 11:44 PM

GENERAL PROCUREMENT SPECIFICATION B50HES1030

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RESPONSIBLE DEPARTMENT
Materials and Process Engineering (Hydro)

WRITTEN BY CHECKED BY APPROVED BY

S Gaudion / A Vaichere Y Abdallahoui / P Feriol T. Kunz

SCOPE AND PURPOSE

The scope of this document is to specify additional requirements to the Quality Sheet (QS) for the supply of
forged products to be used in the manufacturing of hydraulic machines.

DOCUMENT REVISION CHART

DOCUMENT REVISION STATUS : DETERMINED BY THE LAST ENTRY IN THE “REV” AND “DATE” COLUMN

REV. SECTION MODIFIED AND REVISION DESCRIPTION DATE RELEASED BY

DD/MM/YYYY
- First issue Nov 2020 MPE (Hydro) Department

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TABLE OF CONTENTS
1. General provisions ....................................................................................................................................................... 3
1.1. Scope...................................................................................................................................................................... 3
1.2. Applicable Standards ............................................................................................................................................... 3
2. Manufacturing Process Plan ......................................................................................................................................... 3
3. Melting conditions ....................................................................................................................................................... 4
4. Chemical requirements ................................................................................................................................................ 4
5. Discard rate and Forging ratio ....................................................................................................................................... 4
5.1. Discard rate ............................................................................................................................................................ 4
5.2. Forging ratio ........................................................................................................................................................... 4
6. Delivery conditions ...................................................................................................................................................... 4
6.1. Quality heat treatment ............................................................................................................................................ 4
6.2. Welding Production Test Coupon (WPTC) ................................................................................................................. 5
7. Sampling ..................................................................................................................................................................... 5
7.1. General requirements (Location and orientation of specimens) ................................................................................. 5
7.2. Specific sampling location ........................................................................................................................................ 6
8. Mechanical and metallurgical requirements .................................................................................................................. 6
8.1. Simulated post weld heat treatment ........................................................................................................................ 6
8.2. Test methods .......................................................................................................................................................... 7
8.2.1. Chemical composition on product ........................................................................................................................ 7
8.2.2. Tensile test ......................................................................................................................................................... 7
8.2.3. Charpy V-notch test ............................................................................................................................................. 7
8.2.4. Microstructure .................................................................................................................................................... 7
8.2.5. Fracture toughness .............................................................................................................................................. 7
8.2.6. Counter tests ...................................................................................................................................................... 7
9. Material Integrity ......................................................................................................................................................... 7
9.1. Surface delivery condition ....................................................................................................................................... 7
9.2. Surface discontinuities ............................................................................................................................................ 7
9.3. Internal soundness .................................................................................................................................................. 7
9.4. Removal and repair of defects ................................................................................................................................. 7
10. Magnetic properties ................................................................................................................................................ 8
11. Dimensional check .................................................................................................................................................. 8
12. Quality.................................................................................................................................................................... 8
12.1. Marking and identification (traceability) .................................................................................................................. 8
12.2. Delivery certificates................................................................................................................................................. 8
13. Packing and transport.............................................................................................................................................. 8

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1. General provisions

1.1. Scope
This specification defines the general technical requirements for the supply of forged products (sometimes called parts) used in
hydraulic machines such as turbines, valves, generators and hydromechanics.

This specification is valid in combination with drawings and applicable Quality specification sheet (QS) attached to the Purchase
order (PO).

This specification covers the manufacturing and testing of forged products classified by chemical composition into three steel
types in accordance with recognized standard:
- Carbon and carbon-manganese (C and C-Mn) steel,
- Alloy steel,
- Stainless steel.
This specification concerns the delivered state requirements for forged and normalized or quenched and tempered products
in pre-machined or finished machined conditions.

Some options or additional requirements can be asked by GE in the PO within the frame of this specification. In this case, the
conditions and criteria shall be discussed by GE and supplier before placing the PO.

1.2. Applicable Standards

The applicable standard frame is defined by the QS and/or the PO.

2. Manufacturing Process Plan

Prior to production, the supplier shall submit a detailed MPP for review and approval by GE. The purpose of the MPP is to describe
all operations (including manufacturing, inspection and testing) in the sequence in which they are to be performed and show the
process has sufficient controls.
The MPP shall include as a minimum the following items: (all times and temperatures shall contain the aim and tolerance). Once
the process is qualified, the process is considered frozen and shall not be changed without GE approval. An MPP shall be
approved by GE prior to initiation of the First Piece Qualification (FPQ).

This MPP shall include at least the following data:

(1) Applicable documents, standards, drawing, specifications, procedures, etc.
(2) Manufacturing program with main manufacturing steps and inspection activities (Witness and Hold points)
(3) The steelmaking process
(4) Grade of material, including chemical composition ranges
(5) The ingot shape, weight and dimensions
(6) The position of the raw forging and final shape in the ingot
(7) The top and bottom discard rates
(8) Description and dimensioned sketch of the subsequent to each forging operation, including general configuration at the
beginning and end of each different type of hot work or forging operation with hot-working temperature for each
forging step.
(9) Forging ratio for each step and overall ratio of reduction determined
(10) Heat Treatment procedure and thermocouples position
(11) The exact location of sampling for destructive test in the raw forged parts with the indication of the final shape of the
parts
(12) All the NDT procedures established to ensure the right execution of non-destructive test as per this specification

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3. Melting conditions
The steel shall be processed in an electrical furnace and poured under vacuum or degassed in the ladle; no other processing
method can be used without GE formal approval.

4. Chemical requirements
The heat’s chemical composition shall be checked as described in the corresponding standard and shall comply with the additional
requirements in QS if any.

5. Discard rate and Forging ratio

5.1. Discard rate

Discard ratio’s (top & bottom) shall be defined by the steelmaker and there shall be sufficient to ensure elimination of shrinkage
cavities and most segregations. A record of ingot weight and discard percentages shall be kept at the disposal of GE.

5.2. Forging ratio

The forging ratio calculated with all forging steps, except the pre-upsetting, must be ≥ 3.
For annular parts, the forging ratio is calculated using the following formula:

S L' D'
Forging ratio ( Annular parts) =  
S' L D
with:
• S: average cross-section of ingot
• S’: average cross-section of solid forged rough part
• L: average length before forging on mandrel
• L’: average length after forging on mandrel
• D: average diameter of rough part before rolling or forging on the two-beaked anvil
• D’: average diameter after annular rolling or forging on the two-beaked anvil

6. Delivery conditions
The delivery state shall respect the drawing and the QS, it can be:
-Design rough-machining: machined according to rough machining drawing
-Design semi-finished machining: semi-finished machined all over leaving a minimum of 5 mm cutting allowance per surface
according to finished part drawing
-Design finished-machining: machined according to finished part drawing.

6.1. Quality heat treatment

The quality heat treatment conditions are defined for each grade in the corresponding standard and shall comply with the
additional requirements in QS if any.

Heating and cooling rates of Quality Heat Treatments cycles shall be ≤ 150°C/h except cooling rate for quenching (water, oil)
and cooling in forced air after normalizing.
For tempering heat treatment, heating and cooling rate shall be ≤ 55°C/h, from and until 200°C.

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In addition, the maximum difference between the temperature measured by the thermocouples in contact with the load and
the target temperature must be, during the maintenance phase, of ± 15°C.
In any case:
• The part shall not be put in the furnace at a temperature ≥ 200°C
• The part shall be removed from the furnace at a temperature below 200°C.
The heating and cooling rates, holding times and temperatures shall be carefully measured and followed by contact
thermocouples, correctly localized on the parts, during the entire heat treatment. The thermocouples locations on the parts
shall be described in the Manufacturing Process Plan and shall ensure at least one thermocouple is localized on the thickest part
and at least one other on the thinnest part of the product, will ensuring that the homogeneity of the furnace is ensured by
room thermocouples.
In the case of a load comprising several parts, at least one thermocouple shall be placed on one of the parts at the center of the
load
The thermal cycles shall be recorded and given in the delivery certificate.

6.2. Welding Production Test Coupon (WPTC)

When forged products, supplied under the application of the QS to which this specification is associated, are welded as part of a
welded structure (weldable grades only), in addition to the main products to be supplied, 1 coupon per product shall be supplied.
Those coupons will be used as WPTC during manufacturing operations. These tests coupons shall be cut from product they
represent and submitted to the same thermal cycles in the same furnace batches.
Each coupon shall have the following dimensions after cleaning, quality heat treatment and rough machining: (minimum
dimensions)
• Thickness: 50 mm
• Length: 600 mm
• Width: 200 mm
For the requirements of the non-destructive examination, these coupons shall comply with the quality levels of the most restrictive
zone described in the QS.

NOTA: Information if a product will be subjected to welding shall be asked to GE and clarified into the PO.

7. Sampling
The sampling location are proposed by the manufacturer for GE approval before placing the PO. It shall conform to the associated
product standard except if nothing specified, then it shall follow directives of paragraph 7.2.

7.1. General requirements (Location and orientation of specimens)

The samples shall be taken from the part after completion of quality heat treatment.
Samples dimensions shall be sufficient to enable all the tests required in the product standard and possible counter-tests.
The exact samples locations including the distance between samples and heat- treated surfaces are defined in the MPP
according product standard requirements (or by specific requirement as per paragraph 7.2)
To reduce the thickness of the sampling section, the manufacturer can use thermal buffers. The type, dimensions and location of
thermal buffer are proposed by the manufacturer for GE approval before placing the PO. The height of the thermal buffer shall be
at least equal to t/2 (with a maximum of 90mm) and shall apply to the diameter of the considered end of the forging (with t
defined as tR or teq according EN 10250-1, Annex B).
The samples are cut out by cold machining.

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7.2. Specific sampling location

-In case of a shaft/trunnion design, one sampling ring shall be prepared from prolongations at each end of the forged product
resulting in two sampling rings per products. Within each sampling ring, two sampling locations diametrically opposite are defined.
The four sampling locations are arranged in order to be localized at 90° from each other (see Fig1. here after).
-In case of a simple ring design, one sampling ring shall be prepared from prolongation at only one end of the forged product
resulting in one sampling ring per products. Into the sampling ring, two sampling locations diametrically opposite are defined. (see
Fig2. here after).

All specimens shall be taken at a distance of t/4 below the heat cylindrical outer surface at heat treatment profile (with a minimum
of 20 mm and a maximum of 80 mm) and at t/2 (however max. 90 mm) from the end of the forged part (with t defined as tR or teq
according EN 10250-1, Annex B). The specimen reference point to be used for the localization is defined as follow:
• Unixial Tensile test specimen: center of the gage length axis
• Iso-V Charpy specimen: geometrical center of the specimen

Fig1: Shaft/Trunnion forging- Test Fig2: Ring forging - Test

specimens locations & orientations specimens locations & orientations

8. Mechanical and metallurgical requirements

8.1. Simulated post weld heat treatment

When forged products, are welded as part of a welded structure (weldable grades only) a simulated Post Weld Heat Treatment
(PWHT) identical to the thermal cycle that the products will receive during manufacturing is applied to the coupon dedicated to
mechanical tests, to verify the mechanical behaviour of the supply product in its final configuration. General requirements given
in the §6.1 applies, besides the application of the Post Weld Heat Treatment procedure P10HEM5400. This simulated post weld
heat treatment is detailed in the manufacturing process plan.
NOTA: Information if a product will be subjected to welding shall be asked to GE and clarified into the PO.
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8.2. Test methods

The applicable standards describing testing conditions and methodology are given in the applicable QS.

8.2.1. Chemical composition on product

As per applicable standard product and/or required by the QS.

8.2.2. Tensile test

As per applicable standard product and/or required by the QS.

8.2.3. Charpy V-notch test

As per applicable standard product and/or required by the QS.

8.2.4. Microstructure
The product microstructure will be done only if required in the QS or PO.

8.2.5. Fracture toughness

The product microstructure will be done only if required in the QS or PO.

8.2.6. Counter tests

If any one of the tests failed, a new full set of same tests shall be done.
The supplier shall provide enough material in the same conditions as those defined in this specification in order to allow a full set
of counter tests as per this specification.
A Root Cause analysis shall be performed and reported in the test certificate.
If both set of tests (tests and counter tests) failed, the part is rejected.

9. Material Integrity

9.1. Surface delivery condition

The parts shall be delivered free from flaws, cracks, scales, or forging folds. These defects shall be removed by chipping or grinding
followed by surface control as described here after.

9.2. Surface discontinuities

The surface discontinuities shall be checked as described in the QS.

9.3. Internal soundness

The ultrasonic examination shall be performed as described in the QS.

9.4. Removal and repair of defects

Defects may be removed by grinding or chipping and grinding, provided that the product dimensions are acceptable., Complete
elimination of the defective material is to be verified by magnetic particle testing or liquid penetrant testing according to QS.

Caution:
Repair by welding is prohibited*

*For weldable grades, welding repairs could be proposed through a Non-Conformity report and a Prior Agreement of GE is
mandatory before any repairs. As a minimum the supplier documentation will include:

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- Welding Procedure Qualification Report (WPQR)

- Welding Procedure Specification (WPS)
- Welder Performance Qualification (WPQ)
- Report of initial heat treatment cycle applied to the part
- Filler metal certificates
- NDT inspector qualifications
- PWHT process based on GE specification P10HEM5400

10. Magnetic properties

If specified in the PO, the magnetic properties (minimum magnetic induction values at a given field strength) shall be checked and
transmitted to GE for approval. The testing conditions shall be attached to the PO.
The values obtained shall be reported in the delivery certificate.

11. Dimensional check

Dimensional check shall be performed as described in the mandatory appendices of this document and shall comply with the
drawing transmitted with the PO.

12. Quality

12.1. Marking and identification (traceability)

Marking shall be performed as described on the drawing transmitted by GE with the order.

12.2. Delivery certificates

A delivery certificate according EN 10204 shall be issued including all information, test conditions and results required in this
specification including at least:
• Chemical analysis including hydrogen content
• Delivery condition
• Main forging data
• Quality Heat treatment conditions
• Specimen sampling conditions and localization
• Mechanical and metallurgical properties
• Surface and volume inspection conditions and reports
• Conditions and results of bore examination when required
• Results of dimensional check
• Magnetic properties when required

13. Packing and transport

Packing and transport conditions shall be attached to the PO by GE.

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