volume ii - public tenders | offline tenders | online tenders · 2016. 7. 29. · calandria...

e-TPT/SUPPLY-1

Tender № CMM/FTP/10-31-1-1132

VOLUME – II

Brief Description No. of Pages

SECTION - C

Section C Cover

Sub Section – C1

Special Instruction to Tenderers 10

Annexure – 1 1

Annexure – 2 4

Sub Section – C2

Technical Specifications

PC-E- 1047 24

PC-M- 1045 12

PC-M-1046 11

PP-E-1051 26

e-TPT/SUPPLY-1

Tender № CMM/FTP/10-31-1-1132

SECTION – C

TECHNICAL SPECIFICATIONS OF STORES

Supply – 1 Section – C Page 1 of 17

SECTION-‘C’: TECHNICAL SPECIFICATIONS OF STORES AND DRAWINGS.

Sub-section – C-1: Special Instructions to the Tenderer Annexure-1 – List of major components under the scope of Unit-1 and Unit-2 Annexure-2 – Standard format for Non-Conformance Report.

Sub-section - C-2: Technical Specifications and Drawings

1. Following applicable NPCIL Technical specifications are attached.

Sr No

Technical Specification No Technical specification Description

1 PC-E- 1047 MANUFACTURE AND TRANSPORTATION OF CALANDRIA OF 700MWe PHWRs.

2 PC-M- 1045 SS 304L PLATES FOR CALANDRIA OF 700MWe PHWRs.

3 PC-M-1046 FORGINGS FOR NOZZELS FOR CALANDRIA OF 700MWe PHWRs.

4 PP-E-1051 HANDLING & TRANSPORTATION OF CALANDRIA FROM MANUFACTURE’S PLACE TO NPCIL PROJECT SITE


2. Following applicable Tender drawings are attached.

Sr No Title Drawing No.

1 Calandria General Arrangement GHAVP-1&2 /31210/2001/GA

2 Calandria Nozzles Sections GHAVP-1&2 /31210/2002/DD

3 Calandria nozzles details GHAVP-1&2 /31210/2003/DD

4 Calandria Key structure Details GHAVP-1&2 /31210/2004/DD

5 Calandria transportation – Nozzle cover GHAVP-1&2 /31210/2005/DD

6 Calandria manhole cap details GHAVP-1&2/31210/2006/GA

7 Moderator inlet diffuser Details (Sheet 1 to Sheet 3) GHAVP-1&2/31210/2007/DD

8 Calandria handling General Arrangement GHAVP-1&2/31210/2008/GA

9 Calandria handling – Spider for main shell GHAVP-1&2/31210/2009/GA

10 Calandria handling – spider for small shell GHAVP-1&2/31210/2010/GA

11 Calandria transportation – shipping frame GHAVP-1&2/31210/2011/DD




15 Calandria transportation – Trunnion assembly and details GHAVP-1&2/31210/2015/DD

16 Calandria transportation – saddle support for main shell GHAVP-1&2/31210/2016/DD

17 Calandria transportation– saddle support for small shell GHAVP-1&2/31210/2017/DD


Sub-Section-C1

SPECIAL INSTRUCTIONS TO THE TENDERER

1. SCOPE :

The scope of this tender document is manufacture, transportation & Guarantee of Calandria assemblies & associated components for Gorakhpur Haryana Anu Vidyut Pariyojna (GHAVP) Unit 1&2 as per Technical Specification No. PC-E-1047 enclosed as Annexure to this tender document. The scope of this tender includes the following:

• Preparation of manufacturing documents viz. specification for material

procurement, manufacturing drawings, Process plans, Weld location list,

Quality Assurance Plans, NDEs procedures, Examination procedures, Testing

Procedures, Surface treatment procedures, packing procedures etc.

• Procurement of all raw materials and bought out items.

• Manufacture, Examination/Inspection and testing of sub-

assemblies/components and Calandria assemblies - Quantity as indicated in

the tender.

• Supply of all the loose items as per drawings and specifications.

• Packing Calandria assemblies & associated components.

• Loading & Transportation of Calandria assemblies & associated components

from manufacturer’s shop to GHAVP-1&2 project site, Haryana meeting the

requirement of Technical Spec No. PC-E-1051

• Supply of History dockets in both hard form (Bonded volumes) and soft form.

1.1 Proper match marking with all mating loose components shall be ensured for each Calandria Assembly.

1.2 The scope includes digital photography and video coverage for important stages of manufacture, testing, examination, qualification, loading/unloading, transport etc. The contractor shall submit the colour photographs from various angles at different stages of work in progress and the final photographs of finished work so as to cover all important operations for record purpose. A total of 100 shots are envisaged to cover various stages of work for each Calandria. The contractor shall also include video representation of minimum 1 hours duration (edited period) covering all stages such as qualification, manufacturing, examination / inspection, testing, transportation etc. for each Calandria Assembly.

1.3 The bidder is deemed to have examined all the parts of the tender document and fully

informed himself as to the nature & scope of work and conditions related to performance. For any further clarification, bidder is requested to send his pre-bid


queries in writing to NPCIL in the prescribed format i.e. Appendix-Y. The clarifications will be furnished by NPCIL during pre-bid meeting with the suppliers.

1.4 The deviations from the specification / drawings shall be submitted in prescribed

format i.e. Annexure-A.

2. SUB-CONTRACT

2.1 If any item covered in this tender is proposed to be sub-contracted for fabrication, machining, testing, examination/inspection or packing, the same shall be indicated right at the time of submitting the offer (Technical Part-I). Approval of such sub-vendors by purchaser is mandatory. The supplier shall indicate the name of the sub-contractor likely to be engaged, at the time of submission of their Part-I offer.

2.2 The scope of work that are proposed to be sub-contracted (indicated by bidder in Part-

I) only will be allowed for sub-contract after due approval of the sub-contractor by the purchaser after placement of purchase order. All other work shall be carried out In-house by the supplier. Any change in the scope of sub-contract or change of sub-vendor shall be considered in specific cases, only on submission of detailed proposal with proper reasons and this change will be subject to approval of the purchaser.

2.3 If the sub-contractor is not in the approved list of NPCIL, the same needs to be

evaluated first by the bidder and report should be submitted along with the offer. Subsequently, NPCIL will evaluate and approve the proposed sub-contractors prior to finalization of contract against the tender. Later on, the Contractor will not be permitted to change the sub vendor except in unavoidable circumstances, that too, with the consent of NPCIL. In view of this, the bidder is advised to get approved multiple sub-vendors prior to finalization of order against the tender.

2.4 In case of sub-contract, the supplier shall be responsible to the purchaser for all the

work of the sub-contractor. The supplier shall forward to NPCIL the un-priced copies of all purchase orders placed on sub-contractor within two weeks of placement of purchase orders.

2.5 All Technical approvals, permissions, reporting etc. shall be in writing. In lieu of

signed permission or reporting, electronic communication from authentic source shall also be acceptable.

3. MANUFACTURING DOCUMENTS & PROGRESS REPORTS 3.1 The contractor shall record all duly approved deviations, concessions, changes etc.

which occurred throughout the manufacturing, examination/inspection and testing stages.

3.2 Being Class-1 and critical component, any deviation from the drawing / Specifications

requirement will not be preferred. However, in case it happens during the course of manufacture, the same shall be reported immediately to the purchaser. A detailed report along with root cause analysis, steps taken to avoid re-occurrence and action proposed on deviation shall also be submitted for acceptance of the purchaser. The supplier shall proceed further on job only after getting confirmation of acceptance of the deviation from the purchaser. The contractor shall raise Non-Conformance


Report (NCR) for the deviation occurred in the format attached as Annexure- 2 for the approval of the purchaser.

3.3 The Contractor shall prepare detailed monthly progress reports on the works carried out and shall submit each month’s progress report to the purchaser before 7th day of the succeeding month on MS project or any other Project Management package by e-mail.

3.4 The soft copies of all the manufacturing drawings, as built drawings, procedures,

QAP, inspection check lists, reports etc shall be maintained and submitted on DVD/CD/PEN DRIVE to NPCIL on completion of each Calandria assembly.

3.5 Digital videography / photography shall be carried out by the supplier during

important stages of manufacture / Examinations or any such examination/testing, loading/unloading, shipment etc. and the same shall be made available to purchaser as & when demanded. Same shall be transferred on DVD/CD/PEN DRIVE and submitted to NPCIL on completion of each Calandria assembly.

3.6 Contractor shall prepare History docket, for all the Calandria assemblies and associated components covered under this tender (documents not available in soft form may be scanned and compiled in PDF format) and submit 3 copies of properly bound volumes & 4 set on DVD/CD/PEN DRIVE with search facility. The History docket should contain minimum of the following documents.

a. Manufacturer’s Test certificates and compliance certificate.

b. NPCIL Shipping Release

c. Copies of NPCIL Purchase Order and Supplier’s sub-orders

d. Quality Assurance Plans

e. Examination/Inspection reports & Test Certificates of all the raw material and bought out items

f. Material clearance records

g. Manufacturing process plans & weld location list

h. NDEs procedures

i. Heat Treatment Procedures

j. Cleaning, Passivation and contamination check Procedures

k. Packing procedure.

l. Weld location list, Weld Process plans, WPS, PQRs

m. Hard-facing procedure

n. Dimensional Inspection Reports


o. NDEs reports

p. List of as built drawings

3.7 Contractor shall prepare As built drawings in the soft form and submit 3 sets of hard copies of drawings (Out of 3 sets 2 sets to be send to respective project site and 1 set to HQ) and 4 nos. of soft copies on DVD /PEN DRIVE. ( Out of 4 sets 2 sets to be send to respective project site and 2 set to HQ)

3.8 The Contractor shall ensure that his commitments for other contracts will in no way hamper the delivery schedule for this tender.

4. INSPECTION AND TESTING : 4.1 The supplier shall examine all the raw materials for full compliance with the

specifications for dimensional accuracy, complete workmanship, testing, performance and cleanliness as per specification. All major raw materials shall be procured from reputed source having supplied similar materials for any Nuclear components.

4.2 The supplier shall provide all the inspection and testing facilities at all stages during

the period of manufacture of the Calandria assembly and associated components. The examination/inspection and testing shall be done in a manner acceptable to NPCIL.

4.3 The supplier shall have qualified inspectors to carry out the above

examination/inspection. They will report directly to the management and not to the production group. Quality Surveillance by the Purchaser or his authorized representative shall not relieve the Contractor from the responsibility of meeting the specification or the examination/inspection/testing requirements.

4.4 The examination/inspection shall meet the suggested QAP enclosed to respective

Technical specifications. However, depending on the manufacturing procedure, quality assurance system of the Company and manufacturing & Inspection facilities available with the Supplier, some additional checks may also be necessary over & above suggested QAP. Such checks shall be incorporated & implemented by the Contractor without any extra financial implication to NPCIL. However supplier shall submit a QAP likely to be followed depending upon the sequence planned by the supplier for the manufacture of Calandria assembly and associated components for approval of NPCIL before implementation of the same for the work.

4.5 All important events during examination, inspection and testing such as surface

indications in LPE which are mutually agreed upon shall be photographed / video graphed. The UE signal shall be stored in retrievable digital form. In case any repair is carried out on these welds, UE shall be repeated and signal shall be recorded after such repairs. A hard copy of report of the above examination shall be made with appropriate weld/location identification procedure. All the records in soft copy as well as hard copy shall be submitted to the purchaser. This is required as a baseline data for the purpose of comparison during in-service inspection.

4.6 All threaded fasteners shall be checked with standard calibrated thread gauges &

mating components (if available).


4.7 In the event of any failure of the component to meet dimensional, examination/inspection or test requirements specified, the manufacturer shall notify the purchaser or his authorized representative. The manufacturer shall obtain permission from the purchaser before any repair is undertaken. The repair procedure shall be got approved from NPCIL before implementation of the same. All repaired welds shall be re-examined and re-tested as per the requirements of the original weld and shall meet the requirements of the same.

5. CLEANLINESS AND WORKMANSHIP:

5.1 Procedure for Cleaning of all Calandria assembly, Calandria sub-assemblies and

associated components shall be submitted to NPCIL for approval. Water for the cleaning shall not contain free Halides more than 25 ppm.

5.2 All the material shall be thoroughly cleaned to remove all traces of dirt, oil, grease and

other foreign matters. Oil or grease contamination shall be cleaned with suitable cleaning agent. All components shall be cleared after chloride and iron contamination tests as per procedure approved by NPCIL for further manufacture.

5.3 The machines and processes used for manufacture of Calandria sub-assemblies shall

ensure the consistent surface finish and dimensional tolerances specified in specification/ drawings. Every day temperature correction, whenever & wherever required shall be done and record for the same shall be maintained by the contractor.

5.4 Clean conditions shall be maintained at all stages of machining, fabrication,

examination/inspection, storing, handling, and packing. Contact of carbon steel materials with SS shall be avoided to prevent contamination. Grinding wheels, wire brushes once used on carbon steel works shall not be used on SS materials during fabrication.

6. FABRICATION: 6.1 All welding consumables shall meet the required specifications and NPCIL approved

brands only shall be used. Material and weld qualification shall be as detailed in NPCIL specifications.

6.2 The bidder shall give details of storing facility for welding consumables. 6.3 The bidder shall submit weld location list of weld joints indicating seam nos.,

applicable WPS & PQR, NDE to be carried out, drawing number etc. for respective weld joints for review and acceptance to purchaser.

6.4 The bidder shall submit scheme of welding with precautions, sequence, jigs, fixtures

etc. needed to minimize stresses, shrinkage, distortion etc. during fabrication of Calandria assemblies and associated components before start of every stage of fabrication.

7. HANDLING, PACKING & DELIVERY :

7.1 The bidder shall have sufficient shop floor space & handling facilities available at the

place of manufacture, assembly and testing of Calandria assemblies and associated components covered under the scope of this tender.


7.2 The supplier shall ensure that all the Calandria sub-assemblies and associated

components are protected against any corrosion or damage during all stages of manufacture, examination/inspection, testing, handling and storage. The packing shall be suitable and rigid enough to ensure safety and shall be protected from ingress of rain water in to the equipment/component packed during all stages of shipment by road to site, loading, stacking and storage at plant site.

7.3 The packing procedure shall be in accordance with specification and shall be

submitted to NPCIL for approval. Adequate number of silica gel packets along with a copy of shipping release shall be kept inside each crate in the case of loose items supplied. The crate shall be clearly marked with numbers and the quantities. The Calandria assemblies and associated components shall not be dispatched unless shipping release from NPCIL is obtained.

7.4 All openings shall be protected with plastic covers/caps to prevent entrance of dirt and

ingress of moisture during shipment, storage at site and erection. 7.5 Each package shall be stenciled in bold characters with indelible paint, protected with

shellac to indicate shipping mark, package numbers, dimensions and gross weight, the purchase order number, consignee address and any other necessary data to identify the equipment and relate it to the contract.

7.6 Packing list shall clearly show package numbers, kind of packages, contents,

dimensions and net and gross weight of each package. If different items are in a package, the net weight of each item shall be specified.

7.7 Transshipment in transit shall be avoided and Contractor shall arrange specially hired

conveyance for direct delivery to respective sites. 7.8 As these are over-dimensional consignments, clearances / interactions for safe

transportation with statuary bodies, if required lies within the scope of the Contractor. The Purchaser has no obligation in this regard.

7.9 Unloading of Tendered item(s) at Purchaser’s site shall be in the scope of Purchaser.

However, for unloading Contractor shall complete all the pre-requisites such as – • Unlocking the Calandria after dismantling/ de-latching from the transport

fixture and facilitating lifting for unloading. • Stools, if any, required for unloading Calandria at Site.

8. INFORMATION TO BE GIVEN AGAINST PART-I (TECHNICAL PART) AS

PER THE FORMAT GIVEN IN SECTION ‘D’ OF THIS TENDER DOCUMENT:

The tender shall contain complete technical details and information sought in the tender.

8.1 The bidder shall submit the details regarding sources for purchase of raw materials,

consumables for welding and standard items covered under the scope of supplier.


8.2 The supplier shall indicate the scope of work likely to be sub-contracted and the name of the sub-contractor / sub-contractors likely to be engaged.

8.3 The supplier shall confirm and give details of NDE equipments and facilities. 8.4 The supplier shall indicate details of CNC Horizontal Boring Machines & CNC

Vertical Boring Machines in terms

• make, • quantity, • capacity w.r.t X,Y & Z movements • Accuracy (Positional and Repetitive) • Rotating table load carrying capacity for VBM.

8.5 Details of Rolling and bending facilities – make, capacity. 8.6 The bidder must confirm availability of 100 MT minimum handling facility within shop

required during various stages of manufacturing, examination/inspection and testing of Calandria assemblies.

8.7 The bidder shall indicate details of Shop floor area isolated for Stainless Steel fabrication

with handling facility. 8.8 The bidder should give their shop and machine loading plan for next Two years. 8.9 The bidder shall submit schedule on MS-project or any other project management

package for total scope of this tender with the break up schedule of major activities considered for arriving at completion schedule with critical path based on their experience on similar activities.

8.10 The bidder shall give details about their design capabilities, qualified personnel for

fabrication, quality surveillance, qualified NDE personnel, and personnel in Procurement, planning, engineering & production.

8.11 The bidder shall also provide details about their previous experience of similar job

executed by them. 8.12 The bidder shall submit schedule for achieving the important mile stone stages as defined

in Section-D of this tender document. 8.13 In addition to the above, the bidder can also give any other additional information (if

necessary) relevant to this tender.

All information/data as are called for in this tender document must be submitted along with the offer. The Purchaser reserves the right to seek additional information/ data from the Bidder during evaluation of the bid.

9. USE OF DRAWING AND SPECIFICATION :

The drawing and specification forming part of this tender document downloaded by bidders being proprietary information, is prohibited for use other than this tender purpose.


10. DELIVERY PLACE:

All the items covered in this tender pertaining shall be delivered to Manager (Materials), Gorakhpur Haryana Anu Vidyut Pariyojna-1&2 (GHAVP – 1&2), PO – Gorakhpur, Tehsil – Bhuna, Dist – Fatehabad State – Haryana


Annexure-1

List of major Components:

1. For Option – I (Unit – 1) Sr. No. Description Quantity

1. Calandria assembly with associated components 1 No.

2. Male Keys with its support structure (Drg No. GHAVP 1&2/31210/2004/GA) 1 Set

3. Trunnnion assembly (Drg. No. GHAVP-1&2/31210/2015/DD) 1 Set

4. Trunnion Link bar ( Drg. No. GHAVP-1&2/31210/2015/DD) 1 Set

5. Man hole cap with Insert (Drg. No. GHAVP-1&2/31210/2006/DD) 1 set

6. Diffusers (Drg. No. GHAVP-1&2/31210/2007/DD) 1 set

2. For Option – II (Unit – 2) Sr. No. Description Quantity

1. Calandria assembly with associated components 1 No.

2. Male Keys with its support structure (Drg No. GHAVP 1&2/31210/2004/GA) 1 Set

3. Trunnnion assembly (Drg. No. GHAVP-1&2/31210/2015/DD) 1 Set

4. Trunnion Link bar ( Drg. No. GHAVP-1&2/31210/2015/DD) 1 Set

5. Man hole cap with Insert (Drg. No. GHAVP-1&2/31210/2006/DD) 1 set

6. Diffusers (Drg. No. GHAVP-1&2/31210/2007/DD) 1 set

2. For Option – III (For both Unit – 1 and Unit – 2) Sr. No. Description Quantity

1. Calandria assembly with associated components 2 Nos. 2. Male Keys with its support structure (Drg No. GHAVP

1&2/31210/2004/GA) 2 Sets

3. Trunnnion assembly ( Drg. No. GHAVP-1&2/31210/2015/DD) 2 Sets

4. Trunnion Link bar ( Drg. No. GHAVP-1&2/31210/2015/DD) 2 Sets

5. Man hole cap with Insert ( Drg. No. GHAVP-1&2/31210/2006/DD) 2 Sets

6. Diffusers (Type I, Type II and Type III) (Drg. No. GHAVP-1&2/31210/2007/DD) 2 Sets


Annexure-2:

Format for submission of Non-Conformance Report

NUCLEAR POWER CORPORATION OF INDIA LTD (A Government of India Enterprise)

Non-Conformance Report

Non-Conformance Report No.:_________________ Purchase/ Work Order No.____________________ Date of PO / WO ___________ Sub.-Order No. (If applicable) __________________ Date : ___________ Manufacturer / Contractor ____________________ Component / System / Structure/ Item __________ Manf / Contractor’s Ref No. ___________________Spec &Drg. No.____________________ Equipment / Tag No. ____________________ P.O. Item No.______________________ ___________________________________________________________________________ a) Details of Non-conformances: (Attach relevant portions of drawings or sketches / relevant

portion of the specification wherever applicable)

b) Proposal for disposition of the non-conformances :

c) Reasons for the Non-Conformances and Planned Corrective and preventive actions to avoid recurrence.

d) Cost Implication : This request does / does not involve a change in the contract price

Prepared by : Reviewed and approved by Manufacturer / Contractor’s Authorised Manufacturer / Contractor’s Design / Production in-charge QC- in-charge Designation Designation (Name, Signature, Date & Seal) (Name, Signature, Date & Seal) NPCIL QUALITY SURVEYOR’S COMMENTS:


1. All relevant inspection reports / test reports attached Yes / No 2. All the non-conformances are identified and included Yes / No 3. Comment of the QS Engineer on the proposed corrective / preventive

Actions to avoid recurrence (NPCIL QS) (Name, Designation, Signature & Date)

CHECK / COMMENTS BY IDENTING ENGINEER : (Tick as applicable) The component / system / structure / item with the reported non-conformance is proposed for acceptance /rejection. There is no financial implication to NPCIL by acceptance of this non-conformance / Cost Implication as worked out by the Manufacturer/Supplier is justified. Justification is appended. (Refer Page 8 of this procedure for guidelines regarding financial implication). NCR forwarded with comments / technical justification to Design Group for concurrence. Checked by Indenting Engineer (Name, Designation Signature & Date) ………………………………………………………………………………………………… DESIGNERS CONCURRENCE: Acceptance of the deviations will affect / not affect the design intent. The non-conformances as reported will not have adverse affect with respect to the i) the performance of the equipment / component during its service ii) the life of the equipment / component iii) does not alter the functional aspects and safety requirements. 1) Proposal is Concurred / Not Concurred

2) The NCR shall be categorised as below: (One of the categories shall be ticked)

(Guidelines for categorisation are given in the format for ready reference)

Category 1 : Category 1 NCRs are those for which the non-conformances are accepted as is, in view of

equivalence or superiority of the material / product / standard / proprietary items offered with respect to the tender specifications.

Category 2:


Category 2 NCRs are those for which non-conformances are accepted with engineering judgement or specific instructions for assembly / installation and shown to the meeting the functional requirements specified in the tender documents. There is no deviation from the functional requirements / design intent and there is no impact on safety. Category 2 also includes components accepted for mock up or rehearsal facilities (Non reactor use)

Examples a) Marginal variation in material properties (chemical / mechanical etc.) from the specified

values and are acceptable based on applicable. This deviation should not lead to substitution with an inferior material as compared to the material specified in the tender document. In case an inferior material is accepted NCR will be in Category 3.

b) Finished dimensions which are marginally at variance with the specified values and accepted based on checking for functional / assembly requirements. (Locational deviations due to site interferences / Dimensional deviations during manufacturing.

c) Non-conformances of marginal nature observed during performance testing of finished equipment / system and which do not affect the overall functional requirements.

d) In-Process deviations which can be corrected during subsequent stages of manufacture.

e) Deviations in the form of system architecture / display patterns networking subject to meeting the functional requirements (C&I systems). Category 3: Category 3 NCRs are those for which non-conformances a) are accepted with detailed calculations / analyses to ensure that the functional requirements are met and / or b) Waiver of some of the tests called up in the tender specification and/or c) Substitution with an inferior material as compared to the material specified in tender specification and/or d) will result in subsequent rework at NPCIL’s cost and/or e) has an effect on dimensions /performance of interfacing Systems /Equipment (either of same USI or different USIs). However there is no impact on safety because of these non-conformances.

Category 4:

Category 4 NCRs are those for which the non-conformances may have impact on functional requirements and /or safety. Such cases require analysis and safety review and may be accepted in very rare occasions, as a special case, with additional safety provisions.

Authorised Engineer for Design Group (Name, Designation, Signature & Date) To: Indenter for further processing APPROVAL / REJECTION OF NCR :


Tick as applicable:

Design intent is not affected. Justification for acceptance appended with the NCR. Financial implication as brought out in page 2 of 4 of this format is approved.

Non-conformances are accepted after detailed calculations, analysis. Justification for acceptance of the deviation is attached with this NCR. Financial implication as brought out in page 2 of 4 of this format is approved.

No other System/ Assembly / component (of other USIs ) is affected by this deviation / non-conformance.

List of system / components/ assemblies (of other USIs ) affected by this deviation and the concurrence from the concerned design group is approved.

NCR is accepted as proposed / conditional approval of NCR is given subject to meeting the conditions specified in page 2, page 4 of this NCR (Strike off one). APPROVED APPROVED AS NOTED REJECTED

NOTES: Reviewed by Approved by (Name, Designation, Signature & Date) (Name, Designation, Signature & Date) Note: All the signatures shall have valid Technical Authorisation (refer ED-Proc.- 60) ---------------------------------------------------------------------------------------------------------------- CLOSING OF NCR IN CASE OF “CONDITIONAL APPROVAL /APPROVED AS NOTED (TECHNICAL REASONS)/REJECTED “ NCRs : VERIFICATION BY QUALITY SURVEYOR OF MANUFACTURER /CONTRACTOR / QA NPCIL. All stipulations in conditional approval met? Yes / No If No, defective item rejected ……………………………………. If repaired, new NCR No…………………………………..

(Name, Signature & Date) (Name, Signature & Date) QA of Manufacturer /contractor QS NPCIL

To Indentor Distribution by Indentor 1. Indenting Group 7. Concerned Construction Group 2. Design Group________ 8. ED (Engg.) ________________ 3. Consultant ___________ 9. ED (Proc.) _________________ 4. Quality Surveyor / Head (QA) __________ 10. ED (QA) _________________ 5. Contractor /Manufacturer ____________ 11. Head (FE) _________________ 6. Hist. Docket _________ 12. Site Planning ________________


Sub-section - C-2: Technical Specification and Drawings

1. Following applicable Technical specifications are attached.

Sr No

Technical Specification No Technical specification Description

1 PC-E- 1047 MANUFACTURE AND TRANSPORTATION OF CALANDRIA OF 700MWe PHWRs.

2 PC-M- 1045 SS 304L PLATES FOR CALANDRIA OF 700MWe PHWRs.

3 PC-M-1046 FORGINGS FOR NOZZELS FOR CALANDRIA OF 700MWe PHWRs.

4 PP-E-1051 HANDLING & TRANSPORTATION OF CALANDRIA FROM MANUFACTURE’S PLACE TO NPCIL PROJECT SITE


2. Following applicable Tender drawings are attached.

Sr No Title Drawing No.

1 Calandria General Arrangement GHAVP-1&2 /31210/2001/GA

2 Calandria Nozzles Sections GHAVP-1&2 /31210/2002/DD

3 Calandria nozzles details GHAVP-1&2 /31210/2003/DD

4 Calandria Key structure Details GHAVP-1&2 /31210/2004/DD

5 Calandria transportation – Nozzle cover GHAVP-1&2 /31210/2005/DD

6 Calandria manhole cap details GHAVP-1&2/31210/2006/GA

7 Moderator inlet diffuser Details (Sheet 1 to Sheet 3) GHAVP-1&2/31210/2007/DD

8 Calandria handling General Arrangement GHAVP-1&2/31210/2008/GA

9 Calandria handling – Spider for main shell GHAVP-1&2/31210/2009/GA

10 Calandria handling – spider for small shell GHAVP-1&2/31210/2010/GA





15 Calandria transportation – Trunnion assembly and details GHAVP-1&2/31210/2015/DD

16 Calandria transportation – saddle support for main shell GHAVP-1&2/31210/2016/DD

17 Calandria transportation– saddle support for small shell GHAVP-1&2/31210/2017/DD

REVISION CONTROL SHEET

DOCUMENT TYPE : ENGINEERING SPECIFICATION

NO. : PC-E/1047/R0

TITLE : TECHNICAL SPECIFICATION ON

MANUFACTURE AND TRANSPORTATION

OF CALANDRIA OF 700MWe PHWRs

REV. NO.

& DATE

DESCRIPTION

OF REVISION

REVISED BY

NAME &

SIGNATURE

CHECKED

BY

NAME &

SIGNATURE

REVIEWED

BY

NAME &

SIGNATURE

APPROVED BY

NAME &

SIGNATURE

NPCIL PROPRIETARY

This document is the property of the Nuclear Power

Corporation of India Ltd. No exploitation or transfer of any

information contained herein is permitted in the absence of an

agreement with NPCIL and neither the document nor any

information contained herein may be released without the

written consent of NPCIL.

NUCLEAR POWER CORPORATION OF INDIA LTD.

TECHNICAL SPECIFICATION ON

MANUFACTURE AND TRANSPORTATION OF CALANDRIA OF

700MWe PHWRs

PAGE NO : 1 OF 21

REV.NO : 0

31210 / PC-E-1047 FEBRUARY, 2014

NOT FOR PUBLICATION / PRESENTATION OUTSIDE NPCIL

1. SCOPE

This specification establishes the technical requirements for preparation of shop

drawings, procurement of raw materials, fabrication, machining, examination, testing,

packing, loading on tractor trailer / barge for shipment and transportation of Calandria

assembly and its attachment to site for 700 MWe Atomic Power Project.

Other activities like handling of calandria at the site, joining calandria with end shields,

and testing at site etc. are in the scope of site.

This specification is applicable for 700 MWe PHWR Projects beyond RAPP 7&8.

2. CONTENTS

The requirements of this specification are presented under the following headings:

Section title Section number

Scope

Contents

Applicable Codes, Standards, Specifications and Drawings

1

2

3

Materials and Workmanship 4

General Description and Operating Conditions 5

Technical Requirements 6

Examination, Tests, Reports and Documentation 7

Loading on tractor trailer/barge for shipment &

transportation to site

8

3. APPLICABLE CODES, STANDARDS, SPECIFICATIONS AND DRAWINGS

All documents listed below, of the issue in effect on the date of the pertinent Tendering

Documents constitute a part of this specification. In the event that certain requirements of

the specification, drawings or data listed below conflict with the requirements of this

specification, the governing requirements shall be at the discretion of the Purchaser. The

bidder shall obtain all the required clarifications during the bid stage itself.

3.1 Applicable Codes and Standards

ASME Boiler and Pressure Vessel Code Section II, III NB, V & IX

ASTM Standards, Parts 01.01, 01.03, 01.04, 01.05, 03.01, 03.02,

03.03 and 03.05

IS 696 Code of Practice for General Engineering Drawings

IS 919 Recommendation for limits and fits for engineering

IS 3073 Assessment of Surface Roughness

IS 1367 Technical Supply Conditions for Threaded Fasteners




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3.2 Applicable NPCIL specifications

PC-M-1045 – SS 304L plates for calandria of 700MWe PHWRs

PC-M-1046 – Forgings for nozzles for calandria of 700MWe PHWRs

PC-E-1051 – Handling and Transportation of Calandria from manufactures place to

NPCIL project site

3.3 Applicable Drawings

Sl. No. Title Drawing No.

1. Calandria General Arrangement * /31210/2001/GA

2. Calandria Nozzles Sections * /31210/2002/DD

3. Calandria Nozzles Details * /31210/2003/DD

4. Calandria Key Structure Details * /31210/2004/DD

5. Calandria Transportation – Nozzle Cover * /31210/2005/DD

6. Calandria Manhole Cap Details */31210/2006/GA

7. Moderator Inlet Diffuser Details */31210/2007/DD

8. Calandria Handling General Arrangement */31210/2008/GA

9. Calandria Handling – Spider for Main Shell */31210/2009/GA

10. Calandria Handling – Spider for Small Shell */31210/2010/GA

11. Calandria Transportation – Shipping Frame */31210/2011/DD




15. Calandria Handling –Details of Trunnion Assembly and

Link Bar

*/31210/2015/DD

16. Calandria Transportation – Saddle Support for Main

Shell

*/31210/2016/DD

17. Calandria Transportation – Saddle Support for Small

Shell

*/31210/2017/DD

* – Project as applicable

4.0 MATERIALS AND WORKMANSHIP

4.1 Materials, Processes and Parts

Materials, processes and standard parts which are not specifically designated herein and

which are necessary for the fulfillment of this specification shall be of good commercial

quality and in accordance with good practice pertinent to the manufacture of austenitic

stainless steel pressure vessels and heavy engineering and power station equipment. Such

material, processes & standard parts used in the manufacture of the component shall not

alter its design intent.

4.2 Materials

4.2.1 Raw materials for Calandria shall be purchased as per NPCIL specifications and

drawings. (Ref. Sections 3.2 & 3.3)




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4.2.2 All materials designated as in conformance with an ASME Standard shall be examined as

required by such standard. These shall meet the requirements of ASME B&PV code,

Section III, Division I, Article NB 2000. In addition, the material should meet the special

requirements brought out in individual material specification and in applicable drawings.

Proof in the form of certified test reports or mill certificates that the required

tests/examinations have been carried out at the source will be acceptable. However, if the

same are not available, all the tests/examinations shall be performed by the Supplier as

per specification requirement in NPCIL approved testing / examination facilities

(laboratory).

All materials used shall be of good quality from a reputed source of supply. i.e. Materials

shall be procured from the manufacturers or their dealers. Material once used on some

other jobs/products shall not be used for the manufacture of Calandria. Where the use of

a material to an alternative specification is proposed, the alternative shall be subject to

specific approval by the Purchaser.

4.2.3 Diffuser pipes

(A) The moderator diffuser pipes shall conform to the requirements of seamless

austenitic stainless steel pipe ASME-SA-312 Grade TP304L specification with

supplementary and additional requirements as specified in this specification.

(B) Supplementary requirements to SA-312

S1 – Product analysis.

S4 –Etching tests on one pipe of each lot.

(C) In addition to the above, one coupon from each lot shall meet the following:

C.1 The hardness on both surfaces and at five points across thickness shall be

measured. The average hardness shall be 180+/-5

HB. The hardness values shall

be within 170 to 190 HB.

C.2 Inter Granular corrosion test as per ASTM-A-262 Practice E shall be carried

out at mid thickness. Coupons shall be boiled for 72 h instead of the duration

mentioned in A-262. One piece shall be bent as per practice E (and acceptance

as per practice E) and another shall be cut and cross section shall be surface

examined for measuring depth of attack. Depth of attack less than 50

micrometer is acceptable.

C.3 Grain size shall be in the range of 3 to 6.

(D) Residual copper content shall not be more than 0.3% based on product analysis.

(E) The cobalt content shall be less than 0.025% as per product analysis.

(F) Delta ferrite of parent material measured by ferrite meter shall be less than 0.5FN

(G) Hydrostatic test: Each pipe shall be tested by the manufacturer to a hydrostatic

pressure of 10 MPa(g). The test pressure shall be held for a minimum of 5 second.

(H) Pipes shall be examined by straight beam and angle beam ultrasonic

examinations. Acceptance standard as per Subsubarticles NB 2550 of ASME -




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Section III, Division 1- NB. Scanning shall be carried out in two circumferential

directions and two axial directions. The ultrasonic examination shall cover 100%

volume. All ultrasonic examination shall be carried out with equipment having

recording facility. On completion of job, all identified ultrasonic examination

records shall be submitted to the purchaser in soft form.

(I) Pickling and passivation of final product shall be carried out by the supplier.

Procedures shall be submitted by the supplier for purchaser’s approval. Iron and

chloride contamination shall be strictly avoided. Suitable control measures shall

be ensured. The surfaces, on sample basis, shall be examined for iron and chloride

contamination. The quantum of examination and procedures shall be subject to

purchaser’s approval.

4.2.4 Forged Material

All forgings shall be of austenitic stainless steel conforming to NPCIL specification PC-

M-1046.

4.2.5 Bolts, Screws, Nuts, Washers, Dowels and Miscellaneous items

The material for the above parts shall be as specified in Drawings (Refer Sections 3.3).

4.2.6 Welding Materials

Welding materials shall meet the relevant specifications listed in Part C of ASME Section

II. Welding material not listed in Part C of Section II, shall be subject to Purchaser's

approval.

All welding consumables shall be from the list of NPCIL approved brands. Other brands

shall be used with prior approval of purchaser. Methods of storage and baking prior to

use are as per manufacturer’s instructions, wherever not available the same shall be

subject to the Purchaser's approval.

The SS electrodes for SMAW of classification E308 L shall conform to SFA 5.4. The

SS bare electrodes and rods of classification ER308 L Grade shall conform to SFA 5.9.

Electrode coatings and core wire shall be free from undesirable elements that might

combine with the deposited weld metal and alter its composition. Carbon pick up shall

be avoided.

All welding material shall conform to the requirements of Subarticles NB 2400 of ASME

- Section III, Division 1- NB. The acceptable delta ferrite shall be within 5 FN to 10 FN

in all stainless steel welding consumables.

4.2.7 Hard face coating on calandria key mating surfaces

The mating surfaces of calandria key (male block and slot) shall be hardcoated. The

material of hard coating shall be Stellite with composition approved by the purchaser.




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The minimum hard coat thickness shall be 3 mm. The hardness of the coated surface shall

be Rockwell 42 (minimum). All test indentations on the surfaces shall be removed by

final grinding. The minimum bearing area between the mating key surfaces as measured

by blue dye matching, shall be 85%.

4.3 Workmanship

All workmanship shall be of first class, high grade quality and in accordance with the

best manufacturing practices followed in the industry.

5.0 GENERAL DESCRIPTION AND OPERATING CONDITIONS

The calandria is an open stepped cylindrical vessel. The main shell is joined by small

shell at either end by annulus plates. It consists of about 122 nozzles (90 on top, 27 on

sides and 5 at bottom). Since it is a very flexible shell, internal spiders are necessary to

maintain its circularity during fabrication and transportation. The spiders used during

transportation shall be removed only after site installation.

The shells are made by rolling plates to cylindrical curvature and joining them by

longitudinal and circumferential welds. The longitudinal welds are staggered suitably to

avoid single weld line along the length. Small shells are also fabricated in a similar way.

The annulus plates are cut from large plates by a suitable cutting plan avoiding material

wastage and minimising number of welds.

The small shell-annulus plate assembly is formed first (known as hat assembly). Holes

for nozzles are made in the main shell for welding nozzles. Welding of nozzles is done in

number of stages considering shrinkage after each stage. The nozzles are rough

machined first keeping sufficient allowance on ID & OD for shrinkage and shifting of

nozzle centres. The amount of nozzle centre shift and shrinkage shall be established by a

preferably 16 nozzle mock-up (on a small scale). Sufficient margins shall be

maintained for cutting, machining, trimming, defect removal, shrinkage and other

unforeseen distortions.

During operation the Calandria will be completely filled with heavy water. The outside

surfaces of the Calandria will be in contact with demineralised water.

The design internal pressure and the design external pressure of the calandria are 1.84

kg/cm2

(g) and 1.28 kg/cm2 (g) respectively. Design temperature of calandria is 100C.

Under accidental condition (single Calandria tube and coolant tube rupture), calandria

shell would be subjected to a peak instantaneous internal pressure of 5.83 kg/cm2 (g).

6.0 TECHNICAL REQUIREMENTS

6.1 General

The calandria and attachments, as shown on the drawings listed in Section 3.2 shall be

fabricated, examined and tested by the Supplier as specified herein.




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6.2 Preparation of Drawings and Fabrication Procedures

The drawings listed in Section 3.2 are reference design drawings. The Supplier shall

prepare all necessary shop drawings, fabrication, machining, examination/testing

procedures and quality assurance plans (QAPs). These drawings & documents shall be

approved by the Purchaser prior to fabrication/manufacturing. Only approved drawings

shall be used for fabrication / manufacturing. The Purchaser reserves the right to make

minor changes in the course of preparing the final detailed assembly drawings. Such

change shall be considered within the scope of the specified work and not considered as

extras. After completion of fabrication/manufacturing, examination and testing; as built

drawings shall be prepared by the supplier and approved by the purchaser for final

documentation. All these approved documents shall be submitted in the form of hard

copies, reproducible copy and soft copy.

The calandria is designed by the Purchaser, according to the rules of ASME Boiler

Vessel Code Section III, sub-section NB (Class 1 components). The calandria key

structure is designed as per Sub-section NF Supports (Class 1).

6.3 Fabrication

6.3.1 General

The calandria shall be fabricated to the requirements of sub-section NB of ASME

Section III. Additional requirements may be specified by the Purchaser.

The supplier shall prepare a manufacturing plan showing sequence of activities involved,

check points and submit to the purchaser for approval. Only approved manufacturing and

fabrication plan shall be followed.

The Supplier shall be responsible for achieving the dimensional accuracy required as

specified in the specification and in the reference design drawings. Supplier shall be

responsible for providing all additional working jigs and gauges required for achieving

required accuracy.

All joints, unless otherwise specified, shall be full penetration welds. Only approved

Welding Procedure Specifications (WPS) shall be used. The procedures shall be subject

to approval by the Purchaser prior to commencement of production welding. Welding

shall be carried out only by welders qualified by the purchaser or his authorized

representative. Approval of WPS and qualification of welders shall be done by the

Purchaser as per ASME Section IX and Section III NB. Prior to start of production

welding; the supplier shall submit Weld Location List (WLL) indicating; weld seam

number, size of the weld, WPS, welding process, nondestructive examinations (NDEs) to

be performed on the weld, helium leak test requirement etc. for NPCIL approval.

All surfaces to be joined shall be thoroughly cleaned to prevent contamination during

welding. All weld edge preparations shall be machined smooth. Any flame-cut edges

shall be machined or ground back to a minimum of 2 mm past the deepest indentation.

All weld edge preparations and flame-cut edges shall be examined by LPE.




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In multi-pass welding, any porosity, lack of penetration, fusion, inclusion, cracks or other

defects and all slag, oil, penetrant or other foreign material shall be completely removed

before welding of subsequent passes. Covering over of such defects or contamination

shall be a cause for rejection. When accessible, the reverse side of root passes made by

metallic arc welding process shall be back chipped or ground back to clean metal and

then finish welded. The root passes of welds accessible from one side shall be made by

inert gas tungsten arc process (GTAW). The weld shall be purged on both sides with

inert gas throughout the welding operation. The inert gas shall be so vented as to prevent

blow-through when root passes are applied.

The details of welder qualification, WPS qualification and sampling frequency of test

specimen shall be decided after mutual agreement between the Purchaser and the

supplier.

For all welds, the supplier shall make prior assessment to determine the amount of

contraction/distortion and its expected direction. Afterwards, the supplier shall work out

the methods to minimize/ counteract/allow for the distortion.

6.3.2 Hardface coating (Stellite)

The hard coat material and the procedure for hard face coating on the calandria key block

bearing faces shall be subject to approval by the Purchaser. Weld deposition mock-up

shall be carried out by the supplier to ascertain the thickness and surface hardness of the

coating, prior to commencement of production welding.

6.3.3 Requirement of Separate Area for calandria manufacturing

The separate area shall meet the following specific requirements of the Purchaser which

shall be documented in the form of an approved procedure.

1. Adequate space shall be allocated for separate area to accommodate calandria

assembly.

2. Area shall be clean.

3. Complete area at periphery shall be bounded up-to sufficient height (to suit job

height to avoid contamination with foreign material of adjacent job carried in the

shop) by suitable temporary cover.

4. Floor of area shall be flat and have adequate strength to carry-out the job.

5. Contaminations (iron, chloride and other foreign material) are not permitted.

6. Authorised and requisite Personnel shall only be allowed in this area.

7. Use of shoe covers and hand gloves is compulsory.

8. Sufficient space shall be provided to accommodate welding machines, argon gas and

other materials required for welding works.

9. Unnecessary material shall not be stored in this area.

10. Chloride contamination and iron contamination tests shall be carried out on regular

basis.

11. Cleaning using mops shall be carried out on regular basis.

12. Vacuum cleaner may be used for cleaning.




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13. Use of broom sticks for cleaning is not permitted.

14. Adequate ventilation shall be provided.

15. Lighting facility shall be sufficient.

16. All safety provisions shall be provided and these provisions shall be in place during

execution of job.

6.3.4 Carbon Steel Attachments

Temporary carbon steel members required for aligning and restraining purposes may be

attached to stainless steel components. A temporary austenitic stainless steel pad or

poison plate must be provided between carbon steel member and stainless steel

component to prevent contamination of stainless steel by carbon steel. The attachments

shall conform reasonably to the curvature of the shell or other surfaces. All locations,

where temporary attachments are welded shall be dressed smooth, after removal. These

areas shall be examined by LPE. All carbon steel attachments shall be suitably painted by

the supplier. Rust on carbon steel attachments and bare surface of carbon steel

attachments are not permitted during any stage of manufacturing and transportation.

6.3.5 Trunnion Assembly and Link Bar (Drawing No. */31210/2015/DD)

These are required for handling of calandria during installation at site. The Supplier shall

make both components as per the above drawing. These components shall be assembled

with calandria assembly at supplier shop to ensure proper fitting and match marking and

meets it intended function to the satisfaction of purchaser before dispatch to site.

6.4 Fitting and Machining

Fitting and machining operations shall be in accordance with the best practices followed

in the industry. All components to be finally assembled at the site shall be assembled in

the Supplier's shop prior to shipment, to check fit-up. The Supplier shall be responsible

for finalizing methods, tooling and gauging for this purpose and finally approved by the

Purchaser. All loose and bolted parts shall be fitted and clearly match-marked before

dispatch. The procedure of identification, sorting and counting of loose parts shall be

approved by the Purchaser.

The Supplier shall be responsible for the fitting and machining. Comprehensive

fabrication plans giving sequence of all fabrication activities like welding and other

techniques, shall be prepared by the supplier subject to the approval of the Purchaser.

6.5 Threaded Fasteners

All fasteners shall be to IS 1367 unless otherwise specified.

All the internal threads shall be class 6H or better and all external threads Class 6g or

better, unless otherwise specified in the drawing.




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6.6 Residual Stresses

To minimise the residual stresses for ensuring dimensional stability and other deleterious

effect, the calandria manufacturer shall device suitable fabrication sequence &

methodology. All fabrication process plans and procedures shall be submitted to NPCIL

for approval. Excessive force shall not be used in any fitting. Welding and fitting shall

be performed so as to control and minimize distortion and locked-in stresses. To achieve

this, the supplier shall use proper jigs, fixtures, process and its sequencing. Low heat

input welding technique for nozzles to Calandria shell joints shall be used by the supplier.

6.7 Surface finish and cleanliness

All machined surface finish shall be maintained as per drawing requirements.

All welds shall be finished smoothly and merged with the parent metal without ridges or

undercutting. Any dents, gauging marks, scratches etc. which occur during fabrication,

machining, examination, testing and shipment shall be repaired with prior approval of

purchaser to the satisfaction of the Purchaser. Permanent reference center lines required

by the purchaser shall be scribed ensuring that their depth is less than 0.1 mm. No other

permanent marking or stamping shall be permitted. The general plate surfaces shall be

equal or better than a standard pickle finish.

Details of match marking and stamping of parts shall be specified on shop drawings with

the approval by the Purchaser.

All scales, oxide, weld spatter, oil, machining chips and other foreign material shall be

completely removed on both the inside and outside of the Calandria. All surfaces that

become inaccessible for cleaning after complete fabrication shall be cleaned for all

foreign material prior to assembly. Adequate precautions, such as fitting of temporary

covers, shall be taken to ensure that this state of cleanliness is maintained throughout the

completion of all the work.

All stainless steel surfaces and cut-edges shall be protected from contamination by

detrimental and undesirable foreign matter at all stages of manufacture. Use of any

chemicals, oils and grease shall be with prior approval of Purchaser. Any fluid or

chemical like cutting oil, lubricant, grease etc. comes in direct contact with calandria

materials during manufacturing shall have total free halogen content less than 25 ppm.

Plate surfaces shall be thoroughly cleaned for all foreign material prior to forming,

rolling, pressing, machining and heat treatment. Surfaces of components shall be free

from all grease and foreign materials prior to assembly.

Chemical cleaning of stainless steel surfaces like pickling and passivation, shall be

approved by the Purchaser prior to start of cleaning operations. Only certified and

approved chemicals and cleaning agents shall be employed. After cleaning, the surface

shall be free of chlorides and other harmful contaminants such as iron, lead and sulphur.

Immediately after passivation, all traces of acid shall be removed by flushing the surfaces

with potable water (free halogen content 25 ppm maximum) and the assemblies shall be

dried.




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If water flushing is done, only clean potable water with total free halogen content less

than 25 ppm shall be used. A filter shall be installed prior to water inlet to the calandria

assembly. All traces of water shall be removed by using warm dry air (temperature < 60 º

C).

Working surfaces of boring mills, forming rolls, layout tables, etc. shall be kept clean and

free of foreign materials. Physical surface contamination by embedded material shall be

avoided on all assemblies. All components shall be thoroughly cleaned prior to any

heating operation. Cleaning agents used for the cleaning operation shall be approved by

the purchaser. Only clean stainless steel brushes and iron free grinding wheels shall be

used on stainless steel components. Wherever required, clean high grade grit, free from

contaminants shall be used for grit blasting. Grit blasting shall be performed as per

approved procedure.

Immediately after final boring of nozzles, suitable measures (covers) as approved from

NPCIL shall be taken by the supplier to prevent damage to bores and to prevent ingress

of foreign materials within the nozzles.

6.8 Handling

Great care shall be taken at all stages of fabrication, examination, testing and shipping in

the handling of the calandria shell.

Permanent deformation due to bad handling will be cause for rejection. Necessary

precautions in handling shall be taken to protect all surfaces at all stages of fabrication,

examination testing and shipping to prevent any type of damage to the component /

assembly.

Proper material packing shall be given between job and supporting structure.

Wood/carbon steel shall not be used for packing material.

The provision of temporary stiffeners and temporary lugs or other handling devices

which are necessary during fabrication, and their subsequent removal and the

refinishing of the Calandria shell or parts thereof, shall be planned in advance and

included in shop drawings.

Further in order to maintain the circularity of the Calandria during manufacture,

transportation and site work the supplier shall provide shoe type removable spiders for

the main shell and the sub-shells. The design of the spiders shall be such that it can be

disassembled and removed through the 480 mm diameter man hole openings on the

Calandria main shell.

Drawings in section 3.3 of this specification give the general guidelines for design of the

spiders, support pads, saddles, shipping frames, trunnions and lifting lugs. The spiders in

the sub-shells shall not be removed until the root pass of the calandria with end shields is

carried out by the Purchaser at site. The spiders in the main shell shall be removed after

completion of site welding.




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6.9 Dimensional Control

Utmost care shall be taken during all stages of component manufacture, assembly and

transportation to maintain the dimensions of components/assemblies within drawing

limits. Suitable mockups shall be done to estimate the weld shrinkage and it shall be

accounted during every stage of welding.

The sequence of welding of various nozzles, housings and attachments shall be decided

after thorough review of dimensions at each stage. Pre-positioning of opening of

nozzles shall be fixed and sufficient machining allowance shall be kept on ID & OD.

Manufacturing drawings at rough machining stage of nozzle and weld edge preparation at

small shell end shall be approved by Indenter/ designer.

Alignment between any top nozzle and the corresponding bottom housing shall be

maintained by suitable fixtures, clamps and sequence of welding.

Some important dimensions/features to be controlled are shell ovality, nozzle centre

location, flatness of annulus plates, nozzle to nozzle housing alignment & overall length.

7.0 EXAMINATION, TESTS , REPORTS AND DOCUMENTATION

7.1 General

Except as modified by this specification, the Calandria shall be examined and tested

to the requirements of sub-section NB of ASME Section III. Additional

requirements may be specified by the Purchaser to meet the design intent.

The Supplier shall provide all the examination & testing services and facilities for shop

fabrication, machining and assembly work. The examination and testing shall be under

the control of a competent chief inspector whose prime responsibility is examination and

testing & directly reporting to management and not to production departments.

The examination and testing shall be conducted in a manner satisfactory to, and shall be

subject to approval by the Purchaser. Examination and testing by the Purchaser or its

authorized representative shall not in any way relieve the Supplier of the examination and

testing duties called for herein.

The examination and tests on the Calandria and attachments shall be as set forth below.

The Purchaser shall have the right to specify additional examination or testing as it deems

necessary, and the additional cost of such examination or testing will be borne by the

Purchaser. The Supplier shall maintain records of all examination and tests which shall

be made freely available to the Purchaser or its authorized representative.

The supplier shall prepare necessary Quality Assurance Plans (QAPs), examination and

testing procedures, test report formats and all such documents required for examination,

testing and inspection of component and submit for the Purchaser’s approval in standard

format, before start of the examination / test / inspection activity. The QAPs shall contain




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the sequence of examination & testing activities, details of examination, testing and

inspection, reference procedure / standard / code, acceptance standard, sample size, type

of record, parameters to be monitored, responsibility of agencies in respect of

performing, witnessing, reviewing, hold points etc. The QAPs shall be prepared for all

major components, raw materials and all assemblies. A suggested QAP is enclosed for

reference in Annexure-1. There will be more than one QAP, as there are many activities

and assemblies involved. Only approved QAPs shall be followed. All required NDEs

procedures shall be reviewed by the competent level II personal from the supplier end

before submitting to purchaser.

Wherever applicable, ultrasonic examination shall be carried out by both straight beam

and angle beam to meet the requirement of 100% volumetric examination of weld.

7.2 Failure of Examination or Test and repair

In case any component / assembly fails to meet an examination or test requirement

specified herein, the Supplier shall notify the Purchaser or his authorized representative.

The Supplier must obtain permission from the Purchaser before repair is undertaken.

Any repair or rework, shall be performed as per approved procedure. The repair

procedure shall clearly specify the acceptance norms, re-examination and retesting, if

necessary.

7.3 Examination of welds

7.3.1 Examinations and Tests on Sample Welds

The supplier shall carry out mock-ups to demonstrate the suitability of welding

procedures / fixtures, etc. for nozzle to shell, housings to shell and hard face coating of

Calandria keys to the satisfaction of purchaser prior to production welding.

The details of mock-up welds and daily sample welds shall be mutually agreed upon

between the Purchaser and the Supplier. Each sample weld is to be representative of the

geometry, size and procedure of the production welds. Examinations and tests shall be

same as on production welding.

7.3.2 Non Destructive Examinations (NDEs) requirements of important production welds in

calandria fabrication are as per table given below:

S.No. Description of joints NDEs requirement Remarks

RE UE LPE

1. Longitudinal and

circumferential joints of Main

shell and Small shell

yes no Root and final

pass

Helium

leak test

requirement

2. Corner joint between Annulus

plates to Main shell and Small

shell

yes yes Root and

final pass

Helium

leak test

requirement




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3. Main shell to Nozzles yes no Root and

final pass

Helium

leak test

requirement

4. Locator Housing

Corner joints

no yes Root and

final pass

5. Main shell to Locator

Housings

no yes Root and

final pass

6. Between Diffuser plates no yes Root and

final pass

7. Between diffuser pipe to plates no yes Root and

final pass

8. Nozzle to Shroud RE/UE Root and

final pass

9. Hard coat weld deposits on

Calandria Key

no no Each pass

10. Fabricated channel of Key

Structure

no yes Root and

final pass

11. Female Key block with

Calandria shell

no no Each pass

The above welds are identified as important welds. Any other welds, which may form a

part of fabrication will be examined and tested by suitable NDEs/method agreed upon

mutually between NPCIL and supplier. Cleaning after NDEs shall be ensured by NPCIL-

QS.

7.3.3 Radiographic Examination (RE)

All welds as required by sub-section NB of ASME Section III for Class 1 Nuclear

components shall be fully examined by radiographic examination. Acceptance standard

shall be as per Clause NB 5320 of Section III ASME Boiler & Pressure Vessel Code.

The acceptance criteria shall be based on finish size of the material after final machining

wherever applicable.

Radiographic examination of welds shall be carried out as per Section V and Section III

NB ASME Boiler & Pressure Vessel Code. Approved Radiographic examination

procedure shall be followed.

Radiographic examination of joints involving special techniques requiring multiple

exposures shall be subject to the purchaser’s approval. All radiographs shall be digitised

and stored in soft form. On completion of job, these shall be submitted to the purchaser in

soft form (indexed format).

7.3.4 Ultrasonic Examination (UE)

Ultrasonic examination shall be carried out as required by ASME-III-NB-5230 of welds

as per table specified in para 7.3.2 of this specification. All relevant indications shall be

reported. Acceptance standard shall be as per Clause NB 5330 of Section III. The




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acceptance criteria shall be based on finish size of the material after machining wherever

applicable.

Ultrasonic examination of welds shall be carried out as per Section V and Section III NB

ASME Boiler & Pressure Vessel Code. Approved Ultrasonic examination procedure shall

be followed.

All ultrasonic examination shall be carried out with equipment having recording facility.

On completion of job, all identified ultrasonic examination records shall be submitted to

the purchaser in soft form.

7.3.5 Liquid Penetrant Examination (LPE)

The LPE on welds / machined surfaces shall be carried out as per approved procedure.

Acceptance, rejection or repairs of any indications shall be as per the applicable codes

and as per this specification.

All weld edge preparations and cut edges shall be examined by LPE. All indications shall

be removed or repaired to the satisfaction of the Purchaser.

The completed root pass of each weld, back gouged surfaces of double sided welds and

all completed welds shall be examined throughout their entire length, by LPE. All

indications shall be removed or repaired and re-examined to the satisfaction of the

Purchaser.

Acceptance standard shall be as per Clause NB 5350 of Section III of ASME Boiler &

Pressure Vessel Code.

In addition, the following areas shall also be examined by LPE:

(a) Finish machined inner and outer surfaces of all nozzles.

(b) All locations where temporary attachments are welded and later removed.

7.4 Dimensions, Workmanship and Cleanliness

The Calandria and its attachment shall be examined by the Supplier at all stages of

manufacture to verify that the dimensions, fit, alignment and surface finish are in

accordance with the design reference drawings and the supplier’s approved shop

drawings . The reference temperature for dimensions shall be 20ºC unless otherwise

indicated.

The examination shall also verify that the workmanship and cleanliness are in accordance

with the requirements of this specification.




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7.5 Integrity and Leak Test

The calandria is welded to the end shields at site. After installation of calandria tubes,

reactivity mechanism assemblies and moderator system piping etc., the calandria is

subjected to the following tests by the purchaser as per approved procedure:

1) Leak test ( Air hold test)

2) Integrity test (Hydrostatic test)

3) Helium leak test

The supplier shall stand guarantee for no leakage/distortions during the above tests in the

calandria vessel for all the areas fabricated by him. In case any weld defect/leakage/other

defects are found during above tests at site, it shall be rectified and re-examined by the

supplier within notice period given by the purchaser to the satisfaction of the purchaser.

7.6 Examination of Screw Threads

All threaded fasteners and fastener holes shall be examined for thread damage, burrs,

tears and surface discontinuities. All threads shall be dimensionally checked with thread

gauges approved by the Purchaser and these shall be also checked with mating parts

(wherever mating parts are available). Unless otherwise stated, suitable chamfer to suit

fasteners in tapped holes shall be given by the supplier.

7.7 Passivation

After completion of Calandria assembly and its attachment, these shall be passivated as

per NPCIL approved procedure submitted by the supplier. Contamination checks as

mentioned below shall also be carried out by the supplier to ensure successful

passivation. This surface treatment is applicable for austenitic stainless steel material.

7.8 Check for Chloride Contamination

All stainless steel surfaces which have come in contact with chemicals, oils or grease at

any stage of fabrication shall be cleaned and examined for chloride contamination at

suitable stages. The spot-check for chloride contamination of the surfaces shall be

performed on areas designated by the Purchaser as per approved procedure.

If any surface is found to be contaminated, the surrounding areas shall be checked to

establish the extent of the contaminated areas. These shall be cleaned by repeated

swabbing with 10% nitric acid and rinsing with warm demineralised water. Cleaning

shall be continued till effective removal of contamination is ensured.

Note: Care shall be taken to prevent spurious indications through prior contamination of

test tubes, solutions and swabs. These shall be handled with rubber gloves and/or

suitable tweezers.




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7.9 Check for Iron Contamination

All stainless steel surfaces shall be examined after cleaning for iron contamination at

suitable stages. The spot check for iron contamination of the surface shall be performed

on areas designated by the Purchaser as per approved procedure.


establish the extent of the contaminated areas. Contaminated areas shall be ground till

effective removal of contamination is ensured.

7.10 Non-conformance control

a) Efforts shall be made to minimize deviations from technical specification, approved

drawings and approved procedures at every stage of fabrication, examination and

testing of all components and assemblies.

b) Any non-conformance shall be brought to the notice of authorized representative of

the Purchaser immediately before starting any rework or repair. All rework or repair

shall be carried out after finalizing repair proposal and obtaining its approval from

purchaser in writing.

c) A procedure shall be prepared by the supplier and approved by the purchaser for

minimizing and disposing of non-conformances.

d) The following alternatives exist for dealing with a non-conformance:

i. Accept as it is – if it meets design(safety and functional) intent (raise a

Design Concession Request(DCR))

ii. Rework / repair as per approved procedure. If it meets design (safety and

functional) intent after repair, accept with DCR. Otherwise reject it for its

intended use or approved as noted with action to be taken by the supplier or

others.

iii. Reject it. Either use it for alternative purpose or scrap it.

e) The Purchaser exercises the option of choosing the alternative.

f) All non-conformances which are affecting drawing requirements and their disposals

shall be documented by DCRs. All such DCRs shall form a part of the history docket

of the component / assembly. The DCRs shall give technical justification for

acceptance / rejection. The DCRs shall be in the purchaser’s approved format.

7.11 Documentation

a) All activities shall be performed as per approved documents.

b) After successful completion of fabrication, examination, testing etc. of calandria

assembly and its attachment, a history docket shall be made as per NPCIL

approved procedure submitted by the supplier. History docket shall be in properly

bound volumes. Its five hard copies with two soft indexed copies shall be given to

the purchaser for record. History docket shall be made available by the

supplier along with equipment / component dispatch. The history dockets shall

contain at least the following information and any other documents as required by

the purchaser:




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i) Purchase order

ii) Tender drawings

iii) Fabrication drawings/manufacturing drawings

iv) Fabrication plans/machining plans

v) Fabrication procedures/machining procedures/repair procedures

vi) Quality assurance plans (QAPs)

vii) Examination Procedures/ Testing Procedures

viii) Examination reports / Testing reports / Inspection reports

ix) Approved DCRs and Non-conformance reports

x) Packing procedures, transportation procedure and related approved drawings

(shipping frame, lashing arrangement etc.)

xi) Shipping release note

xii) As built drawings(with important dimensions noted)

xiii) Storage procedures

xiv) Sub purchase orders, material Sub purchase orders, material test certificates etc.

8.0 LOADING ON TRACTOR TRAILER / BARGE FOR SHIPMENT &

TRANSPORTATION TO SITE ( Refer relevant drawings in section 3.3)

Relevant drawings of section 3.3 are for reference only considering calandria principal

axis horizontal during loading and transportation.

8.1 The calandria is a hollow cylindrical vessel with spiders in it. Its maximum diameter

(including nozzle lengths) is 8354 mm and length is 5306 mm. Its weight is about

70Tonnes (including the spider assemblies). It has to be transported from the supplier’s

works to the plant site with its principal axis horizontal / vertical. Principal axis may be

tilted suitably as approved from NPCIL. This is a over-dimensional consignment (ODC).

The total transport arrangements shall be submitted by the supplier for NPCIL approval.

The supplier shall make necessary procedures for lashing and transportation and submit

to the purchase for approval. Only approved procedures shall be followed. Extreme care

shall be taken by the supplier to ensure safe delivery at site of all the components of the

Calandria. In all stages of shipment, adequate support to prevent permanent deformation

of the Calandria components shall be provided. The supplier shall be responsible for the

design, fabrication, examination, testing and supply of shipping frames for the Calandria

sub-assembly and other components / parts and also responsible for the proper protection

of all the components during transit. The supplier shall also satisfy himself as to the

suitability of the procedure used in loading, securing, special handling and packaging in

all stages of shipment and transshipment to the site and additional prime mover

requirement during transportation.

Packaging and shipping procedures and detailed assembly drawings of the packaging and

shipping structures shall be submitted to the Purchaser for approval. Shipping structures

shall be designed to cater to the requirements of transportation including ocean shipment

and to facilitate transportation by road tractor trailer as required.

The detailed design of the lifting lugs and shipping frame work and method of attachment

to the Calandria shell shall be subject to the approval of the purchaser.




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Route survey report shall be submitted to the purchaser at-least one month in advance of

final dispatch date.

All nozzle opening covers shall be designed to prevent damage, corrosion and the ingress

of foreign material during transportation and subsequent storage at site. All finish

machined surfaces of the Calandria sub-assemblies and components shall be protected

from mechanical or other damage to the satisfaction of the purchaser. As a minimum

requirement, all machined edges of nozzles and small shells shall be covered by steel /

wooden / other NPCIL approved material covers and the open ends of the Calandria shall

be closed with suitable wooden covers.

Packing list shall be labeled on each box and copy of same to be available with

consignment. All fasteners and loose items shall be properly identified, sorted and

separately crated, as per approved procedure and packing list.

The supplier shall ensure that stainless surfaces of calandria are not in contact with

carbon steel surfaces of shipping frames and transport equipment.

All parts shall be clearly marked with their part numbers and assembly marks to the

approval of the Purchaser. Removal of protective coatings shall not destroy the

identification markings on the parts. Part number and assembly markings shall be easily

seen on the outside of protective coatings. Where marking of parts directly is

impractical, attached markings may be permitted. All shipping crates and boxes shall be

clearly marked with the part numbers of the contents and quantity.

Handling and transportation of Calandria shall meet the requirements specified in PC-E-

1051- technical Specification for Handling and Transportation of Calandria from

manufactures place to NPCIL project site.

Important activities to be done and main precautions to be taken are listed below. These

activities are applicable for road transport. For transportation by sea, similar detailing

shall be done by the supplier.

8.2 Important activities

Loading on the shipping frame

Lashing arrangement between the shipping frame and the tractor bed / barge

Route detailing - details of road map to be followed, civil works to be carried out on

roads, geometries of road infringements, making by-pass roads, removal of electric

poles, overhead power line crossings, telephone line crossings, railway level crossings,

dip fillings, fencing, tree cutting, parapet removal etc.

Obtaining permission from state / central / local authorities for various works listed

above

Convoy formation – Pilot jeep, ODC vehicle and follower vehicle

Convoy program details

Certification of transport equipment




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Convoy communication with the Purchaser’s representative

8.3 Precautions

The consignment shall not be transported in an unbalanced / overhanging position.

No inflammable articles shall be placed in the vicinity of the consignment.

Proper security arrangements shall be made for safe transportation of the consignment

and the personnel.

The consignment shall be fully protected from rain or thunderbolts or electrification or

any other natural calamity.

The consignment shall be suitably covered to avoid scratches or rubbing against other

bodies or trees etc.

All surfaces shall be protected from corrosion during shipment.

8.4 Storage at site

The supplier shall prepare suitable procedure to store the assemblies safely at site for a

minimum period of twelve months from the date of receipt at site.




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Annexure-1

SUGGESTED QAP FOR CALANDRIA FABRICATION, EXAMINATION, TESTING

AND TRANSPORTATION TO SITE

S.No. Description of activity Nature of QA activity to be

performed by

Remarks

Supplier’s

Examinations

and Tests

(All 100%)

Purchaser’s QS

(100% unless

indicated otherwise

within brackets)

1. Raw material examination

1.1 If Original Material Test

Certificates (MTC) are available,

material identification with heat

numbers & stamping

I H

1.2 In case MTCs are not available

1.2.1 Identification I H

1.2.2 Chemical composition I W, R

1.2.3 Mechanical properties I W, R

1.2.4 Inter-granular corrosion test I W, R

1.2.5 Ultrasonic examination for pipes,

plates, forgings wherever specified

I W, R

2.0 Submission of documents

2.1 QAP Preparation Approval

2.2 Qualification of WPS I W, H, R

2.3 Qualification of welders and

welding operators

I W, H, R

2.4 Examination and test procedures Preparation Approval

2.5 Machine / Instrument calibration I W, R

2.6 NDE Personnel qualification I W, R

3.0 Fabrication of Calandria assembly

and all associated components

I W, R

4.0 Examination and testing of

assemblies / sub-assemblies

4.1 Visual examination I W, H, R

4.2 Dimensional examination I H (final

dimension), R




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performed by

Remarks

Supplier’s

Examinations

and Tests

(All 100%)

Purchaser’s QS

(100% unless

indicated otherwise

within brackets)

4.3 Radiographic examination /

Ultrasonic examination of

specified joints

I W, H, R

4.4 LPE of specified joints / WEP /

machined surfaces

I W, H, R (random)

5.0 Cleaning, pickling and passivation I W, H, R

6.0 Protective coating/painting,

packing & transportation to site

6.1 Protective coating/painting

procedure

Preparation R

6.2 Packing and protection procedure Preparation R

6.3 Shipping frames - dimensions I W, H

6.4 Shipping Release - H

6.5 Loading and transportation to site

and storage at site

I W

7.0 Submission of History Docket I R

LEGENDS :

I - Complete action and examination by the supplier on 100% basis (Full responsibility

giving 100% coverage to all raw materials, components, sub-assemblies and

assemblies)

W - Witnessed by the Purchaser (In case the purchaser’s authorised representative is not

able to witness this planned activity, there is no need to stop this activity and

subsequent activities)

R - Review of examination/test records, examination / test reports, procedures,

examination/test certificates, etc.

H - Hold point by the Purchaser (In case the purchaser’s authorised representative is not

able witness this planned activity, this activity and subsequent activities shall be

kept on hold, till it is released by the purchaser’s authorised representative)



NO. : PC-M/1045/R0

TITLE : TECHNICAL SPECIFICATION ON SS 304L PLATES FOR CALANDRIA OF

700MWe PHWRs

REV. NO.

& DATE

DESCRIPTION

OF REVISION

REVISED BY

NAME &

SIGNATURE

CHECKED

BY

NAME &

SIGNATURE

REVIEWED

BY

NAME &

SIGNATURE

APPROVED BY

NAME &

SIGNATURE

NPCIL PROPRIETARY









SS 304L PLATES FOR CALANDRIA OF 700MWe PHWRs

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1.0 SCOPE

This specification gives the technical requirements for the raw material, examination,

testing, packing, shipping and storage of austenitic stainless steel plates for; the shells,

annulus plates, diffuser plates, other plates etc. of calandria of 700MWe PHWRs.

The plate material shall be as per ASME-SA-240 Type 304L with additional

requirements as specified in this specification.

This specification is applicable to 700 MWe PHWR projects beyond RAPP-7&8.

Even though, the size and quantity shall be as per the tender documents, for

information purpose, finished sizes of important components are given below.

1) Outside diameter of Main Shell : 7864

2) Length of Main Shell : 4664

3) Outside diameter of Small Shells at each end : 7064

4) Length of Small Shells at each end : 331

5) Projection of small shells beyond annulus plates : 309

6) Thickness of Main shell and Small shell : 32

7) Thickness of Annulus plates : 22

(All dimensions are in mm.)

2.0 CONTENTS



Scope

Contents

Reference Codes, Standards and Drawings

1

2

3

Materials 4

Manufacture of Plates 5

Quality Surveillance, Examination and Testing 6

Pickling, Passivation & Contamination checks 7

Final Documentation

Identification and Packing

Transportation

Storage

Workmanship

Delivery Schedule

Place of Delivery

8

9

10

11

12

13

14




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3.0 REFERENCE CODES, STANDARDS AND DRAWINGS:

a) ASME-Section III-NB-Class 1 components

b) ASME-Section-II- Part A-Ferrous material specification

c) ASME-SA577- Standard Specification for ultrasonic angle-beam examination of

steel plates

d) ASME-SA578- Standard Specification for straight beam ultrasonic examination

of plain and clad steel plates for special applications

e) ASTM-A-262-IGC resistance test

There are no applicable drawings or sketches, as the requirement is for raw material.

4.0 MATERIALS


which are necessary for the fulfillment of this specification shall be of good

commercial quality from a reputed source of supply. i.e. Materials shall be procured

from the manufacturers or their dealers.

4.1 Material Requirements

4.1.1 The supply condition shall be as per ASME-SA-240 Type 304L with additional

requirements as specified in this specification. Plates shall have no. 1 finish on both

surfaces. The plate material shall be hot rolled, solution annealed, pickled and

passivated.

4.1.2 In addition to above, one coupon from each rolled plate shall meet the following

complete requirements. If several plates of same size are from same heat treatment

batch, then sample shall be drawn from one representative plate. All tests /

examinations / inspections shall be carried out at NPCIL approved facilities /

laboratories.

4.1.2.1 Both longitudinal and transverse directional properties (UTS, YS, % elongation) of the

plates shall be established and shall meet requirements specified in SA-240.

Longitudinal and transverse Coupons shall be taken so that specimens shall have their

longitudinal axes at least 1/4t from a rolled surface and with the mid-length of the

specimen at least t from any heat treated edge, where t is the nominal thickness of the

material.

4.1.2.2 The hardness on both surfaces and at five points across thickness shall be measured.

The average hardness shall be 180+/-5

HB. The hardness values shall be within 170 to

190 HB.

4.1.2.3 Inter Granular corrosion test as per ASTM-A-262 Practice E shall be carried out at mid

thickness. Coupons shall be boiled for 72 h instead of the duration mentioned in A-262.

One piece shall be bent as per practice E (and acceptance as per practice E) and another




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shall be cut and cross section shall be surface examined for measuring depth of attack.

Depth of attack less than 50 micrometer is acceptable.

4.1.2.4 Grain size shall be in the range of 3 to 6. It shall be measured and reported for

records.

4.1.2.5 Residual copper content shall not be more than 0.3% based on product analysis

4.1.2.6 The cobalt content in the plates shall be less than 0.025% as per product analysis.

4.1.2.7 Delta ferrite of parent material measured by ferrite meter shall be less than 0.5FN.

4.2 Ultrasonic Examination Requirements

Entire volume of the material shall be examined by ultrasonic straight beam

examination and ultrasonic angle beam examination.

Straight beam examination shall be as per ASME-SA-578. Supplementary requirement

for 100% scanning shall be carried out as per S1 of SA-578. Ultrasonic Examination

shall be carried out and accepted as per supplementary requirements clause no. S9 (flat

bottom hole of 3mm at depth of T/4, T/2, 3T/4).

Angle beam examination shall be carried out as per ASME-SA-577 from one major

surface using 75 mm grid lines and with 3% notch of finished machined thickness shall

be carried out. Acceptance shall be as given SA-577.

All ultrasonic examinations shall be carried out with equipment having recording

facility. On completion of job, all identified ultrasonic examination records shall be

submitted to the purchaser in soft form.

4.3 Tolerances and Flatness Requirement

Permissible variations in length, width, thickness, flatness and other parameters not

specially mentioned here, shall be as per SA240 and SA480.

4.4 Weld repair of plate material is not permitted.

5.0 MANUFACTURE OF PLATES

5.1 The supplier shall submit the following documents for Purchaser’s approval before

start of manufacture:

a) Manufacturing plan

b) Heat treatment procedures

c) Quality assurance plan (QAP)

d) Dimensions, weight & quantity of finished plates

e) Examination and testing procedures

f) Packing and shipment procedures

g) Examination and test report formats.




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5.2 Only NPCIL approved procedures shall be followed.

5.3 In case of getting material from dealer, all tests / examinations - mechanical, chemical,

Non-destructive examinations (NDEs) etc. mentioned in material clause shall be

carried out by the supplier at his own cost. (Refer suggested QAP appended herewith).

6.0 QUALITY SURVEILLANCE, EXAMINATION & TESTING

6.1 All materials shall be tested / examined to the relevant ASTM / ASME specifications as

specified for each item. Additional requirements as specifically stated herein shall also

be complied with. QAP shall be submitted by the supplier to purchaser for approval

before start of manufacturing of plates. Suggested QAP shall be referred for reference

as given in Annexure-1.

6.2 The supplier shall provide all the examination and testing services and facilities as

required. Supplier’s shop examination and testing shall be under the control of a

competent Chief inspector whose primary responsibility is examination and testing,

reporting directly to management and not to the production department.

6.3 The examination and testing shall be carried out in a manner satisfactory to and shall be

subject to approval by the Purchaser. All works covered by this specification shall be

subject to quality surveillance by the purchaser or his authorized representative.

6.4 The purchaser reserves the right to appoint a third party of his choice for examination

and testing and define the scope of work for the third party. Expenses for such third

party examination and testing shall be borne by the purchaser.

6.5 Quality surveillance by the purchaser or his authorized representative shall not relieve

the supplier of the examination and testing duties called for herein.

6.6 In addition to the examination and testing performed by the supplier, the purchaser

shall have the right to ask for the additional examination or testing as he deems

necessary and the additional cost for such examination and testing will be borne by the

purchaser.

6.7 All NDE personnel deployed for the job shall be qualified as per requirements of

ASME Section III and ASNT-TC-IA.

6.8 Only calibrated instruments/ machines shall be used for measurement or in any

operation. If no calibration has been carried out in last 12 months, then the

instruments/machines shall be recalibrated.

6.9 Results of all examinations and tests shall be properly recorded in approved test report

formats.




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7.0 PICKLING, PASSIVATION & CONTAMINATION CHECKS

Pickling and passivation of material surface at an appropriate stage shall be carried out

by the supplier as per NPCIL approved procedure. Contamination checks as mentioned

below shall also be carried out by the supplier to ensure successful passivation. These

surface treatments are applicable for all austenitic stainless steel materials.

7.1 Check for Chloride Contamination


any stage of manufacturing shall be cleaned and examined for chloride contamination

at suitable stages. The spot-check for chloride contamination of the surfaces shall be




swabbing with 10% nitric acid and rinsing with warm demineralised water. Cleaning

shall be continued till effective removal of contamination is ensured.

Note : Care shall be taken to prevent spurious indications through prior contamination

of test tubes, solutions and swabs. These shall be handled with rubber gloves and/or

suitable tweezers.

7.2 Check for Iron Contamination


suitable stages. The spot check for iron contamination of the surface shall be




effective removal of contamination is ensured.

8.0 FINAL DOCUMENTATION

History docket shall be made after completion of all activities like manufacturing of

raw materials and their examinations & tests, pickling & passivation of surfaces etc..

Soft copy and properly bound volumes of hard copies of history docket & its number as

mentioned in tender documents shall be given to the purchaser.

History docket shall be submitted to purchaser along with dispatch of material.

The history docket shall contain at least the following information and any other

documents as required by the purchaser:

a) Purchase Order

b) Manufacturing plan

c) Manufacturing / Heat treatment procedures




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d) Quality Assurance Plans (QAPs)

e) Examination procedures

f) Examination reports

g) Test procedures

h) Test reports

i) Surface treatment procedures(cleaning, pickling and passivation)

j) Design concession reports & Non-conformance reports, if any

k) Packing procedure

l) Shipping release

m) Shipping procedure

n) Storage procedure

The supplier shall keep a record of all examination and test reports for a period of 5

years after completion of work.

9.0 IDENTIFICATION AND PACKING

9.1 Packing shall be as per approved procedure by the purchaser.

9.2 Each plate shall be suitably marked with the heat number and heat treatment number.

The marking shall be seen on the outside of the protective coating. No permanent

marking or stamping shall be permitted. Standard specification identification markings

shall be prominently marked at two places on either side of each plate. The method of

marking shall be such that it is not chemically or physically injurious to the material.

Free halogen content in any paint used for marking shall be less than 25 ppm.

9.3 All surfaces shall be protected against pitting, corrosion etc. by application of suitable

material as approved by purchaser. All plates shall be crated with proper protection to

retain flatness of each plate and prevent any damage during handling & transit of above

material.

10.0 TRANSPORTATION

The packed plates shall be sent to the destination as per the tender documents/purchase

order. Special care shall be taken by the supplier during sea transit, if material is

shipped from outside India/within India.

All necessary precautions and care shall be taken by the supplier during shipping either

by road transport and/or water transport for safe delivery of material.

11.0 STORAGE

Storage shall be as per NPCIL approved procedure. Storage shall be in a separate

covered shed to avoid contamination and to be stored on sufficient number of pedestals

to prevent sagging of plates. Contamination of any kind shall be avoided. Additional

polythene / tarpolin shall be used as protective cover.




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12.0 WORKMANSHIP

All workmanship shall be of first class, high grade quality and in accordance with the

best approved methods of manufacture.

13.0 DELIVERY SCHEDULE

The total material is to be supplied within dates stipulated in purchase order.

14.0 PLACE OF DELIVERY

All the items covered in this tender shall be delivered to the destination as specified in

tender document.




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ANNEXURE-1

SUGGESTED QAP FOR SS-304L PLATES FOR CALANDRIA


performed by

Supplier’s

examination

and testing (All

100%)

Purchaser’s QS

(100% unless

indicated

otherwise within

brackets)

Remarks

1. Plate material examination and

testing




numbers & stamping

I H






1.2.5 Ultrasonic examination I W, R






3.0 Manufacturing of plates I W, R

4.0 Examination and testing


4.2 Dimensional examination I H, R


6.0 Packing, shipping and storage

6.1 Packing procedure Preparation Approval


6.3 Shipping procedure Preparation Approval




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SUGGESTED QAP FOR SS-304L PLATES FOR CALANDRIA S.No. Description of activity Nature of QA activity to be

performed by

Supplier’s

examination

and testing (All

100%)

Purchaser’s QS

(100% unless

indicated

otherwise within

brackets)

Remarks

6.4 Storage procedure Preparation Approval



LEGENDS :

I - Complete action, examination and testing by the supplier on 100% basis

W - Witnessed by the Purchaser

R - Review of examination and test records, examination and test reports,

procedures, test certificates, etc.

H - Hold point by the Purchaser



NO. : PC-M/1046/R0

TITLE : TECHNICAL SPECIFICATION ON

FORGING FOR NOZZLES

FOR CALANDRIA OF 700 MWe PHWRs

REV. NO.

& DATE

DESCRIPTION

OF REVISION

REVISED BY

NAME &

SIGNATURE

CHECKED

BY

NAME &

SIGNATURE

REVIEWED

BY

NAME &

SIGNATURE

APPROVED BY

NAME &

SIGNATURE

NPCIL PROPRIETARY








TECHNICAL SPECIFICATION ON FORGINGS FOR NOZZLES FOR

CALANDRIA OF 700 MWe PHWRs

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REV.NO. : 0

31210 / PC-M-1046 FEBRUARY, 2014


1. Scope

This specification establishes the technical requirements for the manufacture,

examination, testing, packing and transportation for forgings for nozzles for Calandria of

700 MWe PHWRs. The material shall be stainless steel conform to ASME-SA-182 F

304L with additional requirements as specified in this specification.

This specification is applicable to 700 MWe PHWR projects beyond RAPP-7&8.

All other commercial requirements like place of delivery, quantities, schedule of delivery

etc. shall be as given in tender/Purchase order.

2. Contents



Scope

Contents

Applicable Codes, Dimensions & Quantities and Reference Drawings

1

2

3

Materials 4

Documentation 5

Identification and Packing 6

Shipping 7

Storage

Workmanship

8

9

3. Applicable Codes, Dimensions & Quantities and Reference Drawings

3.1 Applicable Codes

a) ASME-Section III-NB-Class 1 components

b) ASME-Section-II- Part A-Ferrous material specification

c) ASME Section V – Non-destructive examinations

3.2 Dimensions and Quantities of forging

The hollow and solid forgings shall be supplied as per the following finally finished

dimensions. This does not include machining / trimming allowances on outer diameter

(OD). All dimensions are in mm. Quantities mentioned below are for one reactor unit.




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31210 / PC-M-1046 FEBRUARY, 2014


A. Hollow forgings

a) For OPRD & Manhole nozzle

OD 625 x ID 450 x Length 425, Quantity - 5 Nos.

b) For Moderator outlet nozzles


c) For Moderator inlet nozzles


d) For Shut off rod, ZCU, Control rod nozzles


e) For Adjuster rod, PIU, Head tank connecting, View port, VFU-8 nozzles


B. Solid forgings

a) For VFU nozzles

Diameter 160 x Length 350, Quantity - 25 Nos.

b) For HFU nozzles

Diameter 220 x Length 400, Quantity - 9 Nos.

c) For Male key

545 x 525 x 385, Quantity - 4 Nos.

d) For Female key

340 x 245 x 150, Quantity - 4 Nos.

3.3 Reference drawings

Title Drawing No.

Calandria Nozzles Sections * /31210/2002/DD

Calandria Nozzles Details * /31210/2003/DD

Calandria Key Structure Details */31210/2004/DD

* – Project as applicable

These drawings are for reference only showing finished dimension of nozzles.

4. Materials


which are necessary for the fulfillment of this specification shall be of good commercial

quality and in accordance with good practice pertinent to the manufacture of pressure

vessels and heavy engineering and power station equipment.

4.1 Material Requirements

4.1.1 The material shall also meet the requirements of ASME B&PV code, Section III,

Division 1, Article NB 2000.




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31210 / PC-M-1046 FEBRUARY, 2014


4.1.2 The supply condition shall be as per ASME-SA-182 Grade F304L with additional

requirements as specified in this specification. Heat treat type of forged material shall be

solution treat and quench.

4.2 Supplementary requirements and additional requirement in addition to general

Requirements of ASME-SA-182 specification

4.2.1 S1 – Macroetch test: A sample forging shall be sectioned and etched to show flow lines

and internal imperfections. The test shall be conducted according to Test method E340.

Forging flow lines shall be reported

4.2.2 S2 – Complete heat treatment details shall be submitted for purchaser’s approval.

4.3 In addition to above, one coupon from each heat shall meet the following:

4.3.1 All the three directional properties (UTS, YS, % elongation) of the forgings shall be

established and shall be within the values specified in SA-182 Grade F304L. In thickness

direction, miniature coupon shall be drawn. Longitudinal and transverse Coupons shall be

taken so that specimens shall have their longitudinal axes at least 1/4t from a forged

surface and with the mid-length of the specimen at least ‘t’ from any heat treated edge,

where ‘t’ is the nominal thickness of the material. Actual Stress strain plot shall be

submitted for purchaser’s records.

4.3.2 The hardness on both surfaces and at five points across thickness shall be measured. The

average hardness shall be 180+/-5

HB. The hardness values shall be within 170 to 190 HB.

4.3.3 Inter Granular corrosion test as per ASTM-A-262 Practice E shall be carried out at mid

thickness. Coupons shall be boiled for 72 h instead of the duration mentioned in A-262.

One piece shall be bent as per practice E (and acceptance as per practice E) and another

shall be cut and cross section shall be surface examined for measuring depth of attack.

Depth of attack less than 50 micrometer is acceptable.

4.3.4 Grain size shall be in the range of 3 to 6. It shall be measured and reported for records.

4.3.5 Residual copper content shall not be more than 0.3% based on product analysis

4.3.6 The cobalt content shall be less than 0.025% as per product analysis.

4.3.7 Delta ferrite of parent material measured by ferrite meter shall be less than 0.5FN.

4.3.8 Weld repair of forging is not permitted.

4.4 Hollow forgings shall be examined by ultrasonic angle beam examination with notch

depth of 2 mm. Scanning shall be carried out in two circumferential directions and two

axial directions. All ultrasonic examination shall be carried out with equipment having

recording facility. On completion of job, all identified ultrasonic examination records

shall be submitted to the purchaser in soft form.




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4.5 Solid forging shall be examined by straight beam examination with 3 mm flat bottom hole

as a reference. Radial and axial scan shall be carried out by straight beam examination.

All ultrasonic examination shall be carried out with equipment having recording facility.

On completion of job, all identified ultrasonic examination records shall be submitted to

the purchaser in soft form.

4.6 Forging ratio of solid forging / hollow forging shall be mutually agreed after production

trials and testing.

4.7 Making hollow forgings by punching process is preferable to trepanning.

4.8 Pickling and passivation of material surface at an appropriate stage shall be carried out by

the supplier as per NPCIL approved procedure. Contamination checks as mentioned

below shall also be carried out by the supplier to ensure successful passivation. These

surface treatments are applicable for all austenitic stainless steel material.

4.9 Contamination Check

4.9.1 Check for Chloride Contamination


any stage of forging shall be cleaned and examined for chloride contamination at suitable

stages. The spot-check for chloride contamination of the surfaces shall be performed on

areas designated by the Purchaser as per approved procedure.



swabbing with 10% nitric acid and rinsing with warm demineralised water. Cleaning shall

be continued till effective & complete removal of contamination is ensured.

Note: Care shall be taken to prevent spurious indications through prior contamination of

test tubes, solutions and swabs. These shall be handled with rubber gloves and/or

suitable tweezers.

4.9.2 Check for Iron Contamination


suitable stages. The spot check for iron contamination of the surface shall be performed

on areas designated by the Purchaser as per approved procedure.



effective & complete removal of contamination is ensured.




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5.0 DOCUMENTATION

5.1 Initial Documentations

The supplier shall prepare necessary Quality Assurance Plans (QAPs), examination and

testing procedures, test report formats and all such documents required for manufacturing,

examination, testing and inspection of raw material and submit for the Purchaser’s

approval in standard format, before start of the manufacturing, examination / test /

inspection activity.

The QAPs shall contain the sequence of manufacturing, examination & testing activities,

details of examination, testing and inspection, reference procedure / standard / code,

acceptance standard, sample size, type of record, parameters to be monitored,

responsibility of agencies in respect of performing, witnessing, reviewing, hold points

etc. A suggested QAP is enclosed for reference in Annexure-1. Only approved QAPs

shall be followed.

All required NDE procedures shall be reviewed by the competent level II personal from

the supplier end before submitting to purchaser.

5.2 Final Documentation

History docket shall be made after completion of all activities like manufacturing/forging

of raw materials and their examinations & tests, picking & passivation of surface etc..

Soft copy and properly bound volumes of hard copies of history docket & its number as

mentioned in tender documents shall be given to the purchaser.

History docket shall be submitted to purchaser along with dispatch of material.

The history docket shall contain at least the following information and any other

documents as required by the purchaser:

a) Purchase Order

b) Manufacturing plan

c) Manufacturing , Forging and Heat treatment procedures

d) Quality Assurance Plans (QAPs)

e) Examination procedures

f) Examination reports

g) Test procedures

h) Test reports

i) Surface treatment procedures (cleaning, pickling and passivation)

j) Design concession reports & Non-conformance reports, if any

k) Packing procedure

l) Shipping release

m) Shipping procedure

n) Storage procedure

The supplier shall keep a record of all examination and test reports for a period of 5 years

after completion of work.




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6.0 IDENTIFICATION AND PACKING

6.1 Packing shall be as per approved procedure by the purchaser.

6.2 Each hollow forging and solid forging shall be properly marked with Heat No. / Heat

treatment Lot no. etc. and shall be correlated with the Test certificate. The paints used if

any, for marking shall be removable, free of sulfur & also it shall have free halogen

content less than 25 ppm. No permanent marking or stamping shall be permitted.

Standard specification identification markings shall be prominently marked at two place

on either end of each forging. The method of marking shall be such that it is not

chemically or physically injurious to the material, even during prolonged storage.

6.3 All openings of hollow forgings shall be protected and covered to prevent damages,

corrosion and the ingress of foreign material. The supplier shall ensure that stainless

surfaces of hollow forgings and solid forgings are not in contact with carbon steel

surfaces of shipping frames and transport equipment.

The Supplier shall provide robust wood and steel cover and weather proof barriers to

completely cover the hollow forgings and solid forgings. The protective cover and

weather proof barrier shall be applied in such a manner as to prevent the entry or

collection of water inside the barrier during transport and storage.

7.0 SHIPPING

Transportation to required place of delivery shall be done as per approved procedure.

Special care shall be taken by the supplier during sea transit, if material is shipped from

outside India/within India.

All necessary precaution and care shall be taken by the supplier during shipping either by

road transport and/or water transport for safe delivery of material.

8.0 STORAGE

Storage shall be as per approved procedure. Storage shall be in a separate covered shed to

avoid contamination and water ingress.

9.0 WORKMANSHIP

All workmanship shall be of first class, high grade quality and in accordance with the best

approved methods of manufacture.




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31210 / PC-M-1046 FEBRUARY, 2014


ANNEXURE-1

SUGGESTED QAP FOR FORGINGS FOR NOZZLES FOR CALANDRIA


performed by

Supplier’s

examination

and testing (All

100%)

Purchaser’s QS

(100% unless

indicated

otherwise within

brackets)

Remarks

1. Forging material examination and

testing




numbers & stamping

I H






1.2.5 Ultrasonic examination I W, R






3.0 Manufacturing of forgings I W, R

4.0 Examination and testing


4.2 Dimensional examination I H, R


6.0 Packing, shipping and storage

6.1 Packing procedure Preparation Approval


6.3 Shipping procedure Preparation Approval




PAGE NO : 8 OF 8

REV.NO. : 0

31210 / PC-M-1046 FEBRUARY, 2014


SUGGESTED QAP FOR NOZZLES FOR CALANDRIA


performed by

Supplier’s

examination

and testing (All

100%)

Purchaser’s QS

(100% unless

indicated

otherwise within

brackets)

Remarks

6.4 Storage procedure Preparation Approval



LEGENDS :

I - Complete action, examination and testing by the supplier on 100% basis

W - Witnessed by the Purchaser

R - Review of examination and test records, examination and test reports, procedures,

test certificates, etc.

H - Hold point by the Purchaser