Government of India

Bhabha Atomic Research Centre

Tech. Specification For: Thermal Column EP,

Shielding Experiment Facility EP &

Manual Access Cavity EP

Tech. Spec. Number: APS-2/TS/2170 & 2180/001/2014-Rev 0

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1.0 SCOPE

This technical specification covers the requirements of the preparation of fabrication drawings, procurement and testing of raw materials, machining, fabrication, inspection, testing, examination, documentation, guarantee, delivery, loading and unloading at BARC, Trombay Site of the Embedded Parts (herein called "EPs") mentioned below:

1. Thermal Column (TC) EP

2. Shielding Experiment Facility (SEF) EP

3. Manual Access Cavity (MAC) EP

This scope also includes to & fro transportation of a Template fabricated by BARC for drilling boltholes in Thermal Column EP (approx. size: 2.9m x 2.7m; approx. wt.: 200kg) from the purchaser's site (ref. para 6.2.1 & 18.2) as per the requirements mentioned in this technical specification and drawings.

1.1 The components under this specification shall include but not be limited to the following to make the above-mentioned EPs complete as per the enclosed drawings.

1. Thermal Column EP ( Approx. wt. 8.1 Tonnes) a. C.S. Box and Reinforcing Structure b. S.S. Flange c. S.S. Leak Detection Pipe d. S.S. Fasteners (M30, Studs /Bolts) e. C.S. Template

2. Shielding Experiment Facility EP ( Approx. wt. 13 Tonnes) a. C.S. Box and Reinforcing Structure b. S.S. Flange c. S.S. Cover Plate (6 thk) d. S.S. Fasteners (M30, Studs /Bolts) e. S.S. Drain Pipe f. C.S. Template

3. Manual Access Cavity EP ( Approx. wt. 4.1 Tonnes)

1.2 The delivery of all the EP Structures /components shall be within six (06) months from the date of placement of the Purchase Order at the BARC, Trombay site, Mumbai-400085.

2.0 GENERAL REQUIREMENTS

2.1 The Purchaser reserves the right to make minor changes in the design prior to the approval of the final fabrication drawings. Such changes shall be considered within the original scope of the specified work and no extra charges shall be levied for the same.

2.2 Materials and standard parts which are not specifically designated herein and which are necessary for the fulfilment of this specification, shall be of good commercial quality and in accordance with good practice and shall have the approval of the Purchaser.

2.3 Workmanship & finish shall be of the best quality and in accordance with good engineering practices of fabrication, long service life and ease of maintenance as per the requirements of this specification.

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2.4 If the fabrication, examination, inspection or testing is not in conformance to the requirements of this specification, the component will be rejected.

2.5 The completely assembled EPs shall be examined to determine its conformance with this specification with respect to material, dimension, workmanship, finish, cleanliness, markings and to assess its conformance with other requirements stated or reasonably implied but not covered by specific test.

2.6 In the event of the EPs or any part there of failing to meet the examination or test requirements specified herein, the Vendor shall notify the Purchaser. The Vendor shall obtain written permission from Purchaser before repair and subsequent use of any such EPs or any part. If the repairs are likely to affect the results of examination and tests or work previously completed, appropriate re-examination, re-inspection and re-testing shall be conducted.

2.7 Only the reputed manufacturers engaged in fabrication of similar type of structures and having sufficient experience of fabrication & machining of large size component need to submit the tender. Distributors, Dealers, Stockists, Traders, Agents etc., need not quote.

2.8 The Vendor shall have sufficient in house infrastructure for machining, fabrication and handling required for the manufacturing of the subject components. The Vendor shall have the in-house quality control team with required qualification. It shall have qualified people having at least Level-II qualification (ISNT/ASNT) in DP, UT & RT. The Vendor shall have in-house EOT of sufficient capacity for material Handling.

2.9 The Vendor shall furnish a list of similar works executed by them for BARC / NPCIL/ DAE (Dept. of Atomic Energy) or other reputed Organizations, to whom a reference may be made by the Purchaser in case he considers such a reference is necessary along with his quotation.

2.10 The Vendor shall have in-house ACAD/CAM facility & qualified draftsman to produce fabrication drawings.

2.11 Purchaser will interpret the meaning of the drawings or intent of the drawings and tech. specifications and shall have the power to reject any work, material or testing which in his judgement is not in full accordance therewith.

3.0 CODES, STANDARDS AND APPLICABLE DOCUMENTS

The material, manufacturing, fabrication, inspection, examination and testing of the components shall comply with the requirements of the latest edition of codes and standards specified hereunder, the components specification sheet and the applicable drawings. The Vendor/bidder shall indicate date of issue of such applicable documents which form the basis of his quotation. In the event of any conflict between the requirements of this specification and the documents listed below, the decision of the Purchaser shall be final.

3.1 Applicable Standards and Codes

3.1.1 Codes

a) ASME Section III, Division-1, Sub-section NC. b) ASME Section II for Material Specifications. c) ASME Section V for Non Destructive Examination. d) ASME Section IX for Welding & Brazing Qualification.

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3.1.2 Standards

a) IS 800 "Code of Practice for General Construction in Steel"

b) IS 808 ‘Indian Standard, dimensions for hot rolled steel beams columns channels

and angle sections”

c) ANSI B-1.1 for Unified Screw Threads.

3.1.3 Material Specifications, Fabrication & Testing

a) IS 2062 “Steel for General Structural Purposes-Specification”.

b) IS-814 “Covered electrodes for manual metal arc welding of carbon and carbon manganese steel specification”.

c) IS-2074 : Specification for ready mixed paints, red-oxide, zinc-chromate priming.

d) ASTM-A-312 “Specification for seamless and welded austenitic stainless steel pipes”.

e) ASTM-A-193 “Alloy Steel and Stainless Steel Bolting Materials for High Temperature Service”.

f) ASTM-A-194 “Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service”.

g) ASTM-A-370 “Standard Test Methods and Definitions for Mechanical Testing of Steel Products”.

h) ASTM-A262 “Standard Practices for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steels”.

i) ASTM-A-577 “Standard Specification for Ultrasonic Angle-Beam Examination of Steel Plates”.

j) ASTM-A-578 “Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications”.

k) ASTM-E-165 : Standard Test Method for Liquid Penetrant Examination

l) ASME Sec. II-SFA-5.1 “Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding”.

m) ASME Sec. II-SFA-5.4 “Specification for Stainless Steel electrodes for Shielded Metal Arc Welding (SMAW)”.

* Note : ASME stands for ASME Boiler and Pressure Vessel code

3.2 Applicable Drawings

The following drawings are applicable:

a) A0-APS-2/2170/02/DD (Rev-1)

b) A0-APS-2/2180/01/DD (Rev-1) (Sheet 1 & 2)

c) A0-APS-2/2180/02/DD (Rev-0) The Vendor shall prepare fabrication drawings, QAP, fabrication sequence, inspection and testing procedures based on the above drawings and get the approval of the Purchaser before the commencement of the work.

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4.0 MATERIALS OF CONSTRUCTION

4.1 General All materials shall be new, of reputed make and tested quality as per specifications. Materials shall be tested in the NABL (National Accreditation Board for Testing and Calibration Laboratories) or BARC approved laboratories. All the material shall be tested for chemical and mechanical properties and other tests as required under this para 4.0. The material cannot be qualified merely based on Mill test Certificates (MTC). But the Vendor has to produce MTC of all the materials for correlating the heat number. The test shall be conducted by taking at least one test-sample from each heat number and type of material.

4.1.1 The materials of construction as indicated in this specification /drawings are the minimum acceptable. The Vendor may offer equivalent or better materials subject to the Purchaser's approval. The requirements for the materials shall be governed by this specification. Materials and standard parts which are not specifically described herein and which are necessary for the fulfilment of this specification shall be of good quality and in accordance with the best practice pertinent to the manufacture of EPs.

4.1.2 All the materials designated in IS codes or ASME specification shall be subjected to tests for Chemical, Physical and other mandatory tests as required by relevant code or standard. All material test results shall be approved by the Purchaser or his representative before the material is used for the manufacturing/fabrication process.

4.2 Material for different EPs

4.2.1 C.S. Plate Material All carbon steel plate material required for the fabrication of all the EPs shall conform to all the mandatory requirements of IS 2062 Grade-B. All plates shall be chemically and mechanically tested for each heat number. All plates of thickness 20mm or more shall be Ultrasonically Tested as per ASTM—577/578.

4.2.2 C.S. Structural Material Material of all the structural components used for the fabrication of all the EPs shall conform to the requirements of IS-2062 Grade-B. All the structural material shall be chemically and mechanically tested for each heat number.

4.2.3 SS Flange Plate material required for the fabrication of SS Flanges shall conform to all the mandatory requirements of ASTM A-240 Gr. 304-L. Plates shall be chemically and mechanically tested for each heat number. The plates shall be Ultrasonically Tested as per ASTM-577/578 and also Inter Granular Corrosion Tested as per ASTM-A-262, practice-A/E. The SS flanges shall be fabricated from a single piece (without any seam).

(In case single piece plate is not available and it becomes necessary to make it by joining of two plates, the Vendor shall take prior approval of the Purchaser. Vendor shall submit the plate joining procedure & welding details to the Purchaser for approval. In such case, only full penetration welds followed by surface machining and 100% radiography shall be acceptable. Radiography shall be done as per ASME Section III, Division 1 Subsection NC. Penetrameter specification shall be of 2-4t. Sample weld shall be Inter Granular Corrosion Tested as per ASTM-A-262, practice-A/E. Delta Ferrite (FN) determination Test shall be carried out on the test piece for welder qualification and also on the fabricated piece as per the requirements of NC-2433 of ASME Section III, Div 1,

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Subsection NC. The acceptable delta ferrite number shall be 5 to 10FN. Joining of more than two plates shall not be acceptable.)

4.2.4 SS Drain Pipes & Fittings The SS drain pipes and fittings shall be seamless pipe as per the requirements of ASTM A-312 Gr. TP304-L Stainless Steel, Grade 304L. Material shall be chemically and mechanically tested.

4.2.5 Threaded Fasteners Fasteners used shall be of Stainless Steel (SS-304 Gr. B8) with SS 304 washers. The threaded fasteners shall conform to the following specification.

Bolts/Studs SS-304 Grade B8, as per ASTM – A – 193

Washers SS-304, as per ASTM – A – 240

Note: Fasteners sets (bolt/studs with washers) shall be supplied 20% extra.

4.2.6 Hold Fast /Anchor Rods and C.S. Template All carbon steel Anchor Rods (Hold Fast) and template material shall conform to IS 2062 Grade-B. TMT reinforcement bars may also be used for Hold fast / Anchor Rods. Material shall be chemically and mechanically tested.

4.2.7 SS cover Plate Plate material required for the fabrication of SS Cover Plate (6thk.) of Shielding Experimental Facility EP shall conform to ASTM A-240 Gr. 304-L. Material shall be chemically and mechanically tested. The plates shall be Inter Granular Corrosion Tested as per ASTM-A-262, practice-A/E.

4.3 Welding Materials 4.3.1 All welding material used in the construction and repair of components shall be low

hydrogen electrodes conforming to the ASME Sec. II /ASTM-SFA specification as mentioned in para 3.1.3 of this specification. The requirements of ASME Section IX shall be met for applicable qualified welding procedure specification.

4.3.2 Only NPCIL (Nuclear Power Corporation of India Ltd.) or BARC approved brands filler wires/electrodes shall be used in welding.

4.3.3 SS flanges, if in case are fabricated by welding of two plate pieces, the welding shall be tested by 100 % radiography and Inter-granular Corrosion (IGC) Tested as per the requirements of ASTM-A-262 practice A/E. The sample specimen for IGC shall be taken from a weld pool of the same material. Delta Ferrite (FN) determination Test shall be carried out on the test piece for welder qualification and also on the fabricated piece as per the requirements of NC-2433 of ASME Section III Subsection NC. The acceptable delta ferrite number shall be 5 to 10FN.

4.3.4 Proper identification and inventory control of all accepted/approved welding material shall be maintained throughout the process of fabrication of the Components.

4.3.5 Welding electrodes and filler wires used for welding shall be as per the following:-

C.S to C.S Welding E7018

S.S to S.S Welding E308L/ER308L

C.S. to S.S Welding E309L

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5.0 FABRICATION DRAWINGS

5.1 After the award of contract, Vendor shall submit the copies of material specifications and detailed fabrication drawings as called for in this specification within a period of 15 days of placement of order for Purchaser’s review and approval.

5.2 The fabrication drawings shall be made based on this specification, codes and standards, the component data sheets and/or drawings. These drawings must be in sufficient detail to show bill of materials and method of construction, weld details, dimensions, and any other information necessary to permit the Purchaser to check against this specification including data sheets and/or drawings.

5.3 Drawings submitted for approval shall be signed by responsible representative of Vendor and shall be of any one of the following sizes in accordance with Indian Standards: A0, A1, A2, A3 or A4.

5.4 All drawings shall show the following particulars in the lower right hand corner in addition to Vendor’s name:

a) Name of Purchaser b) Project Title c) Purchase order no. d) Title of drawing e) Scale f) Angle of projection g) Date of drawing h) Drawing Number (Apart from Vendor’s number, the Purchaser’s number

shall also be mentioned on the drawing) i) Revision Number

5.5 All dimensions on drawings shall be in metric units. In addition to the information provided on drawings, each drawing shall carry a revision number for revised drawings, date of revision and brief details of revisions carried out. Whenever any revision is carried out, corresponding revision number must be updated.

5.6 Purchaser shall return to Vendor either (a) one print stamped `Approved’ or (b) one print stamped `Approved with comments as noted’ or (c) one print marked with comments. In the case of (a) no further submission of the drawings is required. In case of (b) Vendor shall correct his original drawing to conform to comments of Purchaser and furnish the corrected drawings to Purchaser for the purpose of records. In case of (c) Vendor shall correct his original drawing to conform to comments and corrections of Purchaser and resubmit the drawings to Purchaser within two weeks after receipt of the marked-up print for approval.

5.7 Drawings submitted by Vendor for approval will be checked / reviewed by Purchaser and comments, if any, on the same will be conveyed to Vendor. It is the responsibility of Vendor to incorporate correctly all the comments conveyed by Purchaser on Vendor’s drawings. The drawings, which are approved with comment, are resubmitted to Purchaser for purpose of records. Such drawings will not be checked/ reviewed by Purchaser to verify whether Vendor has incorporated all the comments. If Vendor is unable to incorporate in his drawings certain comments he shall clearly state in his forwarding letter such non-compliance along with valid reasons. He shall proceed for the job only after receiving written approval of Purchaser for such non-compliance.

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5.8 Any work performed or material ordered by Vendor prior to receipt of drawings stamped `Approved’ or `Approved with comments as noted’ by Purchaser shall be at the risk of Vendor. After a print of any drawing has been returned ‘Approved’, Vendor may release all parts covered by the drawing, for the production.

5.9 Changes, if any, required after approval of drawings shall be done only after obtaining written clearance from the Purchaser. It shall be the responsibility of the Vendor to incorporate such changes in the relevant drawings.

5.10 The reproducible of all as built fabrication drawings shall be submitted in five copies after the fabrication is completed. These should be of quality not less than a Kilburn Reproducible tracing film or equivalent capable of producing the clear legible prints. ‘Sepia’ or similar process reproducible shall not be accepted. AutoCAD drawings on compact discs shall also be provided.

5.11 Contractor shall not start manufacturing before approval of drawings and applicable procedures.

5.12 The Purchaser’s approval of the contractor’s drawings does not relieve the contractor of any responsibility with respect to fabrication of the components in accordance with the code requirements.

6.0 FABRICATION

The Vendor shall submit to the Purchaser the detailed fabrication plan and Quality Assurance Plan (QAP) for their approval indicating hold points prior to the commencement to the fabrication. Vendor shall execute the fabrication and testing activities as per the approved fabrication plan and approved QAP.

The vendor shall not weld the SS Flange to the EPs without the prior approval of the purchaser.

The vendor shall intimate the purchaser before cutting the O-ring grooves on the SS Flanges. The grooves shall not be cut without the purchaser's approval.

6.1 Materials and Layout Prior to fabrication, all the materials shall be checked and confirmed to be of the required quality for the intended purpose. Materials shall be subjected to mechanical tests, chemical analysis and any other supplementary tests as required by this specification. Mill test certificate (MTC) of all the material shall be submitted correlating the heat number. Moreover, one test sample from each heat number and type of material shall be tested in NABL /BARC approved laboratory as per the relevant codes /standards.

Prior to cutting of any plate, the Vendor shall intimate the Purchaser for transfer of identification mark so as to ensure that all the individual plates or parts thereof used for the fabrication of the components carry the Purchaser’s identification mark.

Materials of all parts shall be identified, stamped by the Purchaser's representative with material marks so that they can be identified after fabrication of the component. Punching shall be done using blunt tip punch and the depth of impression shall not be more than 2mm.

6.2 Cutting and Aligning Wherever the tolerances are not mentioned in the drawings it shall be as per IS-7215. The plates and other parts may be cut to shape and size by mechanical means such as machining, shearing, grinding, or by oxygen, arc or plasma cutting. After oxygen or arc

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cutting, all slag and detrimental discoloration of material which has been molten shall be removed by mechanical means prior to further fabrication or use.

The SS flanges shall be cut by plasma cutting or by grinding, but gas cutting shall not be used. Welding edges shall be shaped accurately by machining or grinding by the use of jigs or other appropriate means. In case of plasma cutting, a minimum of 4mm material from the cut edge shall be removed by grinding or by machining. Vendor shall ensure that there are no defects on the cut edges of the plates by carrying out visual examination.

Machining of flanges, etc. shall be done accurately and surfaces shall conform to as indicated in the approved drawings. In any case, the thickness shall not be less than the minimum required thickness specified in the drawings.

Parts that are to be joined by welding may be fitted, aligned, and retained in position during the welding operation preferably by the use of tack welds, or temporary attachments.

6.2.1 Template for Thermal Column: A template fabricated by BARC (size 2.9m x 2.7m; wt. 200kg) shall be supplied by the purchaser. Drilling of the boltholes in Thermal Column EP shall be done only with the help of this template. For aligning the template with the EP, the vendor shall mark the centerline of the CS box onto the EP structure and align the template with the centerline. Necessary temporary attachment/fixures to hold the template in place shall be made by the vendor. Prior to drilling the boltholes, the vendor shall intimate the purchaser who shall inspect the alignment of the template with the EP. The vendor shall not drill the boltholes without the approval of the purchaser.

6.3 Machining The SS flange surfaces and the O-ring grooves shall be machined as per the drawings to obtain a surface roughness as follows:

S.S Flange front surface 3.2 µ

S.S Flange back surface 12.5 µ

O-ring Grooves surfaces 1.3 µ

S.S Flange overall flatness 50 µ or better

C.S Flange front surface 12.5 µ

Machining is also applicable for the drilling of bolt holes and tapping of bolt holes.

Vendor shall manufacture templates for drilling of bolt holes in SS Flanges and hand over the same to the purchaser.

6.4 Welding Processes The welding processes used for the welding of the joints shall be SMAW. The Carbon Steel to Carbon Steel weld shall be done using E 7018 electrodes/filler wire, Stainless Steel to Stainless Steel weld shall be done using 308-L electrodes/filler wire and Stainless Steel to Carbon Steel welding shall be done by 309-L electrodes/ filler wire. Only those welding process which are capable of producing qualification requirements of ASME Section IXshall be followed.

No production welding shall be undertaken until the Purchaser has qualified the welding procedures. The method used to prepare the base metal shall leave the weld preparation with reasonably smooth surfaces. The surfaces for welding shall be free of cracks, deep indentations, scale, rust, oil, grease, and other deleterious material. The

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work shall be protected from deleterious contamination and from rain and wind during welding. Welding shall not be performed on wet surfaces.

The specification of electrodes/filler wires, voltages, welding speed, current, polarity and the gas flow rate (for GTAW) shall be as specified in the approved welding procedure. Any deviation from the approved procedure will be treated as objectionable and shall disqualify the procedure and the welder or the welding operator.

The welding procedure shall be such as to assure substantially full root penetration and through fusion in the lands of the root and in the entire weld preparation. Only stringer bead is allowed for root pass. Welding can be carried out by SMAW method. Each pass of weld metal in a multi pass welding shall be cleaned of slag and other deposits before applying the next pass.

Welding electrode shall conform to the requirements of ASME Section-II part-C SFA 5.1 (Carbon steel) SFA 5.4 (Stainless Steel).

Tack welds should be made by a qualified welder and as per welding procedure and shall be ground or removed completely when the purpose is served. The back gauged surfaces shall be thoroughly cleaned prior to filler welding by GTAW. Procedure for back gauging shall be approved by the Purchaser.

6.4.1 Qualification of welder’s, welding operator’s and welding procedures Welding procedures employed shall be such as to produce welds of complete fusion, proper penetration, and free from unacceptable defects. Welding procedures and welders used to join permanent or temporary attachments to make permanent or temporary tack welds shall be qualified by the supplier in accordance with section IX of ASME Boiler and Pressure Vessel code with welder’s photo in WPS. The welder qualification shall be conducted in presence of Purchaser’s representative. A copy of written welding procedure, welding procedure qualification tests report, welder’s performance qualification report shall be submitted to the Purchaser. Removal of test coupons from welds and dimensions of specimen made from them for conducting the tests shall be in accordance with section IX. These documents, after approval by the Purchaser shall be incorporated into the fabrication record.

6.4.2 The Inspector/Purchaser’s representative has the authority to reject any unsatisfactory process, operation, or workmanship at any stage of fabrication.

6.4.3 Weld defects shall be removed by suitable mechanical means. Repaired welds shall be re-inspected in accordance with the original weld inspection procedures.

6.5 Distortion Control 6.5.1 Welding distortion of fabricated items shall be minimized to the maximum extent

possible by following proper welding sequence, low heat input in welding and by using suitable clamps and fixtures so that the required tolerances are achieved. In doing so, care shall be taken to avoid excessive residual stress. Heat input in welding shall be restricted to 1500J/mm.

6.5.2 Adequate care has to be taken to avoid distortion during handling /loading /unloading and transportation of all the EPs / structures.

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7.0 INSPECTION & TESTING

7.1 General 7.1.1 The Vendor shall be responsible to perform all examination and testing in accordance

with the requirements of ASME Section III, Division-1 Subsection-NC and ASME Section-V in addition to the requirements specified herein. Inspection of welds shall be as per ASME section IX ‘Welding and Brazing qualification’.

7.1.2 All non-destructive examination shall conform to the relevant ASTM /ASME Codes in accordance with the written procedures approved by the Purchaser.

7.1.3 Unless otherwise stated, all inspection/test shall be conducted in the presence of the Purchaser and/or his authorised representatives. The Vendor prior to performing test shall submit all the test procedures for Purchaser’s approval. All the test results and the necessary test certificates shall be submitted after the tests for the Purchaser’s approval.

7.1.4 Any welding repair requires prior permission of the Purchaser.

7.1.5 Vendor shall provide all facilities and services for inspection and testing. The records of these inspection and test reports shall be properly maintained and made available to the Purchaser for his approval /reference whenever required.

7.1.6 Vendor shall give due notice to Purchaser in advance of the materials or workmanship getting ready for inspection. All rejected material shall be promptly removed from the shop and replaced with new material for Purchaser’s approval/inspection. The fact that certain material has been accepted at Vendor’s shop shall not invalidate final rejection at site by Purchaser if it fails to be in proper condition or has fabrication inaccuracies that prevent proper installation /assembly.

7.1.7 No part /material or weld area shall be painted or dispatched to site without inspection and approval by Purchaser unless such inspection is waived in writing by Purchaser.

7.1.8 All EPs shall be visually & dimensionally checked in accordance with the drawings.

7.1.9 Inspection of component assemblies shall be carried out as per the approved QAP.

7.1.10 Stage wise inspection shall be as per the following: Preliminary Inspection

A preliminary inspection will be made prior to fabrication of the components, to check materials, welding procedures, welder qualifications and testing of materials. It is the manufacturer’s responsibility to transfer the heat mark at all stages of fabrication.

Intermediate Inspection

Intermediate stage inspections will be made to check the weld fit-ups like root gap, alignment, angle of groove, NDT on root runs, back chipping, edge preparation and orientation, attachment details and preheat temperature deemed necessary by the inspector to ensure that the fabricator’s work meets the requirements of the contract.

Final Inspection

After fabrication is complete, a final inspection shall be made to ensure completeness of fabrication and assembly. This inspection will include radiographs, stress relieving charts, and other specified non- destructive tests, checking as built dimensions, alignment of component parts, tilt, orientation of components, surface finish, assembly testing at shop etc.

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7.2 Inspection on Test Failure In the event the EPs or any part thereof fails to meet the examination or test requirements specified herein, the Vendor shall notify the Purchaser. The Vendor shall obtain written permission from Purchaser before repair and subsequent use of any part. If the repairs, including redesign, are likely to affect the results of examination and tests or work previously completed, appropriate re-examination, re-inspection and re-testing shall be conducted.

8.0 EXAMINATION

8.1.1 The non-destructive examination (Except RT) shall be conducted in accordance with ASME Section V. The radiographic testing (RT) shall be carried out as per ASME Section III Div.1- NC. The results of all examinations shall be evaluated in accordance with the acceptance standards given under each examination in these specifications.

8.1.2 All non-destructive examinations performed under this specification shall be executed in accordance with detailed written procedures, which have been proven by actual demonstration to the satisfaction of the inspector. Written procedures and records of demonstration of procedure capability and personnel qualification shall be made available to the Inspector on request. At least one copy of the approved procedure shall be readily available to all applicable non-destructive examination personnel for reference and use.

8.1.3 Following any non-destructive examination in which examination materials are applied to the component, the component shall be thoroughly cleaned with applicable materials in accordance with this specification.

8.1.4 All welds shall be examined by Liquid Penetrant Test (LPT) as per ASME Section V, Article 6 at root and final pass and LPT shall be done after flush grounding the weld surface. 100% of all the butt-welded joints in the components shall be tested by radiography as per ASME Sec. III -NC.

8.1.5 SS flanges, if in case are fabricated by welding of two plate pieces, the welding shall be tested by 100 % radiography and Inter-granular Corrosion (IGC) Tested as per the requirements of ASTM-A-262 practice A/E. The sample specimen for IGC shall be taken from a weld pool of the same material. Delta Ferrite (FN) determination Test shall be carried out on the test piece for welder qualification and also on the fabricated piece as per the requirements of NC-2433 of ASME Section III Subsection NC. The acceptable delta ferrite number shall be 5 to 10FN.

8.1.6 Radiographic Examination S.S. Flanges (40 mm thk.) will be fabricated from single piece plates. However, in case, if the SS Flanges are to be fabricated from two pieces with full penetration butt weld, the welds radiographic examination shall be done in accordance with ASME Section III Div.1- NC. Radiography shall be carried out by X-ray source only and shall meet the sensitivity and acceptance standards. Only in exceptional cases, use of gamma rays can be permitted. However, the sensitivity requirements shall be met with gamma rays also. The minimum sensitivity requirement should be 2-4t.

8.1.7 Ultrasonic Examination Ultrasonic Examination shall be in accordance with ASME Section V, Article 5.

Ultrasonic test shall be conducted on all the CS plates having thickness of 20mm or more, on SS plates and also on the welds where radiography test is not possible. All

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indications which produce a response greater than 20% of the reference level shall be investigated to the extent that the operator can determine the shape, identity and location of all such reflectors and evaluate them in terms of the acceptance/rejection standards. The Ultrasonic Testing shall be performed as per ASTM A-577/578.

8.1.8 Liquid Penetrant Examination a) Liquid Penetrant Examination shall be in accordance with ASME Sec. V, article 6. b) Halogen free chemical shall be used for dye, developer and cleaner. c) Mechanical discontinuities at the surface will be indicated by bleeding out of the

penetrant; however, localized surface imperfections as may occur from machining marks, surface conditions or an incomplete bond between base metal and cladding may produce similar indications that are non-relevant to the detection of unacceptable discontinuities.

8.1.9 Vacuum Box Test All the welds on the front plate of Shielding Experimental Facility EP shall be checked by Vacuum Box Test in addition to Liquid Penetrant Testing on root and final pass. The Vacuum Box Testing shall be in accordance with ASME Section V, Article 10. The weld shall be acceptable when there is no formation of bubble during the testing.

8.1.10 Examination/Test Acceptance Criteria

Sr. No.

Test/Examination Procedure Acceptance Criteria

1 Radiography Test ASME Sec. III, Div.1, Sub section NC

ASME Sec. III, Div.1, Sub section NC

2 Ultrasonic Test ASME Sec. V, Article 5 3 Liquid Penetrant

Test ASME Sec. V, Article 6

4 Delta Ferrite (FN) Determination Test

ASME Sec. III, Div.1, Sub section NC

5 Vacuum Box Test ASME Sec. V, Article 10

8.1.11 Cleaning a) All surfaces of the stainless steel parts, all the weld joints and heat affected zones

shall be passivated by applying the paste containing 10% by volume HNO3, 5% by weight Na2Cr2O7.2H2O at about 500C for 15 minutes. Then it shall be washed thoroughly by demineralised water to remove the solution completely. Finally water shall be used to rinse the passivated surface to eliminate the contamination of acids.

b) All the parts shall be thoroughly cleaned internally and externally to free all accessible surfaces from oil, grease, scale, rust, chips, organic matter and all other potentially harmful foreign matters.

c) After cleaning, the components shall be dried with hot oil free air.

d) Acid presence on the weld surfaces shall be checked by litmus paper & ensured to be acid free.

9.0 REJECTION

If the Material, Fabrication, Examination, Inspection or Testing is not in conformance to the requirements /intent of this specification, the component will be rejected.

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10.0 PROTECTION AND PAINTING

10.1 Structures /EPs shall be fabricated by the good practice of workmanship and fabrication shall be carried out in neat & clean manner. All exposed metal surfaces shall be made smooth and free from burrs. Welds shall be ground & finished. Exposed surfaces shall be protected against corrosion and mechanical damage.

10.2 All carbon steel parts shall be thoroughly cleaned to remove mill scales, rust, weld splatters, etc. After thoroughly cleaning, two coats (with minimum interval of 24 hrs.) of Zinc Chromate primers conforming to IS 2074 shall be applied by paint-brush at a rate of and in manner, prescribed by paint manufacturer. Thickness of the primer coating shall be 40 microns.

10.3 Primer coating shall be followed by two coat of Yellow epoxy paint of reputed make applied by paint-brush/spray at a rate of and in manner, prescribed by paint manufacturer. The overall thickness shall be 80 microns.

10.4 Stainless steel components shall not be coated with any type of Primer, chemical or Paint.

10.5 Painting or applying Primer on any surface of the EP structure shall not be started without final inspection and clearance from the Purchaser for doing so.

10.6 All parts shall be properly protected for preventing any possible damage to the paint during transportation.

10.7 No painting shall be applied until all repair, and final shop inspection are completed, but shall be applied prior to shipment. Prior approval from the Purchaser shall be taken for qualifying the paints (colour, quality etc.).

10.8 Machined surfaces shall be suitably protected.

11.0 TOLERANCES

General tolerances on dimensions (length/diameter) unless otherwise specified shall be as per IS-7215.

12.0 RIGHTS AND PRIVILEGES

12.1 Purchaser reserves the right to inspect any machinery, material, or equipment furnished or used by Vendor under the contract and to reject any, which is found defective in workmanship or design, or otherwise unsuitable for the use and purpose intended, or which is not in accordance with the intent of the contract.

12.2 Should Purchaser waive the right to inspect any equipment, such waiver shall not relieve Vendor in any way of his obligations under the contract.

12.3 Purchaser or Purchaser’s representatives shall be permitted free access to Vendor’s or his sub- Vendor’s shop at all working hours for the purpose of inspecting work at all stages of progress.

12.4 Purchaser’s representative shall be provided full assistance in the form of necessary tools, instruments, equipment and qualified operators to facilitate inspection.

12.5 Purchaser reserves the right to call for certificates of origin, and test certificates for all raw material and equipment at any stage of manufacture.

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12.6 In the event of Purchaser’s inspection revealing poor quality of goods, Purchaser shall be at liberty to specify additional inspection procedures, if required, to ascertain Vendor’s compliance with the Equipment Specifications.

12.7 The Purchaser shall have the right to conduct any additional examination, inspection or testing he deems necessary. At the request of the Purchaser the Vendor shall re-examine, re-inspect, or re-test any components. Defects, if revealed, during such inspection / test, which do not meet the requirements of this specification shall be cause for rejection of the component, or alternatively for repair and subsequent re-examination, re-inspection and re-testing. Re-examination, re-inspection and re-testing both before and after repair shall be at the expense of the Vendor.

12.8 Even though inspection is carried out by Purchaser or his representative, such inspection shall not however relieve Vendor of the responsibility for furnishing equipment conforming to the requirements of the contract, nor prejudice any claim, right or privilege that Purchaser may have because of the use of defective or unsatisfactory equipment.

12.9 Vendor shall keep a set of latest prints of the approved drawings available, on the shop floor for reference of Purchaser’s representative during the inspection.

12.10 Any error in shop work that prevents proper assembling /installation or fitting up of parts etc. will be classified by Purchaser as defective workmanship. In case Purchaser rejects the material, the cost of all handling and returning the material to Vendor, shall entirely be to Vendor’s account. All the replacement materials shall be supplied free and in all such cases, the cost of handling, transport and delivery to site shall be borne by Vendor.

13.0 DOCUMENTS REQUIRED WITH BID

Quotation shall be submitted in the format given in 'Annexure-1' along with the following information:

1. Fabrication schedule plan. 2. Financial Status of the company for last three years. 3. Guaranteed life (As per para 16.0 of this specification). 4. Complete list of deviations from this specification, if any. 5. Fabrication, inspection, testing and delivery schedule. 6. A list of DAE Units (Dept. of Atomic Energy) and other reputed parties to whom

the company has supplied components similar to this specification along with the purchase order number, date and contact details.

7. Document showing experience of erection work of similar and heavy jobs particularly in nuclear installation.

8. Packing and Transportation procedure in brief for the EPs. 9. List of Machineries available with the Vendor. 10. Manpower details of the organization.

Note:- In case of non submission of the above documents along with the quotation, the offer may be considered for rejection.

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14.0 DOCUMENTS REQUIRED AFTER AWARD OF CONTRACT

14.1 Three copies of the following shall be submitted by the Vendor for review and the approval of the Purchaser:

1. Detailed plan for the engineering and manufacturing programme (shall be submitted within two (2) weeks from the placement of purchase order for approval). Fabrication shall commence only after getting approval from the Purchaser.

2. Detailed Quality Assurance Plan (QAP) indicating the stage wise inspections and hold points of the Purchaser.

3. Detailed drawings of the components indicating dimensions, part list, bill of materials, details of welds, details of bolts, weights of the components etc.

4. Fabrication drawings of each part of the components. 5. WPS, PQR and welder qualification record. 6. Mechanical test procedures and material test reports 7. Liquid Penetrant procedure and weld test reports. 8. Radiographic test procedure and RT test reports. 9. Ultrasonic examination procedure and UT test reports. 10. Welding & weld repairs procedure. 11. Cleaning procedure. 12. Painting procedures. 13. Other inspection/test procedures, if any. 14. Stress relieving procedure and chart.

14.2 Bar chart showing detailed fabrication, cleaning, inspection, testing and delivery schedule shall be submitted for Purchaser’s approval and fabrication shall be started only after getting Purchaser’s approval. Three copies of approved procedures shall be submitted after the Purchaser’s approval.

15.0 HISTORY DOCKET REQUIREMENTS

Vendor shall maintain all records related to structure/components fabricated by him and FOUR (4) copies of such records in the form of HISTORY DOCKET (Hard Cover Bound Volumes) shall be supplied by the Vendor for each structure (i.e. Separate History Docket for each EP). The docket shall include all the relevant tech. documents related to each EP structure, the document mentioned in para 14.0 and the following at least.

a) Purchase order copy b) Approved drawing, fabrication drawings c) Approved Q.A.P. d) Approved NDT test procedure e) Approved stress relieving procedure f) Approved Material test reports. g) Approved Welding procedure and welder qualification reports. h) Stage wise testing reports such as fit-up checks, dimensional checks, NDT done

on welds and any other test done by the Vendor/ Purchaser. i) Shop test and functional tests reports etc.

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j) Final dimensional check and AS BUILT DRAWING of the structure/ component. k) Copy of Design Concession Record’s (DCR’s) approved by Purchaser. l) Copy of shipping release given by Purchaser. m) Acceptance of finished material delivered at Purchaser’s site.

16.0 GUARANTEE

16.1 The Vendor shall warrant that the goods are new and of high quality and that the goods will be free of defects in design, materials, fabrication and workmanship as per the requirements of this technical specification for a period of twelve months (12) months after completion of delivery of the components to the Purchaser’s site. The Vendor shall furnish specific storage instructions, if any, to meet the guaranteed performance values after the storage period of 12 months.

16.2 If within the expired time of the above stipulated guarantee period, the subject goods or any parts thereof are found defective because of poor workmanship or materials, the Vendor at his own expense, shall repair or furnish and install replacement parts of the workmanship and material approved by the Purchaser. The guarantee period for replaced parts or repair work shall be the same as above.

16.3 The guarantee period shall be extended by the length of time required to make any adjustments, changes or repairs necessary to fulfil the guarantee.

16.4 The Vendor shall obtain similar guarantees from each one of his sub-Vendors, if any. However, the overall responsibility shall lie with the Vendor.

17.0 PREPARATION FOR SHIPMENT

17.1 Packing The components shall be prepared for shipment in accordance with the instructions stated below. 1. The Template of SS Flanges shall be fastened with the SS Flange before dispatch

for transportation. Suitable gaskets shall be provided in between Template and SS Flange.

2. All structures shall be wrapped adequately with thick polythene sheets to protect the structures from damage due to dust and moisture.

3. All openings in the structures shall be tightly covered, plugged or capped to prevent foreign material from entering. Metal caps should be minimum 3 mm thick and wooden cap should be minimum 20 mm thick.

4. All structures shall be properly braced & packed in wooden structure of adequate thickness and dimensions and shall be proportional to the size and weights of contents. The packing material constructed shall be using sound material only. Instruction for lifting the packages by cranes shall be clearly marked on the packages.

5. All structures shall be packed and transported in such a way that there shall be no damage during handling and transport. During transportation, the EPs shall be protected against shocks and other jerks. Vendor shall be responsible for any damage during transportation due to inadequate packing / bracing.

6. Joint- Inspection shall be carried out by Purchaser & Vendor after delivery of material at Purchaser’s site and payment shall be released only after Purchaser certifies that the material is accepted. Vendor without any extra cost shall supply any material found short inside the intact packing cases.

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7. All packing cases and packing material shall become the property of Purchaser. 8. Before the EPs are packed, they shall be carefully checked to be sure that all

extraneous matter such as rags, tools, rubbish foreign matter, loose scale and dirt weld rod stubs etc. have been removed. All the tapped holes in SS flanges shall be plugged with removable caps.

9. Loose materials, if any, shall be packed in gunny bags and sealed in polythene bags with proper tagging.

10. The components shall be protected for the entire period of dispatch and storage against corrosion, incidental damage due to vermin, sunlight, rain, high temperature, humid atmosphere, rough handling in transit and storage in the open including possible delays in transit.

11. The packing list in duplicate, containing details of components for verification at site shall correspond with the advice note.

17.2 Marking All the packages shall be clearly, legibly and durably marked on both sides with:

1. Destination address as communicated. 2. Purchase Order No. and Date. 3. Dimensions. 4. Net and Gross weights. 5. Sign showing `Way Up’. 6. Sign showing slinging and sling position. 7. Centre of Gravity (CG). 8. Any handling and unpacking instructions, if considered necessary. 9. All marking shall be made with uniform block letters using waterproof paint. 10. The contents of the package shall be punched on non-corrosive metal plate and

nailed on to the package on a prominently visible place. If the numbers of items in the package are too many, a typed list sealed in transparent water-proof bag shall be kept inside a galvanized steel cover which is nailed on to the outside of package in a prominently visible location.

11. Each spare part shall be clearly marked and labelled on the outside of its packing with its description and catalogues/part number.

18.0 TRANSPORTATION

18.1 Transportation of all the fabricated structures/components and the Template for Thermal Column (supplied by BARC) to the Purchaser’s stores and unloading it there shall be Vendor’s responsibility. Vendor shall be solely responsible for damages during loading, transportation and unloading. Damages in the structures shall be informed to the Purchaser and corrected/ replaced free of cost after getting permission of Purchaser. The corrected/replaced structures shall be subjected to inspections by the Purchaser.

18.2 The vendor has to make necessary transportation arrangement for picking up and transporting the Template (supplied by BARC) for drilling boltholes in Thermal Column EP from the purchaser's site to his workshop. After drilling of the boltholes in the Thermal Column EP with the help of the template, the template shall be returned and unloaded at the purchaser's site.

18.3 Vendor shall be responsible for ascertaining transport limitations for the delivery of fabricated structures between his workshop and the Purchaser’s stores.

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18.4 Adequate number of temporary lifting lugs shall be provided on each EP structure to facilitate the loading and unloading.

18.5 No material shall be dispatched without 'Shipping Release' /written consent issued by the Purchaser.

18.6 Vendor shall intimate at least fifteen (15) days in advance to the consignee as well as to the concerned Engineer at site, the probable date when the components are to be ready for dispatch. A packing list also shall be sent along with this.

18.7 Components shall be dispatched with the necessary tools and tackles for unloading. The required crane and riggers shall be provided by the vendor for unloading the component at BARC, Trombay Site. Since BARC is a high security zone, the vendor shall keep in mind the restriction regarding the movement of vehicles inside the BARC campus and plan accordingly.

19.0 DELIVERY

The delivery of all the EP Structures /components shall be within six (06) months from the date of placement of the Purchase Order at the BARC, Trombay site, Mumbai-400 085.

20.0 QUOTATION

20.1 Vendor shall give his quotation on per piece of fabricated EPs/Structures basis as shown in the attached “Price Schedule Format” (Refer Annexure-1)

20.2 Sales Tax and Surcharge as applicable shall be furnished separately in the “Price Schedule Form”

20.3 Vendor shall be responsible to consider all the applicable taxes /duties etc. regarding exemption /relaxation of any Govt. Taxes /duties against supplies to BARC, Mumbai. Vendor will clarify the same with NRBPSU, Anushaktinagar, Mumbai -94) before submitting the quotation.

20.4 Packing, forwarding and transportation cost for each structure shall be given separately in the “Price Schedule Form”.

20.5 Purchaser reserves the right to place full or part order on Vendors without assigning any reason. An acceptance in this regard shall be mentioned by the Vendors in their quotations.

21. Vendor Qualification Criteria:

21.1 Financial: Vendor should have send financial background including no loss in last three years & minimum two orders executed for 40% of tendered value in last three years.

21.2 Technical: Vendor should have in house welding, fabrication & machining facility including qualified TIG/MIG welders should have executed two similar jobs in last three years.

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***************

ANNEXURE-1

PRICE SCHEDULE FORM

Name & Address of Vendor:

1 2 3 4 5 6 7 8 9 10

Sr. No.

Structure Name Nos. Total Cost of Structure

⊗ See Note-1 (`)

Taxes + Surcharge As Applicable

(`)

Any Other Taxes or Charges

(`)

Packing, Forwarding & Transportation

Cost (̀ )

Loading /Unloading

Cost (`)

Total Cost (`)

{4+5+6+7+8}

Remarks

1. Thermal Column EP ONE

2. Shielding Experiment Facility EP

ONE

3. Manual Access Cavity EP

ONE

⊗ Note-1: Total cost shall include cost of preparation of fabrication drawings, material, fabrication, testing and inspection as required by the tender document.

# Note-2: Refer para 1.0.

GRAND TOTAL: `……………………………

Date: Authorised Signature & Seal of Vendor