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Supply – 1 Section – C Page 1 of 27

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

DIRECTORATE OF CONTRACTS & MATERIALS MANAGEMENT

PROCUREMENT OF RAW MATERIAL,MACHINING, HEAT TREATMENT,

MANUFACTURE, INSPECTION, TESTING,PACKING, SAFE DELIVERY AND GUARANTEE

OF

END FITTINGS AND ASSOCIATED COMPONENTS

FOR

RAPS-3 & KGS-1 En -Masse Coolant Channel Replacement Project

SECTION – C: TECHNICAL SPECIFICATIONS OF STORES


Tender No. CMM/OPS/00-00-9-3193

SECTION – C

TECHNICAL SPECIFICATIONS OF STORES


Tender No. CMM/OPS/00-00-9-3193 Section – C

CONTENTS

Sr. No. CONTENTS No. of Pages

1 Sub Section – C1 1.1 Special Instructions to Tenderers 9

1.2 Annexure – 1- List of Components to be supplied under Option-I (RAPS-3) 2

1.3 Annexure – 2- List of Components to be supplied under Option-II (KGS-1) 2

1.4 Annexure – 3- Standard format for Non Conformance Report 4

1.5 Annexure – 4- List of suggested sub-vendors 3 1.6 Sketch -1 for End Fitting Billet Step forging 1 2 Sub Section – C2

2.1 Technical Specifications 2.1.1 PP-E-00002 2.1.2 PP-E-00003 2.1.3 PP-E-00004 2.1.4 PP-E-00005 2.1.5 PP-E-00006 2.1.6 PP-E-00007 2.1.7 PP-E-00009 2.1.8 PP-E-00010 2.1.9 PP-E-00011

2.1.10 PP-E-00017 2.2 Tender Drawings

2.2.1 RAPS-3/31120/2403/DD Rev. 01 2.2.2 RAPS-3/31120/2409/DD Rev. 01 2.2.3 RAPS-3/31120/2411/DD 2.2.4 RAPS-3/31120/2412/DD 2.2.5 RAPS-3/31120/2413/DD Rev. 01 2.2.6 RAPS-3/31120/2415/DD 2.2.7 RAPS-3/31120/2416/DD Rev. 01 2.2.8 RAPS-3/31120/2419/DD 2.2.9 RAPS-3/31120/2420/DD

2.2.10 RAPS-3/31120/2421/DD 2.2.11 RAPS-3/31120/2426/DD 2.2.12 RAPS-3/31120/2428/DD Rev. 01 2.2.13 RAPS-3/31150/2404/DD 2.2.14 RAPS-3/31160/2401/DD 2.2.15 RAPS-3/31610/2437/DD 2.2.16 KGS-1/31120/2403/DD 2.2.17 KGS-1/31120/2409/DD 2.2.18 KGS-1/31120/2411/DD 2.2.19 KGS-1/31120/2412/DD 2.2.20 KGS-1/31120/2413/DD 2.2.21 KGS-1/31120/2415/DD 2.2.22 KGS-1/31120/2416/DD


2.2.23 KGS-1/31120/2419/DD 2.2.24 KGS-1/31120/2420/DD 2.2.25 KGS-1/31120/2421/DD 2.2.26 KGS-1/31120/2426/DD 2.2.27 KGS-1/31120/2428/DD 2.2.28 KGS-1/31150/2404/DD 2.2.29 KGS-1/31160/2401/DD 2.2.30 KGS-1/31610/2437/DD

2.3 NPCIL Procedures 2.3.1 PP-P-2014-R2 2.3.2 PP-P-2015-R2 2.3.3 PP-P-2049-R2 2.3.4 QAD-NDT-PROC-MT-04- R2 2.3.5 QAD-NDT-PROC-MT-05- R2


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

Sub-section – C-1: Special Instructions to the Tenderer Annexure – 1- List of Components to be supplied under Option-I Annexure – 2- List of Components to be supplied under Option-II Annexure – 3- Standard format for Non Conformance Report. Annexure – 4- List of suggested Sub-vendors. Sketch-1 - End Fitting billet step forging (for reference)

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 PP-E-00002 Coolant Channel End Fittings 2 PP-E-00003 Coolant Channel Liner Tube and Spacers 3 PP-E-00004 Journal Rings 4 PP-E-00005 Retaining Rings 5 PP-E-00006 Split Sleeve Assembly 6 PP-E-00007 C. S. Bellows Attachment Rings 7 PP-E-00009 Shock Absorber Assembly Yokes 8 PP-E-00010 Shock Absorber Assembly Studs 9 PP-E-00011 End Fitting Seal Bellows

10 PP-E-00017 Test Flanges for Calandria Tube rolling & Bellow rolling

2. Following applicable Tender drawings are attached.

Sr. No.

Title Drawing No.

1 Coolant Tube installation Test Rolling Ring Details RAPS-3/31120/2403/DD R1 2 End Fitting Body- Finish Machined Details RAPS-3/31120/2409/DD R1 3 Liner Tube- Finish Machined Details RAPS-3/31120/2411/DD 4 Split Sleeve Assembly & Details RAPS-3/31120/2412/DD 5 Retaining Ring Details RAPS-3/31120/2413/DD R1 6 Bellows Attachment Ring & S.S. Seal Ring RAPS-3/31120/2415/DD 7 End Fitting Body- Dimensions Code for Inspection RAPS-3/31120/2416/DD R1 8 End Fitting Shock Absorber Stud Details RAPS-3/31120/2419/DD 9 Shock Absorber Assembly Yoke Details RAPS-3/31120/2420/DD 10 Shock Absorber Fixing Arrangement & Details RAPS-3/31120/2421/DD 11 Liner Tube- Dimension Code for Inspection reference RAPS-3/31120/2426/DD 12 End Fitting Spool Pieces for Qualification of Bellows

Attachment Ring RAPS-3/31120/2428/DD R1

13 Journal Rings RAPS-3/31150/2404/DD 14 End Fitting Seal Bellows Assembly & Details RAPS-3/31160/2401/DD 15 Lattice tube for Mock up RAPS-3/31610/2437/DD


3. Following applicable NPCIL Procedures are attached.

Sr. No. NPCIL Procedure No. Technical specification Description

1. PP-P-2014-R2 Procedure for Ultrasonic Examination of Steel Forgings for General Purpose

2. PP-P-2015-R2 Procedure for Manual Ultrasonic Examination of Pipes & Tubes

3. PP-P-2049-R2 Standard Welding Procedure Specifications 4. QAD-NDT-PROC-MT-04- R2 Procedure for Magnetic Particle Testing with

Wet Horizontal / Stationary Magnetic Particle Testing machine for Hollow (ID&OD) Parts

5. QAD-NDT-PROC-MT-05- R2 Procedure for Magnetic Particle Testing with horizontal/stationery magnetic particle machine

Sr. No.

Title Drawing No.

16 Coolant Tube installation Test Rolling Ring Details KGS-1/31120/2403/DD 17 End Fitting Body- Finish Machined Details KGS-1/31120/2409/DD 18 Liner Tube- Finish Machined Details KGS-1/31120/2411/DD 19 Split Sleeve Assembly & Details KGS-1/31120/2412/DD 20 Retaining Ring Details KGS-1/31120/2413/DD 21 Bellows Attachment Ring & S.S. Seal Ring KGS-1/31120/2415/DD 22 End Fitting Body- Dimensions Code for Inspection KGS-1/31120/2416/DD 23 End Fitting Shock Absorber Stud Details KGS-1/31120/2419/DD 24 Shock Absorber Assembly Yoke Details KGS-1/31120/2420/DD 25 Shock Absorber Fixing Arrangement & Details KGS-1/31120/2421/DD 26 Liner Tube- Dimension Code for Inspection reference KGS-1/31120/2426/DD 27 End Fitting Spool Pieces for Qualification of Bellows

Attachment Ring KGS-1/31120/2428/DD

28 Journal Rings KGS-1/31150/2404/DD 29 End Fitting Seal Bellows Assembly & Details KGS-1/31160/2401/DD 30 Lattice tube for Mock up KGS-1/31610/2437/DD


Sub-Section-C1

SPECIAL INSTRUCTIONS TO THE TENDERER

1. SCOPE :

The scope of this tender document covers procurement of raw materials, machining, heat treatment, manufacture, inspection, testing, packing, safe delivery & guarantee of End Fittings and Associated Components for Rajasthan Atomic Power Station, Unit-III and Kaiga Generating Station Unit-I (RAPS-3 & KGS-1 respectively) as per Technical Specifications & drawings 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, Quality Assurance Plans, NDE procedures, Examination procedures, Testing Procedures, Surface plating procedures, packing procedures etc.

Procurement/ manufacture of all raw materials and bought out items. Manufacture, Examination/Inspection and testing of assemblies/components for

end fittings & associated components – As per quantity indicated in the tender. Packing & delivery of End Fittings & Associated Components from

manufacturer’s shop to RAPS-3,Rajasthan or KGS-1,Karnataka sites, meeting the requirement of Technical Specifications.

Supply of History dockets in both hard form (Bound volumes) and soft form. OPTION I : Quantity to be delivered to RAPS-3 as detailed in Annexure-1

OPTION II : Quantity to be delivered to KGS-1 as detailed in Annexure-2 The Purchase Orders for RAPS-3 & KGS-1 shall essentially be placed on two separate bidders.

1.1 The scope includes digital photography and video coverage for important stages of manufacture, testing, examination, qualification, loading/unloading, transportation etc. The contractor shall submit the colored 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 the end fittings, 50 shots are envisaged to cover various stages of work for the liner tubes and 200 shots are envisaged to cover various stages of work for all other components as agreed upon between purchaser and supplier. The contractor shall also include video presentation of minimum 4 hours duration (edited period) covering all stages such as qualification, manufacturing, examination/inspection, testing, transportation etc. of the entire job (1 hour for end fittings and 3 hours for other components as agreed upon between purchaser & supplier).

1.2 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, deviation from the specification/ drawing etc. the bidder is requested to send his pre-bid queries in writing to NPCIL in the prescribed format i.e. Appendix-Y attached with section A of this tender only. The clarifications will be furnished by NPCIL during pre-bid meeting with the suppliers.


1.3 The purchaser reserves the right to place the purchase order for full quantity of any one option and supplier should essentially submit his quotation accordingly for both Option-I and Option-II as required in section “E” of this tender.

1.4 Supplier/ Consortium lead Partner shall assign single coordinator as Project Manager to interact, coordinate, monitor, submitting reports of progress etc. and will be responsible to interact with various agencies till completion of work.

1.5 Supplier/ Consortium lead Partner shall ensure that major & critical activities like Finishing operations of critical components of end fittings, liner tube, journal rings etc. are essentially carried out in-house. All such activities which are planned to be carried out in-house shall be indicated during technical bid submission. Activities proposed to be carried out in-house will not be allowed to be sub contracted at any stage during execution. Sub contracting of any or all of such activities may lead to cancellation /short closure of the order. However, in unavoidable circumstances, the supplier needs to submit request with detailed reasons for shifting in-house activities to sub contractor with detailed evaluation of sub contractor, advantages of sub-contracting etc. for consideration of NPCIL and will be permitted only after written permission from NPCIL or issue of necessary amendment in the PO.

2. SUB-CONTRACT

2.1 If any item covered in this tender is proposed to be sub-contracted for forging, fabrication, machining, heat treatment, stress relieving, surface plating, 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 the 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 works 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 works shall be carried out In-house by the supplier as mentioned during technical evaluation. 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 subjected to approval of the purchaser.

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

first by the bidder and the report should be submitted along with the offer. Subsequently, NPCIL will evaluate and approve the proposed sub-contractor 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 approval of multiple sub-vendors, prior to finalization of order against the tender.

2.4 The technical specification and draft sub-PO shall be submitted to NPCIL for approval

prior to placement of purchase order. 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 sub 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.

2.6 The list of suggested sub vendors who had manufactured the End Fitting components is

attached as Annexure-4. However, prior to placement of the sub POs, the suggested Sub vendors need to be evaluated by Main vendor and approval from NPCIL shall be obtained.

3 MATERIAL PROCUREMENT/PROCESSING

All the materials shall be procured/processed and tested in accordance with enclosed NPCIL specifications & drawings attached. The Mill Test Certificates shall be submitted to NPCIL. The source of raw materials procurement/processing as well as shape, size & heat treatment condition may also be indicated. In the absence of original mill test certificates from reputed source, material shall be tested to specification/ drawing requirements as per approved QAP.

Stainless Steel AISI 403 (Modified) End Fitting billets as per Sketch no: RAPS-3 or KGS-1/311200/01/SK shall be sourced from indigenous supplier. The list of suggested Sub Vendors is attached as Annexure-4.

4 PROTOTYPE

The bidder shall initially manufacture 10% or 10 nos. (which ever is less) each of the item as prototype (except gauges). Only after approval of prototype by the purchaser, production clearance shall be given. Accepted prototypes can be included with production lot i.e. quantities mentioned in Annexure-1 or Annexure-2. However, supplier on his own risk can take “lots” of more than 10 nos. In this case, NPCIL will randomly select 10 nos. as prototype for qualification and rejection of any components may cause rejection of full lot.

5 GAUGES

Attention is invited to para 5.4.10.5 of specification no. PP-E-00002 for gauges (L27, L30, B10, C3 & C5) of End Fittings. At the completion of this contract qualified suppliers shall verify the accuracy of the working & master gauges being used by them during inspection of end fitting at shop (L27, L30, B10, C3 & C5) duly certified by the purchaser’s QS engineer and clean, preserve and pack them for shipment to RAPS-3 or KGS-1 site. This will be in addition to supply of one new set of each working & master gauges.

6 MANUFACTURING DOCUMENTS & PROGRESS REPORTS 6.1 Wherever, forgings are used, bidder shall prepare & submit 3 sets of forging drawings and

manufacturing process sheet drawings for approval of NPCIL. Only upon their approval by NPCIL, the manufacturing is to be taken up.

6.2 The contractor shall record all duly approved deviations, concessions, changes etc. which

occurred throughout the manufacturing, examination/inspection and testing stages. 6.3 Being Class-1 and critical component, it is preferred not to have any deviation from the

drawing/ specifications requirement. However, in case it occurs 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 the 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-3 for the approval of the purchaser.

6.4 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.

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

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

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

stages of manufacture / Examinations or any such examination/testing etc. and the same shall be made available to the purchaser as & when demanded. Same shall be transferred on DVD/CD/PEN DRIVE and submitted to NPCIL on completion of each component. The quantum of digital videography / photography is given in para 1.1.

6.7 Contractor shall prepare History dockets, for all the End fittings and associated

components covered under this tender (documents not available in soft form may be scanned and compiled in PDF format) and submit 4 copies of properly bound volumes & 2 set on DVD/CD/PEN DRIVE. The History docket should contain minimum of the following documents.

I. Copies of NPCIL Purchase Order and Supplier’s sub-orders II. Manufacturer’s Test certificates and compliance certificate. III. NPCIL Shipping Releases IV. Approved Quality Assurance Plans V. Examination/Inspection reports & Test Certificates of all the raw materials VI. Material clearance records VII. Manufacturing process plans VIII. Approved NDE procedures IX. Approved Heat Treatment Procedures X. Approved Hard Chrome Plating/Zinc Plating Procedures XI. Approved Hydro test Procedure XII. Approved Packing procedures and all other approved procedures. XIII. Dimensional Inspection Reports XIV. NDE reports XV. Hydro test Report XVI. Technical Specifications XVII. List of manufacturing drawings

6.8 The Contractor shall ensure that his commitments for other contracts in no way hamper delivery schedule. The loading and availability of resources along with man power identified for execution shall be indicated in technical bid.

7 INSPECTION AND TESTING : 7.1 The supplier shall examine all the End Fittings & associated components for full

compliance with the specifications for dimensional accuracy, complete workmanship & testing as per specifications.


7.2 The supplier shall provide all the inspection and testing facilities at all stages during manufacture of the End Fittings and associated components. The examination/inspection and testing shall be done in a manner acceptable to NPCIL. If deemed necessary, NPCIL will have the right to specify additional inspection/testing other than specified in the specifications & drawing and cost of such tests/ inspection will be borne by the purchaser. The supplier shall maintain the records of all the inspection and tests and the same will be submitted to NPCIL.

7.3 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.

7.4 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 End Fittings & associated components for approval of NPCIL before implementation of the same for work.

7.5 All threaded fasteners shall be checked with standard calibrated thread gauges.

7.6 Inspection of critical closure seal face including tangential radius as given in para 5.4.5 of

NPCIL Specification No. PP-E-00002 for End Fitting Body can be done either by taking impression on lead shot or on replica & then inspecting the same by a suitable method.

7.7 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.

8 CLEANLINESS &WORKMANSHIP:

8.1 The machines and processes used for manufacture of End Fittings & Associated

components shall ensure the consistent surface finish and dimensional tolerances given in specification/ drawings.

8.2 End Fittings & associated components 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.

8.3 Clean conditions shall be maintained at all stages of machining, manufacturing,

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


8.4 Cleaning procedure shall be submitted to NPCIL for approval. 8.5 Furnace for heat treatment (Annealing, Hardening, tempering and stress relieving)

should be calibrated and shall be subjected to clearance by the purchaser or his authorized representative, with regard to uniformity of temperature on working zone, correctness of recorded indication etc., wherever need arises.

9 HANDLING, PACKING & DELIVERY : 9.1 The bidder shall have sufficient shop floor space & handling facilities available at the place

of manufacture and testing of End Fittings and associated components covered under the scope of this tender.

9.2 The supplier shall ensure that all the End Fittings and associated components are protected

against any corrosion or damage during all stages of manufacture, examination/inspection, testing, handling, transit 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 component packed during all stages of shipment by road to site, loading, stacking and storage at plant site.

9.3 The packing procedure shall be in accordance with specifications 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/packing. The crate/packing shall be clearly marked with numbers and the quantities. The End Fittings and associated components shall not be dispatched unless shipping release from NPCIL is obtained.

9.4 All openings in the components shall be protected with plastic covers/caps to prevent

entrance of dirt and ingress of moisture during shipment to plant site, storage at site and erection.

9.5 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 component and relate it to the contract.

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

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

9.7 Transshipment in transit will not be allowed and Contractor shall arrange specially hired

transport arrangement for direct delivery to respective site. 9.8 Unloading of Tendered item(s) at the Purchaser’s site shall be in the scope of Purchaser.


10 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.

10.1 Along with the technical part, the bidder shall submit following details covered under the

scope of supplier. I. Details regarding sources and schedule for purchase of raw materials, II. Loading, allocation and availability of resources along with tentative

manufacturing sequence and proposed machinery to be used for machining of end fittings, liner tubes, journal rings, specially long bores, sealing faces, grooves on ID, hub formation, surface, OD & ID grinding etc.

III. Source of forging of End Fitting billets, Journal rings, CS bellow attachment rings, Positioning assembly yokes etc.

IV. Source of bending operation of Split sleeves V. Threading operation of Positioning assembly studs & other fasteners. VI. Source of heat treatment, salt bath furnace/ Vacuum furnace for HT of tool steels,

Hard Chrome plating & zinc plating etc. VII. Details of NDE equipment & facilities, Details of qualified personnel who will be

carrying out NDT. 10.2 The supplier shall also confirm and give details of equipment & facilities for the following:

I. Chemical testing (specially for PPM level elements) II. Micro testing & Macro-graphic testing III. DPT for weld joints and metallic surfaces IV. Heat Treatment (including furnace / instrument calibration) V. Ultrasonic Testing VI. MPI for bars & finished components VII. Details of machines available to meet the specified tolerance requirements in terms

of Make, Quantity, Capacity w.r.t. X, Y & Z movement Accuracy (Positional and Repetitive)

VIII. Design capabilities IX. Stress relieving X. Hard Chrome plating & Zinc plating XI. Hydro testing XII. Boroscopic inspection XIII. Inspection of critical dimensions

10.3 The bidder shall submit sequence wise schedule for raw material procurement, testing,

manufacture, inspection, completion and delivery of all the items. The shortest delivery period of completion shall be indicated separately including the rate of supply of items per month. The bidder shall submit schedule for achieving the important mile stone stages as defined in Section-D of this tender document.

10.4 The bidder must confirm availability of minimum handling facility within shop required during various stages of manufacturing, examination/inspection and testing of end fittings.

10.5 The bidder should give their shop and machine loading plan for next Two years.


10.6 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.

10.7 The bidder shall also provide details about their previous experiences of similar job

executed by them. 10.8 In addition to above, the bidder can also give any other additional information (if

necessary) relevant to this tender.

In addition, to the above clauses certain information in the format given in Section-D against requirements of Appendix-X may also be furnished by bidder.

All information/data as 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. 11 DELIVERY SCHEDULE FROM DATE OF PLACEMENT OF PO

The delivery schedule will be 21 months from the date of Purchase Order for each of the Option-I and Option-II.

12 REJECTION OF OFFER: 12.1 The tenderer shall ensure that all information/ data as called for in this tender is submitted

with offer. If, all the required information/data is not provided in the respective part-I and part-II (price part), the offer of the tenderer shall be rejected.

12.2 The purchaser reserves right to seek additional information/ data (technical / financial or commercial ) from the tenderer during evaluation of bid.

13 GUARANTEE PERIOD The material shall be guaranteed in accordance with the provision contained in the clause 6 of General Condition of contract for supply of Indigenous Stores (Form No. GCC/SUPPLY-1/R4)

14 DISCREPANCY CLAUSE:

In case any of the specified condition/ testing/ examination etc. as given in NPCIL

technical specification, contradicts w.r.t. technical specification or any other specification, then NPCIL technical specification will govern the requirement.

15 PROPRIETARY CONDITION :

In case the bidder is not considered for this tender, drawings and specifications forming part of this tender, downloaded by bidders shall not be used by bidders for any other purpose, other than this tender, being proprietary information of NPCIL.


16 PLACE OF DELIVERY: All the items covered in this tender shall be delivered to

(i) For Option-I : Manager (Materials), Rawatbhata Rajasthan site Unit III (RAPS-3) PO: Anushakti, Dist: Kota, Rajasthan.

(ii) For Option-II: Manager (Materials), Kaiga Generating Station Unit I (KGS-1) PO: Kaiga, Dist: Uttar Kannada, Karnataka.


Annexure-1 List of Components to be supplied under Option-I (RAPS-3)

(1) List of Components required for EMCCR of RAPS-3 :

Sr. No.

Item Qty. for each Unit

Applicable Drg. No.-RAPS-3 / ____/___/DD and Spec No. ___

1.1 End Fitting Body 620 Nos. 31120/2409 PP-E-00002

1.2 End Fitting Flange for Coolant Tube Rolling

100 Nos. 31120/2403 PP-E-00002

1.3 End Fitting Spool Piece-‘C’ for Qualification of Bellow attachment ring

50 Nos. 31120/2428 PP-E-00002

1.4 End Fitting Spool Pieces-‘A’ & ‘B’ for Qualification of Bellow attachment ring

1 Each 31120/2428 PP-E-00002

2.1 Liner Tube 620 Nos. 31120/2411 PP-E-00003 2.2 Liner Tube Spacer 3872 Nos.

3.1 Journal Ring (F/M Side) 620 Nos. 31150/2404 PP-E-00004 3.2 Journal Ring (Cal. Side) 620 Nos.

4.1 Retaining Ring for End fitting 620 Nos. 31120/2413 PP-E-00005

5.1 Split Sleeve Assembly 620 Assemblies

31120/2412 PP-E-00006

6.1 Carbon Steel Bellows Attachment Ring 712 Nos. 31120/2415 PP-E-00007 6.2 Welded Hollow S.S. Seal Ring 712 Nos.

7.1 Shock Absorber Assembly Yoke 630 Pairs 31120/2420 PP-E-00009

8.1 Shock Absorber Stud 1324 Nos. 31120/2419 PP-E-00010

9.0 Shock Absorber Fixing Arrangement and Hardware Details as explained below

9.1 Threaded Fixing Block (Item No.3 ) 1350 Nos.

31120/2421

9.2 Unthreaded Fixing Block (Item No. 2) 1350 Nos. 9.3 SQ Head Screw (Item No. 4) 2700 Nos. 9.4 Hex. Nut (Item No. 5) 2700 Nos. 9.5 Hex. Lock Nut (Item No. 6) 1350 Nos. 9.6 Spring Washer –B-16 (Item No. 1) 2700 Nos. 9.7 Spring Washer B-8 (Item No. 7) 2700 Nos. 9.8 Hexagonal Soc Head Cap Screw

M4x0.7x27 Lg. (Item No. 8) 2700 Nos.

10.1 Master Gauges for dimensions L-27, C-3, L-30, B-10 and C-5

1 Set Each PP-E-00002 PP-E-00002

10.2 Working Gauges for dimensions L-27, C-3, L-30, B-10 and C-5

1 Set Each

11.1 C.S.End Piece of End Fitting Seal bellow for Lip welding Qualification

70 Nos. 31160/2401 PP-E-00011

12.1 Lattice tube for Mock-up 5 Nos. 31610/2437 PP-E-00017


(2) List of Components required for 16 Channel Mockup Facility for RAPS-3 :

Note:

1. Purchaser reserves right to obtain Price Break-up to facilitate dispatch of items in number of lots.

2. The Specification nos. given above are common & applicable for both RAPS-3 & KGS-1.

Sr. No.


Applicable Drg. No.-RAPS-3/ ____/___/DD and Spec No. ___

1 End Fitting Body 32 Nos. 31120/2409

PP-E-00002 2 Liner Tube 32 Nos. 31120/2411

PP-E-00003 3 Liner Tube Spacer 200 Nos. 4 Journal Ring (F/M Side) 10 Nos. 31150/2404

PP-E-00004 5 Journal Ring (Cal. Side) 10 Nos. 6 Retaining Ring for End fitting 10 Nos. 31120/2413

PP-E-00005 7 Retaining Ring for Lattice Tube (F/M

Side) 32 Nos. 31120/2413 PP-E-00005

8 Retaining Ring for Lattice Tube (Cal. Side) 32 Nos. 31120/2413

PP-E-00005 9 Split Sleeve Assembly 32

Assemblies 31120/2412 PP-E-00006

10 Carbon Steel Bellows Attachment Ring 32 Nos. 31120/2415 PP-E-00007 11 Welded Hollow S.S. Seal Ring 32 Nos.

12 Shock Absorber Assembly Yoke 32 Pairs 31120/2420 PP-E-00009

13 Shock Absorber Stud 64 Nos. 31120/2419 PP-E-00010

14 Shock Absorber Fixing Arrangement and Hardware Details as explained below


31120/2421


M4x0.7x27 Lg. (Item No. 8) 128 Nos.

15 Lattice tube for Mock-up 10 Nos. 31610/2437 PP-E-00017


Annexure-2 List of Components to be supplied under Option-II (KGS-1)

(1) List of Components required for EMCCR of KGS-1 :

Sr. No.


Applicable Drg. No.- KGS-1/ ____/___/DD and Spec No. ___

1.1 End Fitting Body 620 Nos. 31120/2409 PP-E-00002

1.2 End Fitting Flange for Coolant Tube Rolling

100 Nos. 31120/2403 PP-E-00002

1.3 End Fitting Spool Piece-‘C’ for Qualification of Bellow attachment ring

50 Nos. 31120/2428 PP-E-00002

1.4 End Fitting Spool Pieces-‘A’ & ‘B’ for Qualification of Bellow attachment ring

1 Each 31120/2428 PP-E-00002

2.1 Liner Tube 620 Nos. 31120/2411 PP-E-00003 2.2 Liner Tube Spacer 3872 Nos.

3.1 Journal Ring (F/M Side) 620 Nos. 31150/2404 PP-E-00004 3.2 Journal Ring (Cal. Side) 620 Nos.

4.1 Retaining Ring for End fitting 620 Nos. 31120/2413 PP-E-00005

5.1 Split Sleeve Assembly 620 Assemblies

31120/2412 PP-E-00006

6.1 Carbon Steel Bellows Attachment Ring 712 Nos. 31120/2415 PP-E-00007 6.2 Welded Hollow S.S. Seal Ring 712 Nos.

7.1 Shock Absorber Assembly Yoke 630 Pairs 31120/2420 PP-E-00009

8.1 Shock Absorber Stud 1324 Nos. 31120/2419 PP-E-00010

9.0 Shock Absorber Fixing Arrangement and Hardware Details as explained below


31120/2421


M4x0.7x27 Lg. (Item No. 8) 2700 Nos.

10.1 Master Gauges for dimensions L-27, C-3, L-30, B-10 and C-5

1 Set Each PP-E-00002 PP-E-00002

10.2 Working Gauges for dimensions L-27, C-3, L-30, B-10 and C-5

1 Set Each

11.1 C.S.End Piece of End Fitting Seal bellow for Lip welding Qualification

70 Nos. 31160/2401 PP-E-00011

12.1 Lattice tube for Mock-up 5 Nos. 31610/2437 PP-E-00017


(2) List of Components required for 16 Channel Mockup Facility for KGS-1:

Notes:

1. Purchaser reserves right to obtain Price Break-up to facilitate dispatch of items in number of lots.

2. The Specification nos. given above are common & applicable for both RAPS-3 & KGS-1.

Sr. No.


Applicable Drg. No. KGS-1/ ____/___/DD and Spec No. ___

1 End Fitting Body 32 Nos. 31120/2409

PP-E-00002 2 Liner Tube 32 Nos. 31120/2411

PP-E-00003 3 Liner Tube Spacer 200 Nos. 4 Journal Ring (F/M Side) 10 Nos. 31150/2404

PP-E-00004 5 Journal Ring (Cal. Side) 10 Nos. 6 Retaining Ring for End fitting 10 Nos. 31120/2413

PP-E-00005 7 Retaining Ring for Lattice Tube (F/M

Side) 32 Nos. 31120/2413 PP-E-00005

8 Retaining Ring for Lattice Tube (Cal. Side) 32 Nos. 31120/2413

PP-E-00005 9 Split Sleeve Assembly 32

Assemblies 31120/2412 PP-E-00006

10 Carbon Steel Bellows Attachment Ring 32 Nos. 31120/2415 PP-E-00007 11 Welded Hollow S.S. Seal Ring 32 Nos.

12 Shock Absorber Assembly Yoke 32 Pairs 31120/2420 PP-E-00009

13 Shock Absorber Stud 64 Nos. 31120/2419 PP-E-00010

14 Shock Absorber Fixing Arrangement and Hardware Details as explained below


31120/2421


M4x0.7x27 Lg. (Item No. 8) 128 Nos.

15 Lattice tube for Mock-up 10 Nos. 31610/2437 PP-E-00017


Annexure-3

Standard Format for Non Conformance Report (NCR)

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

Non-Conformance Report Non-Conformance Report No.:_________________ Date ___________ 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 Authorized 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)

Page 1 of 4


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 justifications 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 effect 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 categorized as below: (One of the categories shall be ticked)

(Guidelines for categorization 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 judgment or specific instructions for assembly/ installation and shown to be 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).

Page 2 of 4


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

values and are acceptable based on application. 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.

Authorized Engineer for Design Group (Name, Designation, Signature & Date) To: Indenter for further processing Page 3 of 4


APPROVAL / REJECTION OF NCR : Tick as applicable:

Design intent is not affected. Justification for acceptance is 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 Authorization (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 are met? Yes / No If No, defective item rejected …………………………If repaired, new NCR No……………………… (Name, Signature & Date) (Name, Signature & Date) QA of Manufacturer /contractor QA NPCIL To Indenter Distribution by Indenter 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 ________________

Page 4 of 4


Annexure-4 List of Suggested Sub-Vendors For Manufacturing of End Fitting Components

Sr. No.

Item Vender /Sub vender

Address/ Contact

1. End Fitting Forgings (Sub Vendors)

i) M/s Bharat forge Ltd.

Mundhwa, Pune-411036 Contact Person- Shri Sandeep Goel, AVP Mob. 9850813070, Ph. 20-26702416 [email protected] Website-www.bharatforge.com

ii) M/s Star Wire (India) Ltd.

21/4, Mathura road, Ballabhgarh-4, Haryana Contact Person- Shri P.N. Singh, Sr. Mgr (Marketing) Mob. 9350150755, Ph. 0129-4094200 [email protected] Website-www.splsteel.com

iii) M/s Mishra Dhatu Nigam Ltd.

Ministry of Defence, P.O-Kanchanbagh, Hyderabad-500058 Contact Person-Shri A. Ranganathan, Dy. G.M.,(Marketing) Phone- 040-24341228, Fax-040-24341250 Email- [email protected]

2 Raw Material Liner Tubes (Sub- venders)

i) M/S Ratnamani Metals & Tubes Ltd

Survey NO. 769, Ahmedabad Mehesana- Highway, Village Indrad, Near Chhatral GIDC, Chatrel, 382729, GUJRAT (Tubes)

ii) NFC NFC, HYDERABAD 3 Stainless Steel

17-4 PH Bars for studs

i) M/s Mishra Dhatu Nigam Ltd.

Ministry of Defence, P.O-Kanchanbagh, Hyderabad-500058 Contact Person-Shri A. Ranganathan, Dy. G.M.,(Marketing) Phone- 040-24341228, Fax-040-24341250 Email- [email protected]


21/4, Mathura road, Ballabhgarh-4, Haryana Contact Person- Shri P.N. Singh, Sr. Manager (Marketing) Mob. 9350150755, Ph. 0129-4094200 [email protected] Website-www.splsteel.com

iii) M/s Kalyani Carpenter Special Steel Ltd.

Mundhwa, Pune-411036 Contact Person-Shri Nitin Bhat Mob.9850007269, Ph. 020-66215000 Website-www.kalyanicarpenter.com

4

D-2 Tool Steel Material For Journal Rings (Sub-Vendor)

i) SAIL- Visvesvaraiya Iron & Steel Ltd.

SAIL-VISL Plant, Bhadravati- 577 301. Contact Person-Shri K.K.R. Udupa, DGM(M-SS) Mob.9969200445, 7506641272 Ph. 022-25299243 [email protected]/[email protected] Website-www.sail.co.in


21/4, Mathura road, Ballabhgarh-4, Haryana Contact Person- Shri P.N. singh, Sr. Manager (Marketing) Mob. 9350150755, Ph. 0129-4094200 [email protected] Website-www.splsteel.com


5 Forgings For CS Rings, Journal Rings, Yokes (Sub-Vendor)

i) M/s Bharat forge Ltd.

Mundhwa, Pune-411036 Contact Person- Shri Sandeep Goel, AVP Mob. 9850813070, Ph. 20-26702416 [email protected] Website-www.bharatforge.com


21/4, Mathura road, Ballabhgarh-4, Haryana Contact Person- Shri P.N. Singh, Sr. Manager (Marketing) Mob. 9350150755, Ph. 0129-4094200 [email protected] Website-www.splsteel.com

iii) M/s Western India Forgings Pvt. Ltd.

GAT no. 163, Tal- Shirur, Nagar Road, At. Sanswadi, Pune – 412208 Contact Person- Shri Habib Sheikh Mob – 09075037710 Phone – 02137-679832

6 Heat Treatment facility for Journal Ring Forgings & other components.

M/s Kalyani Technoforge Ltd.

Plot No. D-41, MIDC, Ranjangaon Industrial Area, Tal-Shirur, Maharashtra Contact Person- Shri Vitthal Chungiwadar, Technical Manager, Mob.- 9922404640Mob.- 9922404640 Phone-2138-663608 Fax-2138-670705 [email protected] Website-www.bodycote.com

7

Hard Chrome Facility for Journal Rings

M/s Shri Parshwanath Industries

Plot no. W-62, M.I.D.C. Shiroli, Kolhapur-416112. Contact Person- Shri Anil Shah / Shri Gaurav Shah Mob – 09561071319 Phone – 0230-2469171 Email- [email protected]

8 Welded Hollow SS rings (Sub Vendor)

M/s Perfect Hydraulic Systems (Distributer for HTMS make metal seals)

210, Punit Chambers, Sector-18, Turbhe, Navi Mumbai-400705 Contact Person-Mr. Peter Jacob, Partner Mob.9821019367, Ph. 022-27881667 [email protected]

9 C S Bellows Attachment Ring (Sub Vendors)

i) M/S Kalyani Engineering Works ,

M/S Kalyani Engineering Works, 109, 110, Anand Industrial Estate, Mohonnagar, GAZIABAD-201007, PH.: 0120-2657241/201/072

ii) M/s WIL, Satara Road

M/S WIL, Satara Road Engineering and foundary division Satara Road, P.O. 415010. Contact person Shri J.D. Jadhav, Gen. Manager (W) Tel. 02163-27203


iii) M/s Yantra Kaushalya Engineers Pvt. Ltd.

R.S. No. 880/2, Margen Impex Ltd. Near GIDC Phase IV., Vitthal Udyog Nagar-388121, (Gujrat) Contact Person-Shri Jagrut Bhatt, MD Mob. 9825008424 Phone-2692-2351182, FAX-2692-236385 [email protected]

10 Shock Absorber studs , Yokes and Hardware

i) M/S Kalyani Engineering Works,

109, 110, Anand Industrial Estate, Mohonnagar, GAZIABAD-201007 PH.: 0120-2657241/201/072

ii) M/s Fastener & Allied Products Pvt. Ltd. , Hubli

M/s Fasteners & allied Products (Pvt). Ltd., M-3, Industrial Estate, Gokul Road, Hubli-580030, Karnataka (India) Ph.: 91-836-2330132/2330062, Fax- 91-836-2330431 Email- [email protected], Web Site : www.fappl.com Contact person- shri B.D. Bennadi, Executive

iii) M/s Yantra Kaushalya Engineers Pvt. Ltd.


11 Retaining Rings i) M/s Kalyani Engineering Works

M/S Kalyani Engineering Works 109, 110, Anand Industrial Estate, Mohonnagar, GAZIABAD-201007 PH.: 0120-2657241/201/072

ii) M/s Yantra Kaushalya Engineers Pvt. Ltd.



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