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

SPECIFICATION NO. : PP-E-2329

REVISION NO. : 0 DATE OF ISSUE (MONTH/YEAR)

: OCTOBER 2006

TOTAL NO. OF PAGES (Including Cover Sheet, Annexures-A&B)

: 31 (=2+20+1+8)

TECHNICAL SPECIFICATION

FOR

MANUFACTURE, SUPPLY AND ERECTION OF

PHT FEEDERS AND HEADERS INSULATION CABINETS

OF KAKRAPAR ATOMIC POWER STATION UNIT– 1

REF. USI NO. : 33110

PREPARED BY CHECKED BY

: S.N.PRASAD N.PRASAD

REVIEWED BY

: R.BANERJEE

APPROVED BY : V.K.BHATNAGAR

Name Signature Date

FIRST ISSUE : OCTOBER-2006 (For Revisions see Revision Control Sheet )

File Name : PP-E-2329 Floppy No.:

REVISION CONTROL SHEET

DOCUMENT TYPE : TECHNICAL SPECIFICATION

NO. : PP-E-2329 / Rev. No. 0

TITLE : TECHNICAL SPECIFICATION FOR

MANUFACTURE, SUPPLY AND ERECTION OF PHT

FEEDERS AND HEADERS INSULATION CABINETS OF

KAKRAPAR ATOMIC POWER STATION UNIT– 1

Rev. No. Date Description of Revision

Prepared By

Checked by

Reviewed by Approved by

NUCLEAR POWER CORPORATION OF INDIA LTD. PAGE 1 OF 20

KAKRAPAR ATOMIC POWER STATION-1 TECHNICAL SPECIFICATION

FOR MANUFACTURE, SUPPLY AND ERECTION OF PHT FEEDERS AND HEADERS INSULATION CABINETS

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1. SCOPE

This Specification establishes the requirements for the design detailing, preparation of shop and `as-built' drawings, manufacture, inspection, shop assembly, packing, delivery to site and erection of the North and South Feeders and Headers Insulation Cabinets (FHICs) and attachments at the site of Kakrapar Atomic Power Station Unit-1 during EMCCR campaign. The site is located at Kakrapar near Surat in Gujrat state.

The Specification is written in the singular sense for one feeder and header

insulation cabinet.

2. CONTENTS The requirements of this Specification are presented under the following

headings : Section

SCOPE 1.0

CONTENTS 2.0

APPLICABLE SPECIFICATIONS AND DRAWINGS 3.0

MATERIALS, PROCESSES AND WORKMANSHIP 4.0

GENERAL FUNCTION AND DESCRIPTION 5.0

REQUIREMENTS 6.0

INSPECTION AND TESTS 7.0

PACKING AND SHIPMENT 8.0

ERECTION AT SITE 9.0

SUBCONTRACTING 10.0

GUARANTEE 11.0

QUALITY ASSURANCE PLAN (QAP) ANNEXURE-A

NPCIL TITLE BLOCK FOR MANUFACTURER'S ANNEXURE-B DRAWINGS

3. APPLICABLE SPECIFICATIONS AND DRAWINGS

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

tendering documents, constitute a part of this Specification and shall apply as specified




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herein. In the event that certain requirements of the specifications, drawings or data listed below conflict with the requirements of this Specification, this Specification shall govern. Any deviations from the materials, dimensions, data or design indicated in the drawings mentioned in this Section and requirements mentioned in this Specification, shall be clearly stated in the tender by the Bidder. The Purchaser reserves the right to accept / reject the deviations. In case the Purchaser accepts some or all deviations, any changes required in the design, manufacture and erection of the different faces of FHICs arising out of such deviations, shall be carried out by the Contractor at no extra cost to the Purchaser and no extension in the delivery period. 3.1 Applicable Specifications

ASME B&PV Code Section II Part C

: Specifications for welding rods, electrodes and filler metals

ASME B&PV Code Section IX

: Welding and brazing qualifications

ASME Section VIII Div-I

: Rules for construction of pressure vessel

ANSI / ASME B 18.6.5 M : Metric thread forming and thread cutting screws ASTM A240 : Specification for heat resisting chromium and

chromium-nickel stainless steel plate, sheet and strip for pressure vessel

ASTM A262 : Practices for detecting susceptibility to

intergranular attack in austenitic stainless steels ASTM D3359 : Test methods for measuring adhesion by tape

test IS:277 : Specification for galvanised steel sheet

IS:549 : Split pins IS:808 : Dimensions of hot rolled steel beam, column,

channel and angle sections

IS:5986 : Specification for hot rolled steel Flat products for structural Forming & Flanging purposes

IS:1173 : Specification for hot rolled slit steel tee bars




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IS:1239 (Part I) : Mild steel tubes, tubular and other wrought

steel fittings - Mild steel tubes

IS:1341 : Specification for steel butt hinges IS:1364 (Parts – 1,2&3) : Specification for hexagonal head bolts, screws

and nuts of product grades A&B.

IS:1367 (Parts 1,2,3,6,7,9, 10,11,13,14)

: Technical supply conditions for threaded steel fasteners

IS:1477 (Parts I & II) : Code of practice for painting of ferrous metals

in buildings

IS:1862 : Specification for studs

IS:2016 : Specification for plain washers

IS:2062 : Specification for steel for general structural purpose

IS:2232 : Slotted and castle nuts IS:3818 : Specification for continuous (piano) hinges IS:7173 : Specification for slotted pan head tapping

screws IS:8183 : Bonded mineral wool

IS:9549 : Dimensions for split pin holes and head slots

for bolts

3.2 Applicable Drawings

Drg. Number Title

1. KAPS-1/33110/2411/GA - Feeders and Headers Insulation Cabinets

North and South Structural Frames -General Arrangement

2. KAPS-1/33110/2412/DD - Feeders and Headers Insulation Cabinet Lower Rear Face - Assembly and Details

3. KAPS-1/33110/2413/DD - Feeders and Headers Insulation Cabinet East face and West Face - Assembly and Details




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4. KAPS-1/33110/2414/DD - Feeders and Headers Insulation Cabinet Top Face and Top Center Face - Assembly and Details

5. KAPS-1/33110/2415/DD - Feeders and Headers Insulation Cabinet Lower Center Face and Upper Rear Face- Assembly and Details

6. KAPS-1/33110/2416/DD - Feeders and Headers Insulation Cabinet Bottom Face and South Cabinet Upper Front Face - Assembly and Details

7. KAPS-1/33110/2417/DD - Feeders and Headers Insulation Cabinet Lower Front Face and North Cabinet Upper Front Face - Assembly and Details

8. KAPS-1/33110/2418/DD - Feeders and Headers Insulation Cabinet East and West Face - Sectional Details of Boxes for Snubbers

9. KAPS-1/33110/2419/DD - Feeders and Headers Insulation Cabinet Venting Damper - Assembly

10. KAPS-1/33110/2420/DD - Feeders and Headers Insulation Cabinet Jigsaw Panel Outer Ring - Assembly and Details

11. KAPS-1/33110/2422/DD - Feeders and Headers Insulation Cabinet Jigsaw Panel Angle Ring Insulation - Assembly and Details

12. KAPS-1/33110/2423/GA - Feeders and Headers Insulation Cabinets Insulation Assembly - General Arrangement

13. KAPS-1/33110/2424/DD - Feeders and Headers Insulation Cabinets Boxes for Annulus Gas Tubes - Assembly and Details

14. KAPS-1/33110/2425/GA - Feeders & Headers Insulation Cabinet North Insulation Cabinet - Pictorial View

15. KAPS-1/33110/2430/DD - Feeders and Headers Insulation Cabinets Supporting Hanger Arrangement for Lower Center Face - Details

4.0 MATERIALS, PROCESSES AND WORKMANSHIP General

The Contractor shall be responsible for the procurement of all materials, fittings, pneumatic cylinders and hardwares necessary for manufacturing, assembly and erection at the site of the FHICs. All the items mentioned above shall meet the respective specifications brought out herein. Materials, processes and standard parts which are not specifically designated herein and which are necessary for the fulfilment of this Specification shall comply with applicable Indian Standards or other standards permitted by the Purchaser. All materials, fittings, fasteners and other items shall be new and unused and of the best commercial quality.




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4.1 Materials 4.1.1 Carbon Steel rolled sections, sheets, plates and bars Steel used for Angles, Tees, Flats, Plates and Channels used for structural steel frame; bars used for carbon steel (CS) studs, tie rod supports, insulation studs; tubes; rounds, insulation stud washers, non-standard washers used at the stud locations, shall conform to IS 2062 Grade A. 4.1.2 Carbon Steel sheets

(a) All 16 gauge (outside) facing sheet of panels shall be hot rolled sheets conforming to IS : 5986 Grade Fe 410 / IS : 2062 Gr Fe 410WA.

(b) All 26 gauge (inside) galvanised sheet lining shall conform to IS 277 (Grade of Zinc coating-450 ) .

(c) Sheets used for jig saw panel outer ring shall be galvanised sheet and conform to IS 277 (Grade of Zinc coating-450 ) .

4.1.3 Fasteners (bolts, nuts, washers and rivets) and Hinges

All standard carbon steel bolts, nuts, jam/lock nuts, castle nuts and washers shall be zinc plated / galvanised, of commercial quality and of the make(s) approved by the Purchaser. The threaded studs to be welded to the structurals and insulation studs to be welded to panels and structurals by stud welding shall be cold rolled and of carbon steel suitable for stud welding (carbon - 0.22% maximum and carbon equivalent - 0.41 maximum). The threaded studs shall meet requirements of IS1862. The rivets, self tapping screws and blind rivets used shall be of carbon steel and of good commercial quality.

The steel for square butt hinges shall meet the requirement of IS 1341.

4.1.4 Thermal Insulation Material

Insulation material shall be resin bonded mineral wool conforming to IS 8183 and suitable for application on flat and curved surfaces. Thermal conductivity of the insulation shall be as low as possible, but shall not exceed 0.060kcal/hr.m. 0C at 2000C mean temperature.

The material shall be suitable for continuous use at a temperature of 3250C

and with vibrations normally occurring in boiler areas of conventional power plants, without deterioration of any kind. The material shall be able to withstand an integrated dose of nuclear radiation (gamma radiation) of minimum 10 Megarad without deterioration. The Contractor shall furnish the following for the insulation material in his offer for the review / approval of the Purchaser :




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(a) Value of thermal conductivity and corresponding temperature and density for specified 100 mm thickness of insulation,

(b) Source / make (c) Certificate for capability to withstand specified integrated dose of

nuclear radiations. (d) Leachable chloride content

Any other thermal insulation material having lower thermal conductivity,

for example Microtherm thermal insulation (information for this is available on website www.microtherm.uk.com), and meeting the other requirements mentioned above can be used. The Supplier shall indicate in his bid the alternative material, if any, and its thickness(es) he proposes to use. The material and its thickness(es) shall be subject to Purchaser's approval. The Supplier shall also mention prices for the FHIC with the above mentioned resin bonded mineral wool as well as with alternative material proposed by him. 4.1.5 Welding consumables

Electrodes and consumables for welding of carbon steel shall meet the relevant specifications given in ASME Section II, Part C. The brands of electrodes and welding consumables shall be as per the NPCIL's approved list. 4.1.6 Paint System

The primer and top coat used for the plates, tees, channels, flats and angles of steel frame, 16 GA sheet of panels, insulation studs, panel supporting studs and clamping plates shall be Dimetcote 6 and Amercoat 90 (manufactured by M/s Goodlass Nerolac Paints Ltd., India), respectively. Dry film thickness (DFT) of Dimetcote 6 (applied after sand / grit blasting to white metal) shall be 75-90 microns and DFT of subsequent two top coats shall be 200 microns (DFT of each top coat is 100 microns). 4.1.7 Asbestos tapes, asbestos tadpole seals, and washers used shall be of commercial quality, however, their leachable chloride content shall not exceed 25 ppm. 4.1.8 Any item of steel directly exposed to the inside atmosphere of the FHIC shall be hot dip galvanized with zinc thickness 80 microns minimum. 4.1.9 Where the use of an alternative specification / material is proposed, the alternative shall be subject to approval by the Purchaser. 4.2 Workmanship

Workmanship shall be of the best quality pertinent to manufacture and installation of similar equipment in nuclear /conventional power plants. 5.0 GENERAL DESCRIPTION AND OPERATING CONDITIONS




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The FHIC encloses Primary Heat Transport (PHT) system feeders and

headers completely and coolant channel end fittings partly. The pictorial view of the FHIC is shown in drawing KAPS-1/ 33110/2425/GA. Both (North and South ) FHICs will be removed to get access to calandria vault liners for their repair work during KAPS-1 EMCCR campaign.

The FHIC consists of a steel structural frame work, insulating panels and

boxes. An insulation panel assembly consists of 16 gauge steel sheet facing, mineral wool insulation and 26 gauge galvanised steel sheet lining. The side faces of the insulation are contained by chicken wire mesh and 330-380 microns thick glass cloth which are held by peripheral insulation studs welded on 16 GA sheet. The insulation is held on 16 GA sheet by the studs welded on it. The insulation is then covered by 26GA galvanised steel lining to confine and protect it. The 26 GA lining is secured in its position by sandwiching it between the sleeves slipped over the studs and steel washers welded to the insulation studs. The gap between the 26 GA and 16 GA sheets are maintained by the sleeves slipped over the insulation studs on 16 GA sheet. The structural members are connected to each other by welding or threaded fasteners. The panels are supported on the structural members of the frame work by threaded fasteners, rivets or clamping plates. The cabinet is formed when the panels and boxes are connected to the steel framework. This enclosure has 10 faces, namely Lower Rear Face (LRF), Top Center Face (TCF), Upper Rear Face (URF), Top Face (TF), Upper Front Face (UFF), Lower Center Face (LCF), Lower Front Face (LFF), Bottom Face (BF), East Face (EF) and West Face (WF). The FHIC is supported by fastening it at a number of locations to the following equipment / structures :

(i) Fuelling Machine side tube sheet (FSTS) of the end shield (ES) (ii) Fuelling machine (F/M) vault side face of Calandria vault wall

accommodating the ES (iii) Roof of the fuelling machine (F/M) vault. To avoid excessive pressure rise in the FHIC in the event of a large leak

from the tubing inside the cabinet, one (1) counter weighted swing-out type pressure equalisation (PE) damper is provided. Similarly, one (1) swing-in type pressure equalisation damper is provided to cater to any pressure rise outside the cabinet. These dampers form part of the WF. The area of these dampers are arrived at so as to limit the differential pressure across the steel panel to 1.9 x 10-2 kg/cm2.

The lower front face includes a jigsaw panels assembly. The end fitting

penetrates through this assembly. The portion of an end fitting within FHIC can be accessed, when required, by dismantling jigsaw panels around it.

In the west face of each cabinet one hinged insulated door is provided to

reach interior walkways provided inside the cabinets for accessing feeders, headers etc. An exterior walkway is provided on the TCF. Two venting dampers, one in LFF and the other in UFF, are provided to cool the inside of the cabinets when required.




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The fuelling machine vault in which the cabinet is located, contains normal atmospheric air. The average temperature inside the cabinet will be approx. 2710C during normal operation. The fuelling machine vault cooling system will limit the temperature of the atmosphere in the vault surrounding the cabinet to approximately 500C. There is an intended gap of minimum 35 mm between the lower rear face insulation panel 16 GA sheet and fuelling machine vault liner. Cold air will be blown through this gap and leave the FHIC through the gap between the roof of F/M vault and top face after flowing past TCF and URF.

6.0 REQUIREMENTS 6.1 General

The FHIC shall conform to the arrangement shown in the drawings listed in Section 3.2 of this Specification. Design detailing, where called for / required, construction and erection of the all the faces of FHIC shall be such as to minimise the heat loss and leakage of hot air across the cabinet

The clearances between the faces of FHIC and other equipment are very

limited, hence the Contractor shall maintain the dimensions within limits specified in the drawings.

The Contractor shall procure carbon steel items (structural members, plates,

16GA sheets, 26 GA GI sheets, rivets, blind rivets, screws, nuts washers, studs, self tapping screws, GI wire mesh etc.), insulation material, glass cloth, asbestos tape and tadpole seal, etc. in sufficient quantity required for the manufacture and erection of the FHICs. The Contractor shall be responsible for drilling or / and tapping holes in structural and other already installed items e.g. end shields, if required. The technical specifications prepared by the Contractor for procurement of different items shall be subject to NPCIL's approval. These approved specifications shall form part of enquiries prepared by the Contractor for procurement of the items. 6.2 Manufacturing, drawings and Procedures for the FHIC 6.2.1 Shop Drawings

Drawings mentioned in Section 3.2 are reference design drawings not shop / manufacturing / fabrication drawings. The Contractor, shall scrutinize these drawings before preparation of the shop / manufacturing drawings. Discrepancies / missing information / mismatch / errors , if any, in the Purchaser's drawings shall be brought to his notice by the Contractor for Purchaser's advice / action / clarification. If not done so by the Contractor, the Contractor shall be fully responsible for any problems faced (i) due to procurement of items of incorrect sizes / quantity / specification (ii) during manufacture,




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and (iii) while erecting the cabinets at the site. The Contractor shall bear the cost of any repair / rework carried out to solve the problems and not be allowed any extension in delivery period for such repair / rework.

The Contractor shall prepare all necessary shop drawings as per latest Indian Standards.

As a minimum, the shop drawings shall show the following :

1. Assembly and details of each face and its position with respect to other faces of the

insulation cabinet. Assembly and details of structural frame of each face. 2. Details of each structural member, panel, clamping plate and insulation box. These

would include size and shape, locations of insulation studs and their sizes and method of fixing; thickness and shape of insulation on each structural member and panel; projections of insulation along the edges of each panel and its protection by glass cloth and chicken wire mesh; holding / anchoring of chicken wire mesh and glass cloth on the panel (thickness of glass cloth and size of chicken wire mesh shall also be mentioned); size of 26 GI lining on each panel and structural member, and method of fixing of the same on them; thicknesses of zinc coatings on 26 GI sheet, members of internal walkways, jig-saw panel outer rings, etc.

3. (a) Location, type and size and dressing up of each weld used for connecting different members or pieces of rolled sections to get full size member.

(b) Size and type of bolts, nuts and washers of each bolted connection. (c) Method(s) of locking nuts - it is recommended that self locking nuts are used

wherever it is possible. (d) Method(s) of fixing bolts / studs to structural member, or to panel where

specified / shown. (e) Sizes, type(s) and locations of self tapping screws. (f) Size and type of rivets of riveted connections or where fixing of an item to

the other item by rivets is specified. (g) Type and thickness of corrosion protection coating on fasteners.

4. Details of insulation boxes provided at locations of the different penetrations in the insulation cabinet faces and arrangement(s) for preventing leakages at the penetrations.

5. Locations and details of splices in 16 GA panels and arrangement for preventing leakages.

6. Locations, types and details of pneumatic cylinders and their fixing arrangements. 7. Dimensional tolerances for assembly of insulation cabinets and compatible

tolerances for each structural members and panel, allowances for cutting, machining (if any), and field adjustments during erection.

8. Locations of field / in-situ weld joints, bolted joints and riveted joints. 9. Method and details of supporting panels on structural members and of insulation

boxes on the structural members / panels. 10. Items to be manufactured in the shop, at the site, and partly in the shop and the rest

at the site. 11. Identification of each item / component / panel by item number and subassembly

number.




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12. Bill of materials for each sub-assembly and number / quantity of each subassembly required for one reactor unit. In the bill of materials, the following shall be indicated for each item : subassembly number, item number, complete description and details of the item, applicable material and other relevant specifications / standards, exact quantity required, make in case of bought-out / standard items, remarks (if any) relevant to the item from manufacturing / erection considerations / sequences.

13. All the necessary notes to ensure that the members, subassemblies and assembly manufactured and erected meet the requirements specified in this Specification.

14. Locations and sizes (width, thickness and length) of asbestos tape and asbestos tadpole seals used for sealing, insulation or both purposes. Compression of these shall be such that air does not leak across these items.

The Contractor shall incorporate NPCIL title block (shown in Fig.A of

Annexure-B) in his drawings. The title block shall be just above Contractor's title block. The size of the block, height of lettering, margins, spacings, etc. shall be as per Fig.B of Annexure-B.

The shop drawings shall be subject to the Purchaser’s approval prior to

commencement of manufacture. The approval of shop drawings by the Purchaser shall not relieve the Contractor from his responsibility of correctness / accuracy of dimensions and details shown and quantities of items indicated in his drawings.

The Purchaser reserves the right to make minor dimensional or structural

changes until such time as the Supplier’s shop drawings are approved for manufacture. Such changes shall be considered within the scope of the specified work and shall not be considered as extras. Any change proposed by the Contractor and approved by the Purchaser, shall need revision of shop drawings. All revised shop drawings shall be subject to the Purchaser's approval.

The Contractor shall prepare and submit as-built drawings within 20 days

from the date of completion of erection of FHICs at the site. These drawings shall include all the deviations / modifications / revisions / substitutions, etc. requested by the Contractor and approved by the Purchaser during manufacture and erection and also all the revisions / modifications made by the Purchaser in his drawings. The “as-built” drawings shall be subject to approval of Purchaser’s QA engineer / Engineer In-charge at site, prior to issue of shipping release / construction completion certificate. Prior to submission of these drawings, `APPROVED' shall be written in NPCIL title block as shown in Fig.B of Annexure-B and other details such as name, date, drawing number shall be filled by the Contractor as per information provided by the Purchaser.

The shop drawings and `as-built' drawings shall be prepared on clear

tracing paper / dilar / reproducible tracing film (RTF). It is desirable that the drawings are prepared on computer, using AutoCAD software, and stored on compact discs (CDs). A legible reproducible of each shop and as-built drawings, along with number of prints as specified by the Purchaser, shall be submitted by the Contractor. If drawings are prepared




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on computer, the Contractor shall copy them on CD(s) and submit to the Purchaser for retention. 6.2.2 Manufacture of the FHIC 6.2.2.1 General

(a) The cabinets shall conform to the arrangement shown on the relevant drawings listed in Section 3.2.

The design details, construction and assembly of the cabinets shall be such as to minimise leakage of hot air from the cabinet to F/M vault. The panels shall be supported on structural members properly so as to avoid any bulging during erection and limit bulging during operation. The insulation shall be arranged to provide continuous insulation of the specified thickness(es) in the interior of FHIC.

(b) As the actual locations of the items penetrating the different faces of FHIC

may be different from those shown in drawings after their installation at site, it is the responsibility of the Contractor to visit the site and make necessary field measurements for these items to obtain exact locations and sizes of penetrations required to be made in the central top and rear faces, upper front face, top face, east and west faces, bottom face, lower front face, etc. This will avoid / minimise any rework / mismatch of fabricated panels at the time of erection. Penetrations shall be sealed properly to avoid any air leakage across them. However, in case the information is not available at the site due to components not having been installed, the contractor shall follow NPCIL drawings only.

(c) The Contractor shall interact extensively with the Purchaser during

preparation of shop drawing(s) for jigsaw panels assembly, fabrication and erection of jigsaw panels assembly for ensuring proper sealing of the gaps, ease in fixing and removal of jigsaw panels, etc.

6.2.2.2 Welding 6.2.2.2.1 Only electric welding shall be used. The Contractor shall prepare the welding procedures to be employed by him for welding carbon steel members of the frames, insulation studs to 16 GA panels and structural steel frame members, welding M10 studs to structural members. All welding procedures shall be subject to the Purchaser’s approval. The procedures, welders and welding operators shall be qualified in accordance with ASME Section IX.

All surfaces to be joined shall be thoroughly cleaned and free of grease, dirt,

oil, scale, slag and deleterious foreign matter to prevent weld contamination. Suitable measures shall be adopted to prevent deformation / distortion of members during welding.




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Deformed / distorted structural members / panels which can not be corrected to fulfil the functional requirements shall be rejected.

In multipass welding, if employed, the weld shall be subject to visual

examination before proceeding for the subsequent pass. Self locking nuts shall be used where FHIC environment permits their use.

Unless specified otherwise, in case of LRF locking of (i) nuts to the bolts, structural member, panel and studs, and (ii) bolt / screw heads to panels or structural members shall be by tack welding. Where tack welding is to be done, zinc or any other permitted coating shall be removed from those areas of nuts, bolts / studs / screws, panels, structural member to avoid contamination of weld. In case of the other faces, method(s) of positive locking of nuts to bolts / studs shall be subject to approval by the Purchaser. For each bolted / screwed connection, one standard or specified size washer shall be provided under the nut/screw head.

On the basis of field measurements, lengths of straight and curved members

of the structural steel frames shall be worked out and these shall be welded at appropriate stage. 6.2.2.2.2 Stud welding The welding of 3 mm diameter insulation studs to 16GA steel sheets and structural members and 10/12 mm diameter studs to the structural members shall be carried out by the Contractor as per the procedure(s) prepared by him and approved by the Purchaser. The welding procedure(s) and performance qualification shall comply with the requirements of ASME Section IX. 6.2.2.3 Manufacture of Prototypes:

The Contractor shall prepare the following prototypes:

1. Assembly of two (2) 1000 mm x 1000 mm panels having insulation studs and the tubes, 100 mm thick insulation whose side faces protected by glass cloth and wire mesh, 26 GA GI lining fixed in position by welding washer to the insulation studs, 16GA sheet facing containing two perpendicular splices.

2. 2000 mm long angle and Tee with 100 mm insulation, insulation studs and studs for clamping plates.

3. Insulation box for Annulus Gas Monitoring System (AGMS) tubing in lower front face (see drawing No.KAPS-1/33110/2424/DD).

4. 1000 mm long clamping plate with 12 GA sheet welded along one of the long edges.

5. Insulation box as per `Detail-A3' in drawing No.KAPS-1/33110/2417/DD for the upper front face of the insulation cabinet.




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The above prototypes shall be inspected and approved by the Purchaser prior to taking up manufacture of the cabinets. 6.2.2.4 Clamping plates Normally a panel is held along its edges on structural members by clamping plates which are kept in position by M10 studs welded on the structural members. There are two types of clamping plates : one having 6 mm wide 12 GA thick strip stitch welded along its one of the two long edges (see drawing no. KAPS-1/33110/2415/DD) and the other without 12 GA strip. These shall be straight and flat after fabrication. The type of clamping strips used for supporting edges of panels shall be clearly indicated in the shop drawings. 6.2.2.5 Door in West Face The door shall be fabricated as per details given in drawing No. KAPS-1/33110/2413/DD. However, the Contractor may be required to slightly alter size / details of the door to suit site conditions. This shall not be considered as extra work.

The Contractor may offer alternative design of the door. The design shall be such that door operates smoothly and easily and allows no air leakage across itself and across the overlap between its frame and itself. Adequate number of strong hinges shall be provided to support the door and prevent its drooping. 6.2.2.6 Contact between 26 GA GI sheet and structural member / 16 GA sheet :

In order to minimise heat flow from the 26 GI lining (directly exposed to interior environment of the FHIC) to structural member / 16 GA panel, direct contact between the lining and structural member / 16 GA sheet shall be avoided to the maximum possible extent by inserting asbestos tape between them. 6.2.2.7 Projection of Insulation beyond the edges of the panels Insulation shall project sufficiently beyond the edges of 16 GA and 26 GA sheets of panels in order to ensure that when the panels are installed, the insulation of each of the neighbouring panels gets compressed by 25 mm minimum. In case panel edge is butting against 26 GA GI sheet of a structural member, the compression of the insulation of the edge butting against structural member shall not be less than 25 mm. 6.2.2.8 Splicing of 16 GA and 26 GA panel sheets

Splices required in 16 GA panels are shown in the drawing. More number of splices of 16 GA panels are permitted if available maximum sizes of these sheets and ease in handling require so. These splices shall be made as shown in drawing. The number of splices, which shall be kept as minimum as possible, and locations of the splices shall be subject to approval of the Purchaser. This applies to joints in 26 GA GI sheets also.




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6.2.2.9 Flattening of panels / straightening of structural members The Contractor shall flatten the 16 GA sheets, particularly near edges resting on the structural member, and straighten the structural members to ensure proper contact between structural member and the panels. 6.2.2.10 Thickness of Zinc Coating The thickness of zinc on hot dip galvanised items shall not be less than 80 microns. 6.2.2.11 Pneumatic Cylinders The pneumatic cylinders for operation of venting dampers shall be of the make approved by NPCIL. It shall be possible to adjust its stroke length to suit site conditions. It should open and close the damper fully and smoothly. Spares specified by the cylinder manufacturer for minimum 2 years trouble free operation shall be supplied free of charge by the Contractor. 6.2.2.12 Painting

Prior to application of primer and top coat of painting system to all the surfaces of all the members of the structural steel frame, 16 GA panels, and insulation studs, these surfaces shall be grit blasted by the Contractor to white metal or as specified by the paint manufacturer, to remove all visible oil, grease, dirt, dust, mill scale, rust, paint, oxides, corrosion product and other foreign matter. The grit blasting procedure, which will be prepared by the Contractor on the basis of procedure recommended by the paint manufacturer, shall be submitted for the Purchaser’s approval. Immediately after grit blasting and prior to application of primer the surfaces shall be cleaned by air blast and visually 100% inspected by the Contractor. Spot checks of the blasted surface for cleanliness, if desired by the Purchaser, shall be carried out randomly as per procedure given below.

Copper sulphate solution with copper sulphate and water in approximately equal volumetric proportions shall be prepared and filled in a bottle with a rubber dropper. The copper sulphate solution shall be applied over the cleaned surface. If the sand blasted surface being tested is clean, the copper sulphate solution when applied will quickly change to a bright reddish copper colour. If sand, iron oxide or any foreign matter is present on the surface, the solution will retain its original colour or may turn black. Surfaces treated with copper sulphate shall be cleaned by sand blasting again before painting.

The primer shall be applied by the Contractor as per procedure

recommended by the paint manufacturer. A continuous and adherent dry film coating of thickness 75-90 microns shall be achieved. However, maximum dry film thickness (DFT) upto 150 microns is permitted in areas like bend of panels, roots of stud. Two top coats of




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Amercoat 90 shall be applied on the primed surface as per procedure recommended by paint manufacturer. The DFT for each top coat shall be 100 microns.

Painting procedure shall be prepared by the Contractor on the basis of

instructions of the paint manufacturer, and the same shall be submitted to the Purchaser for approval. Prior to start of bulk painting work, 2 sample panels (1m x 1 m size each) with welded studs and bent edges shall be sand blasted, painted and got approved by the Purchaser’s inspector for qualification of sand / grit blasting and painting procedures. The Contractor shall conduct tape test on the samples for adhesion as per ASTM D 3359. The acceptance scale is 3A or above. 6.2.2.13 Insulation Boxes for Annulus Gas Tubes These boxes are most likely to be located in the east and west faces at the elevations mentioned in drawing no.KAPS-1/33110/2417/DD. Although the sizes and locations of these boxes are indicated in drawing no. KAPS-1/ 33110/2424/DD; however, their locations and sizes shall be reconfirmed by the Contractor from the site prior to their manufacture and making corresponding cut-outs in the relevant panels of the appropriate faces. 6.2.2.14 Identification

All structural members and components shall be permanently identified / marked in a manner satisfactory to the Purchaser, to facilitate field assembly. 6.2.2.15 Placement and Supporting of Insulation

a) The insulation shall be arranged to provide continuous insulation of specified thickness on the structural members and 16 GA panels. The insulation shall be supported on 3 mm diameter insulation studs welded on 16 GA panels and structural members. The insulation shall be confined and protected by providing 26 GA GI sheet panel / lining over the insulation and holding them in position by insulation studs and washers welded to these studs. A 6 mm OD x 3.6 mm ID x 100 mm (approx) long tube shall be slipped over each insulation stud to prevent compression of the insulation beyond specified thickness.

b) One layer of 50 mm thick insulation material, in the form of mattresses, shall be laid on the top of entire top face after its installation. Each mattress shall be completely contained in a glass cloth enclosure. The glass cloth covered insulation mattresses shall be placed and stretched on the top face as per procedure approved by the Purchaser. If any alternative insulation material is used, the thickness to be used shall be confirmed from the Purchaser by the Contractor.

6.2.2.16 Shop Assembly




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The structural frames, panels and other components of all faces manufactured by the Contractor in his shop on the basis of site measurements, shall be shop assembled by him to check their fit-up. However, if the site front is not available for these measurements at the time of manufacture of the component, the Contractor shall manufacture as per the drawing. The same shall be offered to the Purchaser's QA engineer for inspection. It may be noted that in case of the LRF only structural members and uninsulated 16GA panels shall be shop assembled. These items shall be despatched to the site for erection only after these have been cleared by Purchaser's QA engineer. It shall be responsibility of the Contractor to ensure that the final assembly of the cabinets after erection at the site meet requirements of this Specification. 7.0 INSPECTION AND TESTS 7.1 General

All tests and inspections required by this Specification shall be made/conducted by the Contractor as per methods/procedures approved by the Purchaser. The Contractor shall produce a detailed quality assurance plan (QAP) in line with suggested QAP enclosed as Annexure-1 and the QAP shall be approved by the Purchaser prior to implementation. The Contractor shall maintain records of all inspections and tests, which shall be made freely available to the Purchaser or his QA engineer / authorised representative(s).

During the various stages of manufacture and erection, the Purchaser will

depute his QA engineer(s) to witness or cross check the inspections/tests, being carried out/already carried out by the Contractor. For this, the Purchaser’s QA engineer shall be allowed access to place of manufacture. The inspector shall also be provided all inspection and testing facilities and services by the Contractor.

Conducting/witnessing of any inspection or test by the Purchaser’s QA

engineer shall not relieve the Contractor from any of his responsibilities. If the Contractor is permitted by the Purchaser to sub-contract a part of

work, the Contractor shall be fully responsible for the sub-contractor’s work. The Contractor shall mention name(s) and address(es) of sub-contractor(s) and the job(s) he is planning to sub-contract to them, in his tender so that they can be evaluated and approved by the Purchaser prior to placement of the purchase order. The sub-contractor also shall provide facilities asked for by the Purchaser's representative required for witnessing / rechecking inspection and tests. 7.2 The inspections and tests to be conducted by the Contractor shall be as set forth below. 7.2.1 Material Testing




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All materials designated as in conformity with IS / other standards shall be tested as required by such standards. The stainless steel items shall be subject to intergranular corrosion test as per ASTM A262 Practice A/Practice E.

The Contractor shall produce at his own cost for the Purchaser’s verification

and approval correlating Test Certificates in original for various tests for materials mentioned in Section 4.1. In the absence of correlating test certificates, the Contractor shall arrange at his own cost conducting of the tests at the Purchaser’s approved testing laboratories. The test certificates duly Counter-signed by the Purchaser’s representative shall be submitted to Purchaser for record. 7.2.2 Examination of welds 7.2.2.1 Final pass of each fillet weld shall be 100% examined by liquid penetration inspection (LPI) as per Appendix-8 of ASME Section VIII, Division 1. Acceptance standard is as per 8-4 of Appendix-8. 7.2.2.2 The root passes and final passes of all groove welds shall be 100% examined by LPI as per Appendix – 8 of ASME Section VIII, Division 1. Acceptance standard is as per 8-4 of Appendix-8. 7.2.2.3 The stud-weld test specimens shall be subject to bend and tensile test as per Clause QW-192 of ASME Section IX. Acceptance criteria for bend and torque tests shall be as per Clauses QW-192.2 and QW-192.3 of ASME Section IX , respectively. 7.2.3 Dimensional Inspection

All components and assemblies shall be inspected by the Contractor at pertinent stages of manufacture and erection to ensure that all dimensions, workmanship and cleanliness meet the requirements of this Specification and approved shop drawings. 7.2.4 Inspection of Fasteners

All threaded fasteners shall be inspected for thread damage, burrs, tears and discontinuities. No visual defects are acceptable. The threads of the fasteners shall be matched with those of the corresponding mating parts. It shall also be checked that these fasteners have required corrosion protection coating. 7.2.5 Non-conformance

In the event of non-conformance to any of the requirements of this Specification during manufacture and/or erection, the Contractor shall notify the Purchaser or his authorised representative. The Contractor shall obtain approval of the Purchaser before any corrective action is taken.

All such non conformances and their corrective actions shall be

documented.




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7.2.6 Inspection and Test Reports

The Contractor shall submit various inspection and test reports at the various stages of manufacturing as required by the Purchaser's Inspector. 8.0 HANDLING, PACKING & SHIPMENT Great care shall be taken at all stages of manufacture, inspection and shipment, in handling of insulated structural members and panels and also other items so that these are not damaged.

If some or all components are manufactured by the Supplier’s at his works,

he shall despatch them to site after packing them properly so that these do not get damaged during handling and transportation. Packing of the different components shall be as per packing procedure prepared by the Contractor and approved by Purchaser. Safe transportation of these components to the site shall be the responsibility of the Contractor. The items shall be dispatched from the shop only after issue of clear shipping release by the Purchaser's QA engineer.

The Contractor shall furnish the inspection reports duly signed by the

Purchaser's QA engineer who inspected the work completed in the Contractor's shop. 9.0 ERECTION AT SITE

The Contractor shall note that the sequence of erection of insulation

cabinets is to be followed as per the sequence specified by Site Engineer In-charge. The Contractor shall arrange required fixtures, tools, welding machines, handling facilities, materials, manpower, etc. at the site at his own cost for completion of erection of the different faces within the periods specified by the Purchaser. The Contractor shall take all necessary precautions to ensure that already installed components / equipment / item are not damaged by his persons / their actions. He shall also ensure that required cleanliness is maintained in the area.

The erection of PHT feeders and headers insulation cabinets in fuelling machine vaults is required to be done in permissible radiation environment. The working personnel shall wear radiation protection gears during working inside the reactor building. They have to follow all the discipline required in a radioactive environment –like taking radiological work permission, wearing TLD/ DRD during work inside the reactor, deposition of all TLDs/ DRDs back to the department for monitoring of radiation uptake for the job etc. Hence the Bidder is advised to make himself aware of various constraints and approaches to the site and surroundings before submitting his tender. For this purpose, the Bidder is advised to discuss the arrangements of all the items mentioned in previous paragraph with Purchaser, prior to submission of offer.




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The structural frames and insulation panels of the different faces shall be erected in a manner to meet the requirements specified in the drawings and to the satisfaction of the Purchaser. The Contractor shall make all necessary modifications / adjustments in the FHIC components during erection to suit site conditions and meet functional requirements. This shall not be considered as extra work. After erection, the Contractor shall demonstrate that the pneumatic cylinders, venting dampers, pressure equalization dampers and doors operate smoothly and easily to the satisfaction of the Purchaser and that the dampers and doors are butting firmly against their frames all along to prevent air leakage.

During and after erection of the faces of FHIC, the Contractor shall

constantly check that inside the cabinet there is no gap left between the following: (i) insulation of adjoining panels (ii) insulation of panels and 26 GI sheet covering the insulation on the structural members, (iii) insulation of adjoining structural members, (iv) insulation of panel and items(s) penetrating it. He shall push loose insulation wrapped in glass cloth in these gaps to seal the air leak paths. These shall be secured to adjoining panel or items suitably to the satisfaction of the Purchaser / Site Engineer. However supplier may suggest some other suitable arrangement for fixation of insulation panels apart from bolting arrangement, like- push fit arrangement with sliding/ rotating (clit type) locking arrangement etc to save assembly & disassembly time for the panels.

Changes, if any, made in the FHIC during erection shall also be

incorporated in `as-built' drawings and got countersigned by authorised Site Engineer. The Contractor shall submit a detailed erection procedure(s), mentioning

handling of components, sequence in which different panels and component of each face will be erected and the sequence in which the different faces will be erected. While preparing procedure, he shall take into consideration the various activities going on in the F/M vaults.

Upon completion of erection of the different faces in all respects, the

Contractor shall offer the cabinets to the authorised site QA engineer(s) and prepare and submit a detailed report of the entire work done to the Engineer In-charge (EIC) at site. Acceptance of the work done will be conveyed by the EIC by issuing `Construction Completion Certificate' to the Contractor certifying that the work has been done as required and the FHIC is taken over by the Purchaser. The Contractor shall be deemed to have completed the erection work only on the issue of Construction Completion Certificate.

10.0 SUBCONTRACTING The Contractor shall not subcontract any or all of the work without a written consent from the Purchaser. In case the Bidder desires to subcontract part of the work, he shall include the details of works he is planning to subcontract and names and addresses of the corresponding subcontractors in his tender so that the Purchaser can evaluate them at an appropriate stage prior to placement of PO. Only those subcontractors who have been




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approved by the Purchaser shall be used. The Contractor shall be fully responsible to the Purchaser for all works of the subcontractors. Subcontractors shall allow access to his works / shop and provide all facilities, instruments, tools, etc. to carry out quality surveillance as desired by the Purchaser or his representative(s). 11.0 GUARANTEE The Contractor shall guarantee the feeders and headers insulation cabinets supplied and erected by him as per provisions of Clause 9 of CMM-11. In addition to the above the purchaser will execute thermograph of the insulation panels of both north and south FHIC to check its effectiveness. If any hot spots or thermal leakages are observed the same shall be rectified by the supplier without any extra cost. The supplier should do the necessary rectification work, whenever requirement is reported by the purchaser up to a period of three years from the date of completion of erection work at site.

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