2014

Jawaharlal Nehru National College Of Engineering, Shimoga

Ritesh R. Marathe

NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A Government of India Enterprise)

Kakrapar Atomic Power Project 3&4

[INTERNSHIP REPORT]
15 January 2014 to 30 January 2014

Mechanical Construction & Quality Control

Acknowledgement
It gives me immense pleasure to present this report on the project assignment titled MECHANICAL CONSTRUCTION & QUALITY CONTROL. I feel very fortunate to have the support of number of key individual during the project work. I would like to express our gratitude to those whom have contributed so much of themselves in helping us throughout the completion of the project. I would also extremely indebted and thankful to Shri V Ramesh Kumar (CE Mech & GP KAPP 3&4),my project guide Shri Suresh V. Kolekar (SO/D PIPING KAPP 3&4), Shri Raju B. Marathe(SA/E Electrical KAPP 3&4),Shri Uday P. Madangeri(ACE NP,CP&V KAPP 3&4) & Smt. Anshu Yadav(DM HR) for their very valuable professional guidance, tips, necessary support, suggestions and for making all the resources available to enable me to carry out the project work successfully and presentable style. I am greatly thankful to my teachers Shri R. SrinivasRao Kunte (Principal JNNCE, Shimoga) & Dr. D.S.Ramakrishna (HOD Mechanical JNNCE, Shimoga) who gave us their guidance to complete this project. And last but not the least a great thanks to all those people who knowingly or unknowingly supported and helped in making this project.

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Daily Schedule
Day Date Study Topic Understanding about companys profile, mission, organization, working culture and execution methods. Study of Engineering Drawing being used in the construction.

15 January 2014

16 January 2014

17 January 2014

18 January 2014

Study of construction materials being used in the piping system. Visit to various Fabrication shops and various equipment being used for fabrication and study of fabrication process Study of fabrication process Understanding various Welding methods used in construction Study of various cleaning methods being used for piping system and pipe support and painting. Understanding various methods of Pipe bending and its acceptance standards Understanding about Quality control and their acceptance standards. Quality assurance. Understanding DPT &MPT Understanding Radiography Visit to KAPS- 1&2 station Submission of pre final report Submission of final report

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20 January 2014 21 January 2014

22 January 2014

23 January 2014

24 January 2014

10 11 12 13 14

25 January 2014 27 January 2014 28 January 2014 29 January 2014 30 January 2014

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Contents
1. Company Profile 2. Kakrapar Atomic Power Project 3. Internship Activities 3.1Drawing 3.2Materials Used in Piping Systems 3.3Fabrication 3.3.1Cleaning 3.3.2Cutting 3.3.3Pipe Bending 3.3.4Welding 3.4Quality Control 4. Bibliography

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Company Profile
Introduction
The Nuclear Power Corporation of India Limited (NPCIL) is a government-owned corporation of India based in Mumbai. NPCIL is administered by the Department of Atomic Energy (DAE). NPCIL is the only power utility company in India which uses nuclear fuel sources. NPCIL was created in September 1987 as public limited company under the Companies Act 1956, "with the objective of undertaking the design, construction, operation and maintenance of the atomic power stations for generation of electricity in pursuance of the schemes and programmes of the Government of India under the provision of the Atomic Energy Act 1962." All nuclear power plants operated by the company are certified for ISO-14001 (Environment Management System). NPCIL is the sole body responsible for constructing and operating India's commercial nuclear power plants. As of 17th January 2014 the company had 21 nuclear reactors in operation at seven locations, a total installed capacity of 5780 MWe. Operating Income-7962 crore rupees Net Income- 2101 crore rupees Total equity-20740 crore rupees

Mission
To develop nuclear power technology and to produce nuclear power as a safe, environmentally benign and an economically viable source of electrical energy to meet the increasing electricity needs of the country.

Board of Directors
The business of the company (NPCIL) is managed by the Board of Directors appointed by the President of India. The Chairman and Managing Director is the Chief Executive of the company and looks after the day-to-day affairs of the company under the superintendence of the Board of Directors

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Details of Operating Reactors as per Jan 2014 Operating Reactors Type of Reactor Rated Capacity MW 160 160 540 540 100 200 220 220 220 220 220 220 220 220 220 220 220 220 220 220 1000 5780 Location Commercial Operation 28/10/1969 28/10/1969 18/08/2006 12/09/2005 16/12/1973 01/04/1981 01/06/2000 23/12/2000 04/02/2010 31/03/2010 27/01/1984 21/03/1986 01/01/1991 01/07/1992 06/05/1993 01/09/1995 16/11/2000 16/03/2000 05/05/2007 20/01/2011 22/10/2013

TAPS-1 TAPS-2 TAPS-3 TAPS-4 RAPS-1 RAPS-2 RAPS-3 RAPS-4 RAPS-5 RAPS-6 MAPS-1 MAPS-2 NAPS-1 NAPS-2 KAPS-1 KAPS-2 KAIGA-1 KAIGA-2 KAIGA-3 KAIGA-4 Kudankulam-1 Total

BWR BWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR PHWR VVER 22

Tarapur (Maharashtra)

Rawatbhata (Rajasthan)

Kalpakkam (Tamil Nadu) Narora (U.P.) Kakrapar (Gujarat) Kaiga (Karnataka)

Kudankulam (Tamil Nadu)

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Reactors Under Construction as per Jan 2014 Projects Kudankulam-2 Type Of Reactor VVER Rated Capacity(MW) 1000 Location Kudankulam (Tamil Nadu) Kalpakkam (Tamil Nadu) Kakrapar (Gujarat) Rawatbhata (Rajasthan)

Fast Breeder (BHAVINI) KAPP-3 KAPP-4 RAPP-7 RAPP-8 Total

PFBR

500

PHWR PHWR PHWR PHWR 5

700 700 700 700 3300

Reactors proposed Projects JNPP Type Of Reactor EPR Rated Capacity(MW) 1650x6 Location Jaitapur (Maharashtra) Gorakhpur (Haryana)

GHAVP

PHWR

700x4

Total

10

12700

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Kakrapar Atomic Power Station

The Kakrapar Atomic Power Station (KAPS) is a nuclear power station in India, which lies in the proximity of the city of Surat in the state of Gujarat. It consists of two 220 MW pressurized water reactors with heavy water as moderator (PHWR). NPCIL is constructing two unit of capacity 700 MW x 2 Pressurized Heavy Water Reactors indigenously developed by India. Construction is being carried out by awarding various EPC packages to contract. Total construction period is 5 years. KAPP 3&4 is being headed by Project Director.
Project director

Chief Constuction engineer

Field Engineering

safety

Quality Group

Civil group Instrumentaion group Mechanical group Piping Group Electrical group

In construction Prime importance is given to Safety and Quality. Workers and engineers are being trained and assessed before putting them on actual job.

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Internship Activities
1. Drawings
An engineering drawing is used to fully and clearly define requirements for engineered items. Following three Types of drawings are being used for piping system: P&ID (Process and Instrumentation Diagram): This drawing indicates process flow direction. With this we can check completeness of the system installed and to finalize testing circuits. GA (General Assembly) : General assembly drawings are used for laying pipe at field and to plan the sequence of pipe installation. It also indicates the plan location with respect to plant grid

DD (Detailed Drawing/Isometric):

This drawing is used for prefabrication. In this drawing bill of materials, pipe support location and location of pipes with respect to plant grid location are shown. 3rd Angle projection system is used

The above drawings may be preliminary, tendering or field construction issue. 1. Preliminary issue drawing is issued to get the basic knowledge of the system 2. Tendering drawings is used to estimation of the quantum of work involved and the material requirement and thus cost is estimated. These drawings are issued along with tenders to the contractor. 3. Field Construction drawing is the final drawing used for the implementation/construction of the system. If there are any subsequent changes in the drawings being reflected by revision of the drawing (R0, R1, R2) All construction drawings are drawn according to plant north .Plant north may not coincide with actual north. Similarly, Elevation of systems are taken from 100m reference plane which is the ground level decided at construction site. Universal System of Indexing (USI) is used to identification of system and its subsystem and same being used for numbering of the drawing All Construction Design is based on ASME sections.

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2. Materials used in Piping Systems:

Materials used in piping systems for the reactors are Carbon Steel and Stainless Steel Structural material made from plain carbon steel were observed to be fabricated at the CS fabrication shops of standard IS2062 Gr.A Fe350 ASTM Materials are being used for piping system. CS Pipe material: SA106Gr.B, SA333Gr.6, SA672Gr60Cl12, SA53 CS Pipe Fitting materials: Flange: SA515Gr60, SA350LF2 SS Pipe Material: SA312 WP304L SS Pipe Fitting Material: Elbows: SA403 WP304L

Seamless and Seam Pipes of 300 Series (austenitic chromium-nickel alloys) of 304L grade were observed which is same as the 304 grade but lower carbon content to increase weldability. Also valves made of 316L grade are used which is an extra low carbon grade of 316 and is used due to its high resistance to corrosion.

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2. Components of Piping System

1. Pipings 2. Fittings 3. Fasteners 4. Valves 5. Supports 6. Pumps

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4. Fabrication

4.1 Cutting
Gas Cutting/Oxy Fuel Cutting
Gas cutting is a process which uses Dissolved Acetylene (D.A.) Gas and Oxygen to cut metals. An acetylene/oxygen flame burns at about 3,500 C. Components of Gas cutting setup 1. D.A. Cylinder Consists of Acetylene Dissolved in Acetone at Low pressure stored in a low pressure cylinder. These Low pressure cylinders are formed and then welded. D.A cylinders have left handed female thread. It is identified by a short maroon cylinder. 2. Oxygen Cylinder Oxygen cylinders are seamless vessel contains high pressure oxygen. These high pressure cylinders are completely formed in one piece and machined accordingly .Oxygen cylinders have right handed female thread. It is identified by tall black cylinder. Note: Gas Cylinder Storage: Above cylinders have to be stored in semi closed /closed conditions to avoid direct sunlight and also away from any source of heat. It must be stored vertically .It should be chained to avoid its accidental fall. Water collection should not be allowed at the storage area to avoid corrosion of the cylinders. Cylinders must be stored with valve cover caps, if so equipped. Storage cylinders must be segregated into FULL or EMPTY groups at location. Flammable gas cylinders whether full or empty must not be kept near an exit or any location which could block an exit. 3. Regulator The regulator is used to control pressure from the cylinders to the required pressure in the hose. Regulators used for gas cutting are of single stage type. Different regulators are used for DA gas and Oxygen. DA gas regulator (Red): Left handed male thread Oxygen regulator (Blue): Right handed male thread 4. Hose The hoses are specifically designed for welding and cutting metal. The hose is usually a double-hose design, meaning that there are two hoses joined together. These hoses are color-coded for visual identification and their threaded connectors are handed to avoid accidental misconnection: oxygen is right-handed as normal, fuel gases use a left-handed thread. Hoses are colour coded, red is for DA gas and blue is for Oxygen.

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5. Flashback arrestor/Non-Return Valve Between the regulator and hose, and ideally between hose and torch on both oxygen and fuel lines, a flashback arrestor and/or non-return valve (check valve) should be installed to prevent flame or oxygen-fuel mixture being pushed back into either cylinder and damaging the equipment or making a cylinder explode. 6. Cutting Torch A cutting torch head is used to cut materials. It can be identified by the oxygen blow out trigger or lever. Nozzle for the torch comes in various sizes according to thickness of the metal to be cut. Nozzle Size 1/32" (0.8mm) 3/64" (1.2mm) 1/16" (1.6mm) 5/64" (2.0mm) 3/32" (2.4mm) 1/8" (3.2mm) Plate Thickness 3-6mm 5-12mm 10-75mm 70-100mm 90-150mm 190-300mm

Flame Types Only Neutral Flame is used for gas cutting. Note: Protective eye gear should be of minimum filter shade 5 for gas cutting

Methods: 1. Manually :Gas cutting can be done manually by a skilled gas cutter and is preferred because of its versatility 2. Automatic: Automated cutting of the metal can be done using Pug cutting machine.

Cutting using Angle Grinder

An angle grinder is a handheld power tool used for cutting, grinding and polishing. AG-7 and AG-4 Angle grinders were observed .The cutting Wheels are made from Alumina Oxide or Boron Carbide

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 Pipe Bending
Pipe bending using Numerical controlled (NC) pipe bending machines. Pipe bending radius is adjusted using dies. Joviality of the bent pipe is maintained below 8%. Ovality is maintained using correct dies. Ovality= [(Major Dia-Minor Dia)]/ [Nominal Dia] *100

Measuring Instruments used in pipe bending.

1. Master Level gauge: used to check horizontality and verticality. 2. Plum and Straight edge 3. Measuring Tape 4. Steel Scale 5: Templates 6. Bevel Protractor: Both analogue and digital bevel protractors are used for measuring pipe bend angle. 7. Ultrasonic thickness gauge: Its used to measure the thickness of the pipe.

Welding
Welding is fabrication process to join metal components.

Shielded Metal Arc Welding (SMAW) Tungsten Inert gas welding (TIG) Shielded Metal Arc Welding (SMAW)
SMAW is done to join pipes & structural supports. Welding Equipments 1. Rectifier: Its used to convert AC current to DC current. 2. Electrodes: E 7018-1 electrode is used for SMAW. 3. Flux oven: The electrodes are baked in the oven at 300oC for 1 hour to remove the moisture content in the electrode. 4. Electrode drying oven: Its also used to remove the moisture content in the electrode. Its portable.

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Tungsten Inert Gas (TIG) Welding

Tungsten Inert Gas welding is done to join stainless steel components such as pipes and its fittings, Welding Equipments: 1. High frequency Current source 2. Inert gas: Argon is used as inert gas 3. Tungsten torch: Heat is generated from the current passing through 4. Electrode: Tungsten electrode WT20 type is used. 5. Filler rod: ER308L 6. Welding Inserts : Grade 1 'T type' welding inserts are used 7. Tacking supports 8. Thermo pen: Used to measure interpass temperature

Pipe Cleaning
Cleaning is also an important process to be carried out in an industry. Usually pipes are cleaned to remove the dirt, grease, foreign matter & halide contamination due to handling.

Components used in pipe cleaning

1) 2) 3) 4) Monorails/Trolleys are used to carry the pipes. Tanks: 2 tanks are used in SS pipes cleaning & 3 tanks are used for the cleaning of CS pipes. Heaters: Heaters are used to maintain the temperature for detergent washing in SS pipes. Brush: Nylon brushes are used in SS pipe cleaning & Metal wire brushes are used for the cleaning of CS pipes. 5) Detergent: Lisopol 100X is the detergent used in the SS pipe cleaning shop. 6) De mineralised water (DM Water): Specific resistance is minimum 50000 ohms and the pH value should be between 6.5-8

Carbon Steel (CS) pipe cleaning

1. Pipe is lowered in 8% NaOH solution tank. 2. Its cleaned & degreased using metal wire brush. 3. Its then rinsed with water.
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4. 5. 6. 7. 8.

Pickling of the pipe is done in 15 %( by weight) H2SO4 solution for 10-15 mins. Its again rinsed with water. Its neutralized in 2% NaOH solution. The pipe is then rinsed with Demineralised water (DM water). The pH of the pipe is checked using Litmus Paper.

Stainless Steel (SS) pipe cleaning

1. Passivation of the pipe is done by the manufacturer of the pipe. 2. Pipe is then degreased & cleaned with detergent solution (Lisopol 100X) 3. Finally its then rinsed with water.

Feeder pipes cleaning

1. The pipes are kept in the tank containing 8% NaOH solution which is heated till 45oC for 10-15 mins. 2. The pipes are cleaned using Nylon brushes. 3. The pipes are then rinsed with water. 4. Finally they are cleaned with DM water.

Grit blasting or Abrasive Blasting

Abrasive blasting is the operation of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface, or remove surface contaminants. A pressurized fluid, typically air, or a centrifugal wheel is used to propel the blasting material (often called the media).

Angular grits are used up to size of 1.6mm delivered at a pressure of 10Kg/cm 2. CS pipes are grit blasted to SA2 standard. Surface Roughness Comparator is used to check the roughness.

Quality control (QC)

Quality control and Assurance is important part of an industry. QC ensures the quality of the product under acceptable standards. Quality Control ensures quality of the product under acceptable standards. Different types of NDT being used to ensure the quality of the job depending on quality requirement. At fabrication facility NDT being carried out are VT, LPT, MPT & RT. For pipes Non Destructive Testing (NDT) are used to check the weld joints & bended pipe portion.

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The various NDT methods are:

Visual Test (VT) Visual test is done using either or all senses of humans such as vision, hearing, touch and smell. Non Equipments such as magnifying glasses or mirror is used. The VT is done in luminosity of 500-1000 lux with viewing distance of 300-600mm.

Advantages
No special equipment is required for the test. Its fast and easy.

Disadvantages
Minor cracks, subsurface cracks cant be detected. The inspection depends on the capability of the observer.

2. Dye penetrating test (DPT/LPT/PT) Dye penetrating test is done to detect surface defects.

Advantages
Its quick and easy. Doesnt require skilled personnel. Inexpensive.

Disadvantages
Detects only surface defects. Should be done on smooth and cleaned surface.

Magnetic particle test (MPT) MPT is used for detecting slightly surface and sub surface discontinuities in ferromagnetic materials such as iron, cobalt, nickel and some of their alloys.

Advantages
Shows both surface & subsurface defects (3-6 mm). Its quick & easy. Elaborate pre cleaning is not necessary. Its not expensive. 16 | P a g e

Disadvantages
Its messy. Need for electricity. Interpretation is a skilled task. Its restricted to ferromagnetic materials & not applicable to austenitic stainless steel.

4. Radiography test (RT) Radiography test is a type of volumetric test which is done to detect flaws using X rays or Gamma rays which are emitted from radioactive substance. X rays are generated using high frequency cathode ray tubes (CRTs). Gamma rays are obtained from radioactive source. Generally used source are Iridium-192, Cobalt-60.

Advantages
Radiographic tested films can be recorded & stored for later use. Its a volumetric test.

Disadvantages
X rays & Gamma rays are harmful. Using Gamma rays method involves handling of radioactive source. X ray method of RT is not portable.

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