NUCLEAR POWER CORPORATION OF INDIA LIMITED

KAHRAPAR ATOMIC POWER PROJECT-3&4 Page 3 of 12

ENGINEERING SPECIFICATION ON Rev. No.0
PROCESS EOUIPMENTS FOR
DELAYED NEUTRON MONITORING SYSTEM

1.0 SCOPE
This specification establishes the technical requirements for the manufacture,
inspection, testing and supply of Fitters, Sample Tube Headers, Sample Monitoring
Tubes, Return Headers and Pipe-to-Tube Adaptors tor use in the Delayed Neutron
Monitoring System of KAPP-3&4.

2.0 CONTENTS

DESCRIPTION SECTION
APPLICABLE STANDARDS AND DRAWINGS 3

MATERIALS ANO WORKMANSHIP 4

GENERAL FUNCTTON ANO DESCRIPTION 5

REOUIREMENTS 6

INSPECTION, TESTS AND REPORTS 7

PACKING AND SHIPPING 8

DOCUMENTATION 9

GUARANTEE 10

CHECK LIST FOR THE BIDDER ANNEXURE-I

OUALITY ASSURANCE PLAN ANNEKURE-II

3.0 APPLICABLE STANDARDS & DRAWINGS

Latest issues of all the standards listed below constitute a part of this specification. In
the event that certain requirements of these documents conflict with the requirements
of this specification, the requirements of this specification shall govern.

3.1 Applicable Standards .

ASME-B S PV Code Section IIl Division 1, Subsection NB for class 1 nuclear
components.
Section V- Nondestructive Examination.
Section IX - Welding & Brazing Qualifications


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NUCLEAR POWER CORPORATION OF INDIA LIMITED
KAHRAPAR ATOMIC POWER PROJECT-3&4 Page 4 of 12
ENGINEERING SPECIFICATION ON Rev. No.0
PROCESS EOUIPMENTS FOR
DELAYED NEUTRON MONITORING SYSTEM

ASTM A106 Specification for seamless carbon steel pipe for high
temperature service.

ASTM A-252 Standard practices for detecting susceptibility to intergranular
attack in Austenitic Stainless Steels.

ASYM A-479 Specification for Stainless S Heat-Resisting Steel wires, bars
and shapes tor use in boilers and other pressure vessels.

ANSI B1.20.4 Dryseal Pipe Threads.

ANSI B31.1 Code for pressure piping.

AWS A-5.4 Specification for Corrosion-Resisting Chromium and
Chromium-Nickel Steel covered welding Electrodes.

AWS A-5.9 Specification for Corrosion-Resisting Chromium and
Chromium-Nickel Steel covered welding Electrodes.

PC-M-267 NPC specification for seamless austenitic stainless steel
tubing for 700 MWe PHWR.

PC-P-198 NPC specification for general cleaning and handling
requirements for instruments and fittings for use in heavy
water and helium service.

PB-E-182/pp-e-1209 NPC specification for Liquid Penetrant Examination.

PP-E-1212 NFC specification for Radiographic Examination of Metallic
Products.

PP-E-1213 NFC specification for Ultrasonic inspection of Metallic
Products.

3.2Applicable Drawings

KAPP-3&4/63132/2007/DD DNM Filter details
KAPP-3&4/63132/2008/DD DNM Sample Tube Header details
KAPP-3&4/63132/2009/DD DNM Return Header details
KAPP-3&4/63132/2010/DD DNM Pipe-to-Tube Adaptor details
KAPP-3&4/63132/2011/DD DNM Sample Monitoring Tube detail

63132/PC-E-277 November 2008


NUCLEAR POWER CORPORATION OF INDIA LIMITED
KAHRAPAR ATOMIC POWER PROJECT-3&4 Page 5 of 12
ENGINEERING SPECIFICATION ON Rev. No.0
PROCESS EOUIPMENTS FOR
DELAYED NEUTRON MONITORING SYSTEM

4. MATERIALS ANQ WORKMANSHIP


alternate materials are used
shall be of good quality and in accordance with good practice pertinent to the
manufacture of steel pressure vessels and piping, subject to approval of purchaser.

lass, high grade quality and in accordance with the
best methods of manufacture to ensure satisfactory operation and service life in


5. GENERAL FUNCTION AND DESCRIPTION
The Filters, Sample Tube Headers, Sample Monitoring Tubes, Return Headers and
pipe-to-
and are, therefore, designed for pressure & temperature of 126 kg/cm and 326C
respectively. All the equipments are required for continuous duty.

6. REQUIREMENTS

6.1 General

All the equipments shall be constructed in accordance with ASME Boiler & Pressure
Vessel Code, Section Ill, subsection NB tor Class 1 nuclear components and the
requirements stated herein. The design and construction shall be appropriate for 40
years of trouble free power plant service for the conditions stipulated.
The manufacturer shall prepare fabrication drawings, fabricate, inspect, test and ship
completed Filters, Sample Tube Headers, Sample Monitoring Tubes, Return Headers
and Pipe-to-Tube Adaptors. Manufacturers work shall be deemed to be complete only
when the equipment has been delivered undamaged to the KAPP-3&4 Site.

6.2 Materials

All material rdance with ASTM standards shall be tested as required
by those standards. Such tests shall be in addition to the requirements of section S of
this spe s shall be free of dirt, grease, oil, rust, metal chips or
shavings and loose or heavy scale. r S
Return headers shall be fabricated from 5U NS double extra strong seamless carbon
steel pipe conforming to ASTM A-1115 Grade B.
Stainless steel material used in fabricating the sampl e
monitoring tubes shall be conforming to ASTM standards.


63132/PC-E-277 November 2008

NUCLEAR POWER CORPORATION OF INDIA LIMITED
KAHRAPAR ATOMIC POWER PROJECT-3&4 Page 6 of 12
ENGINEERING SPECIFICATION ON Rev. No.0
PROCESS EOUIPMENTS FOR
DELAYED NEUTRON MONITORING SYSTEM

6.3 Welding

All welding in accordance with ASME code for each equipment shall be electric and
in accordance with section IX of the ASME
B&PV
conform to any further requirements stated herein. All welding procedures must be
approved by NPCEL prior to their use.

Filler wire used for welds between SS St SS shall be of ER HUB L type as per AWE A-
5.9 and welding electrodes used for welds between S5 St CS shall be of type SUE} cb as
per AWS A-5.4.

All surfaces to be joined shall be thoroughly cleaned to prevent weld contamination. In
Multipass welding, any porosity, lack of penetration, inclusions or other defects and all
slag, oil, penetrant or other foreign material shall be completely removed alter root
pass, before subsequent passes are applied.

The root passes of welds accessible from one side only shall be made by the inert Gas
Tungsten Arc Welding (GTAW) process. The welds shall be purged on both sided with
inert gas. Fillet welds shall be continuous and shall completely seal off crevices. For
pipe and tube welding, the initial volume of air in the pipe and/or tubing shall be purged
with at least 6 times the air volume of inert gas before any welding is performed. The
purge gas shall continue to flow throughout the welding operation. The inert gas shall
be vented so as to prevent blow through when root passes are made. All welds shall

cuttings.

Electrode coating and core wire shall be free from undesirable elements that might
combine with deposited welded metal and alter its composition. To avoid moisture pick-
up, electrodes shall be kept in dry heated storage oven.

All welds shall be examined during and on completion of the process in accordance
with section 7.2.2, 7.2.3 and 7.2.4 and as required in the drawings and by Quality
Surveyor.

Weld defects shall be removed fully by grinding or chipping to ensure good weld
Preparation for rewelding.

6.4 Surface Finish and Cleanliness
All weld surfaces shall be smooth and merge smoothly into the parent material. All
scale, oxide, weld splatter, oil, chips and other foreign material shall be completely
removed from the inside and outside of ail components. All surfaces, which will not
permit internal cleaning after complete fabrication and assembly, shall be cleaned of all

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NUCLEAR POWER CORPORATION OF INDIA LIMITED
KAHRAPAR ATOMIC POWER PROJECT-3&4 Page 7 of 12
ENGINEERING SPECIFICATION ON Rev. No.0
PROCESS EOUIPMENTS FOR
DELAYED NEUTRON MONITORING SYSTEM

foreign material visible to the naked eye prior to assembly. Adequate precautions such
temporary covers shall be taken to ensure that this state of cleanliness is
maintained throughout upto the completion of alt work. Particular care should be taken
to ensure that ail tubing is kept clean and free of any m

Degreasing agents or other chemicals shall not be used without prior approval of the
purchaser. Chemicals containing chlorine or fluorine will not be approved.

Cleaning procedure shall be submitted to the purchaser by the manufacture: and shall
be approved by the purchaser.

6.5 ldenti on
Each equipment shall be tagged with the following information:

1)Manufacturer's name and identity
2} Unit name and identity of the project

Filters 63132-FR-1 through 63132-FR-392 & 40 spares.
Sample Tube Headers 63132-STH-1 through 63132-STH-28 & 6 spares.
Sample Monitoring Tube type A 63132-SMT-t through 63132-SMT-14 & 3 spares.
Sample Monitoring Tube type B 63132-SMT-15 through 63132-SMT-28 & 3 spares.

7. INSPECTION, TESTS AND REPORTS

7.1 Inspection

The manufacturer shall be responsible tor conducting all the tests as per the NPCIL
al
QA plan and detailed test procedure covering all the tests stipulated vide the QA plan
attached as Annexure-I as well as any other test deemed necessary to meet the
requirements. Three copies of these documents shall be submitted to NPCIL by the
manufacturer tor approval before commencement of fabrication.

The manufacturer's works shall be accessible to the authorized NPCIL representatives
for conducting/witnessing the inspection/testing at all the reasonable time. Any
deviation in_ the inspection/test results shall be subject to review by NPCIL and it found
acceptable shall be covered by a Design Concession Request to be submitted by the
manufacturer in a prescribed format and duly approved by NPCIL.

The manufacturer shall submit 3 sets of Test Reports based on approved test
procedure of the equipment.



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NUCLEAR POWER CORPORATION OF INDIA LIMITED
KAHRAPAR ATOMIC POWER PROJECT-3&4 Page 8 of 12
ENGINEERING SPECIFICATION ON Rev. No.0
PROCESS EOUIPMENTS FOR
DELAYED NEUTRON MONITORING SYSTEM


7.2 TESTS

7.2.1 Material Tests

All materials designated in accordance with ASTM standards shall be tested as required
by such standards, Proof that the required tests have been conducted at the source of
supply will
tests shall be preformed by the manufacturer at his expense. All bars shall be subjected
-E-12t3. All tubes shall be tested as per
-M-267.

7.2.2 Visual Examination

All welds shall be examined visually to ensure that they are ot good quality. Should the
purchasers inspector be dissatisfied with the quality of such welds, the contractor shall
conduct the necessary repairs at his own expense.

7.2.3 Liquid Penetrant Examination

Root and final passes of all seal welds, socket welds & butt weld shall be liquid
penetrant checked in accordance with PB-E-182/PP-E-1209 Penetrate and deyetoper
shall be removed completely on completion of inspection. The penetrant, developer and
cleaning agent shall be approved by the purchaser and shall not contain halogens and
sulphur in excess of 25 ppm each.

7.2.4 Radiographic Examination

All butt welds in the sample monitoring tube shall be radiographically examined in
accordance with PF-E-1212. Records of radiographic inspection shall be submitted to
NPCIL and shall remain as the property of NPGIL.

7.2.5 Hydrostatic Test

headers and pipe-to-tube adaptors shall be subjected to cold hydrostatic test as given in
respective drawings.

7.2.6 Helium Leak Test
All sample shall be
pressurized to 1 kg/cm with a gas containing at least 50% helium. Leakage to
atmosphere shall not exceed 10
6
cc/s of helium at a point and 10
5
cc/s overall as
determined by mass spectrometer. In lieu of helium leak test, a bubble test shall be
accepted under the following conditions. The devices shall be immersed in water and

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NUCLEAR POWER CORPORATION OF INDIA LIMITED
KAHRAPAR ATOMIC POWER PROJECT-3&4 Page 9 of 12
ENGINEERING SPECIFICATION ON Rev. No.0
PROCESS EOUIPMENTS FOR
DELAYED NEUTRON MONITORING SYSTEM

pressurized to pressure of 110 kg/cmg with helium. visual observations shall be made
for bubble formation. The rate of bubble formation shall not exceed 9 bubbles/hr. of
approx. 2 mm diameter.

7.3 Reports

The manufacturer shall submit 5 sets of Inspection Reports and Test Reports based on
approved test procedures.

8. DOCUMENTATION

3 sets of detailed fabrication drawings giving all the major dimensions shall be
submitted by the manufacturer to NPCIL for approval before commencement of
fabrication. 5 sets of As built drawings St Inspection History Docket and 1 set-.of
reproducible tracings shall be submitted by the manufacturer to NPCIL after fabrication
before shipping.

9. PAGHENG AND SHIPPING

Procedure proposed for the preparation of equipments for shipment shalt be submitted
to the purchaser for approval and shall meet the following requirements:
1. All shipment shall be tropically packed, suitably boxed, crated and protected
from damage in transit to site. .
2. Equipments shall be prepared for a storage period exceeding six months.
3. Suitable rust inhibitor approved by purchaser shall be applied to carbon steel
surfaces.
4. the interior of equipments shall be cleaned dry and ail openings shall be
blanked, plugged, capped or otherwise suitably sealed to prevent the ingress of
moisture. "
5. All packages shall be suitable for rail/road transport and shall have adequate
cushioning, blocking, bracing, skidding, hoisting and tie down provisions.
5. All packages shall be clearly and legibly marked in a suitable, permanent
manner with the following information:
Purchase Order No............
USI No: 63132
No. of equipments in each package.......... ..

9. GUARANTEE
The equipments shall be guaranteed against defects arising out of faulty design,
materials and workmanship at least tor a period of one year after commissioning or
eighteen months from the date or despatch whichever is earlier.

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NUCLEAR POWER CORPORATION OF INDIA LIMITED
KAHRAPAR ATOMIC POWER PROJECT-3&4 Page 10 of 12
ENGINEERING SPECIFICATION ON Rev. No.0
PROCESS EOUIPMENTS FOR
DELAYED NEUTRON MONITORING SYSTEM


ANNEXURE-1
CHECK LIST FOR THE BIDDER
(To be submitted along with the Quotation)

1. Complete technical details of seal plates are being submitted Yes/No
along with the Quotation.

2. AIE fabrication drawings including bill of material shall be submitted Yes/No
to NPC for approval within one month of receipt of purchase order.

3. Fabrication procedure and Inspection Er Testing procedure shall be Yes/No
Submitted to NFC within two months after receipt of purchase order.

4. 5 sets of As built drawings 8. Inspection history Docket shall be Yes/No
(Submitted to NFC after completion of the order.

5. All the raw material sha Yes/No
Q5 Engineer before taking up fabrication work to ensure that alt the
relevant tests such as chemical composition, physical tests. IGC test,
ultrasonic tests etc., as applicable, are carried out.

6. Aii the machined components shall be inspected and cleared by NFC Yes/No

and tolerances.

7. All welding Yes/No
welder.

B. All tests detailed below shail be carried out as per this specification.

8.1 Material Tests (section 7.2.1) Yes/No

8.2 Visual Examination (section 7.2.2) Yes/No

8.3 Liquid Penetrant Examination (section 7.2.3) Yes/No

8.4 Radiographic Examination (section 7.2.4) Yes/No

8.5 Hydrostatic Test (section 7.2.5) Yes/No

8.6 Helium Leak Test (section 7.2.6) Yes/No

63132/PC-E-277 November 2008

NUCLEAR POWER CORPORATION OF INDIA LIMITED
ENGINEERING SPECIFICATION ON PROCESS EOUIPMENTS FOR DELAYE Page 11 of 12
NEUTRON MONITORING SYSTEM Rev. No.0

ANNEXURE-II
QUALITY ASURANCE PLAN
SL
NO.
Components Characteristic Type of
check
Classifi
cation
of test
Quantum
of check
Reference
Document
Acceptance
Norms
Format
of
Record
Agency

P W V
Remarks
1 Raw Material Chemical
Composition

Analysis/
Test
Major 1 sample
Per heat
Relevant
ASTM std.
Relevant
ASTM std.
Product
Analysis
Report
3 2 1 To be
Done in
NPCIL
Approved
Lab
Physical
Properties (tensile,
Yield, %elongation
& %reduction in
Area , hardness)
Inter Granular
Mechanical
Testing

-do-

1 sample
Per heat

-do-

-do-

Test
certificate

3 1 1 -do-
-do-
Corrosion (IGC)
Test

IGC Test -do- 1 sample
Per heat
ASTM A-262
Prac-E
ASTM A-262
Prac-E
Test
certificate
3 1 1
Physical Defect

Ultrasonic
Test
-do- 100% PP-E-1213 PP-E-1213 Inspection
Report
3 1 1 -do-
Visual
Examination

Visual for
Any visible
Defects
-do-


100% --- --- Internal
Quality
Control
Records
2 1 1
2 Finished
Machined
Parts
Dimensions Dimension
Inspection
-do- 100% NPCIL
Approved
Manufacturers
Drawing
NPCIL
Approved
Manufacturers
Drawing
Inspection
Report
2 1 1

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ENGINEERING SPECIFICATION ON PROCESS EOUIPMENTS FOR DELAYE Page 12 of 12
NEUTRON MONITORING SYSTEM Rev. No.0

SL
NO.
Components Characteristic Type of
check
Quantum of
check
Reference
Document
Acceptance
Norms
Format of
Record
Agency

P W V
Remarks
3 FINISHED
PRODUCTS
Weld Joints Visual
Examination
100% NPC Spec. NPC Spec. Test Reports 2 1 1
4 -do- Liquid
Penetrant
Examination
100% -do- -do- -do- 2 1 1
5 -do- Radiograpic
Examination
of
Butt Welds
100% -do- -do- -do- 3 1 1 To be done
By NPC
Approved
Test House.
6 -do- Leakage Hydrostalic
Test
100% -do- -do- -do- 2 1 1
7 -do- Helium Leak
Test
100% -do- -do- -do- 2 1 1
8 -do- Final Packing Final Packing
Check
100% -do- -do- -do- 2 1 1


P- Performed By 1. NPCIL

W- Witnessed By 2. Manufacturer

V- Verified By 3. Third Party






63132/PC-E-277 November 2008