GENERAL TECHNICAL SPECIFICATIONS FOR PRESSURIZER

1 SCOPE AND DELIVERABLES

This Specification establishes the technical requirements for the procurement and inspection of raw
material and standard components, manufacture/fabrication and inspection of components and parts
from these raw materials, design and fabrication of supports, complete assembly, shop testing,
packing and safe delivery of the following component (Table-1, Page-1) as the specifications and
drawings:
Table 1: Vessel to be fabricated and delivered
S no. Description Quantity
(nos.)
1 Pressurizer with supports (details in Annexure-1) 1

The following shall be the supplier’s broad scope of work. Greater details are given in respective
annexures.
1.1 Preparation of detailed Quality Assurance Plan (QAP) in line with this specification and getting them
approved by purchaser or his representative prior to initiation of material procurement.
1.2 Design of supports according to the requirements of this specification and getting the design approved by
purchaser or his representative.
1.3 Preparation of detailed fabrication drawings in line with this specification and getting them approved by
the purchaser or his representative prior to initiation of fabrication.
1.4 Procurement of raw materials, consumables and standard components required for the work specified
herein.
1.5 Inspection and testing of procured raw materials other items and standard components according to
approved QAP.
1.6 Qualification of various procedures which will be adopted for fabrication according to approved QAP.
1.7 Fabrication, assembly and shop testing of the vessels with supports according to approved QAP and
approved drawing.
1.8 Testing during and after fabrication, assembly and shop testing according to approved QAP and
approved drawing.
1.9 Pickling and passivation of stainless steel equipment.
1.10 Painting, packaging and safe delivery to designated delivery place specified herein.
1.11 Documentation of all design, testing, procedure qualification and fabrication activities and submission of
these to purchaser in a history docket.

The detailed technical specifications of the components as mentioned in Table-1 (Page-1)Table 1 are
provided in respective annexures.

2 PLACE OF DELIVERY:
ITFT Building, NPCIL R&D Centre, TAPS 3&4, Tarapur, Maharashtra Site, Tarapur, Maharashtra.
Pin-401502

3 DELIVERY TIME
Delivery period shall not exceed 18 months from the date of placement of purchase order.

4 REQUIREMENTS FOR VENDORS

4.1 Initial Eligibility Criteria for bidders:
The bidder should have the following:
a) Registration in Appropriate Class of Contractors, if any.

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 b) Average Annual Financial Turnover should be at least Rs 3.5 crores, during immediate last 3
consecutive financial years ending 31st March, 2019. This should be duly audited by a
registered Chartered Accountant.
c) Should not have incurred any loss in more than two years during last five years ending 31st
March, 2019.
d) List of similar work completed during last 7 years.
e) Construction Plant & Machinery, equipment, accessories & other infrastructure facilities to
complete the work in time.
f) Valid GST Registration Certificate.
g) Permanent Account Number (PAN).
4.2 Mandatory Requirements for bidders:
The following are mandatory requirements for bidders. Bids of only those vendors/ manufacturers
who satisfy the below criteria will be taken into consideration.
a. Vendors/ manufacturers should have experience in fabrication of high pressure (greater than
or equal to design pressure 70 kg/cm2) and high temperature (greater than or equal to
design temperature 200oC) vessels and/or heat exchangers having shell diameter of at least
400 mm. Both these criteria should be met simultaneously in a single vessel/heat
exchanger.
b. The vendors/ manufacturers should have adequate knowledge of design, fabrication and
testing procedures and requirements as per ASME Boiler and pressure vessel code.
c. Vendor/ manufacturer’s workshop should have the capacity to handle equipment up to 8 m in
length and 300 mm diameter.
d. Vendor/ manufacturer should have experience of procurement and testing of raw materials of
stainless steel and carbon steel. They should also have experience of machining and
fabrication of vessels/ heat exchangers with shell outer diameter of at least 300 mm
employing these metals. Further, the vendors/ manufacturers should have previously
executed jobs involving welding of stainless steel and carbon steel pipes/plates of
thickness 30mm or more.
e. The vendors/ manufacturers should have prior experience of fabrication and testing of
integrally finned tube heat exchangers and cladded tube sheets.
f. Vendor/ manufacturer should have a minimum a design engineer, fabrication engineer and a
quality engineer along with sufficient numbers of fitters, machinist and welders to take up
all jobs in parallel.
g. Vendor/manufacturer should have on its rolls a design group and a QA group. QA group
should have at least one person with Level-II certification.
h. Vendor/ manufacturer’s average annual financial turnover for fabrication works should be at
least Rs 50 lakhs, during the immediate last 3 consecutive financial years ending 31st
March, 2020. This should be duly audited by a registered Chartered Accountant.
i. Bids of only those bidders who have quoted for all the components as in Table 1 (Page-1) will
be considered. Part bids will be rejected. Bidder shall quote all items separately.
j. It may be noted that the purchaser has the discretion to place part order.
k. Vendor/ manufacturer should have experience of having successfully completed similar
works (pressure vessels or heat exchangers) during last 7 years ending last day of month
previous to the one in which this tender is invited should be either of the following:
i. Three similar completed works costing not less 20 lakhs each.
ii. Two similar completed works costing not less than 30 lakhs each.
iii. One similar completed work costing not less than 50 lakhs.
Documentary proof of meeting the above criteria must be provided while submitting technical bid.
Bids which do not conform to any one of these mandatory criteria are liable to be rejected. After
receiving the bids, the BARC will at its discretion verify the credentials of the bidders by making
factory visits. The essential documentary evidences required are tabulated in Table-2 (Page-3):

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Table 2: Documentary evidence required for bidder qualification
Criteria Documents required
4.2a, 4.2d, 4.2e Successful work completion certificate from Department of Atomic Energy
(DAE) organizations or other government organizations or Public sector
undertakings or reputed private companies
4.2b Copy of ASME U certification
4.2c, 4.2f, 4.2g Self-certification from vendor in form of declaration on letter head or
informational flyer etc.
4.1b, 4.1c and 4.2h Audited balance sheet for previous financial 5 year

5 APPLICABLE CODES AND STANDARDS

The fabrication procedure associated testing of the aforementioned pressure vessel and heat
exchangers along with design of support must conform to the latest edition of the following codes and
standards as listed in Table-3 (Page-3).

Table 3: Applicable codes and standards

ASME Standards
ASME Section-II Material specifications
ASME Section - V Non-destructive examination
ASME Section - VIII Div.1 Rules for construction of pressure vessels division 1.
ASME Section-IX Welding and brazing qualifications
ASME SA-182 Forged or Rolled Alloy Steel Pipe Flanges, Forged Fittings, and
Valves and Parts forHigh-Temperature Service
ASMESA-193 Alloy Steel & Stainless Steel Bolting Material for High
Temperature Service.
ASME SA-194 Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-
Temperature Service,or Both
ASME SA-240 Heat-resisting chromium and chromium-nickel stainless steel
plate, sheet and strip for pressure vessels
ASME SA-213 Seamless ferritic and austenitic alloy-steel boiler, superheater, and
heat-exchanger tubes
ASME SA-312 Seamless and Welded Austenitic Stainless Steel Pipe
ASME SA-480 General requirementsfor flat-rolled stainless and heatresistingsteel
plate, sheet, and strip
ASME SA-516 Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-
Temperature Service
ASME SA-578 Specification for straight-beamultrasonicexamination of plain and
clad steelplates for special applications
ASME SA-745 Practice for Ultrasonic Examination of Austenitic Steel Forgings
ASME SA-999 General Requirements for Alloy and Stainless Steel Pipe
ASME SB-167 Specification for nickel-chromium-iron alloys (UNS N06600,
N06601, N06690, N06025, and N06045) seamless pipe and tube
ASME A-388 Standard practice for ultrasonic examination of heavy steel
forgings
ANSI
ANSI B16.5 Pipe flanges and flanged fittings
ANSI B16.34 Valves - Flanged, threaded and welded end
ANSI B36.10 Welded and seamless wrought steel pipe
American Society for Testing and Metals (ASTM)
ASTM-A-182 Dished head with austenitic stainless steel
ASTM A-262 Practices for Detecting Susceptibility to Inter-granular attack in Austenitic
Stainless Steels
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ASTM-A-312 Seamless and welded austenitic stainless steel pipes
ASTM A-370 Test Methods and Definitions for Mechanical Testing of Steel Products
ASTM-A-380 Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel
Parts, Equipment, and Systems
ASTM-A-530 Standard Specification for General Requirements for Specialized Carbon and
Alloy Steel Pipe
ASTM-A-578 Standard Specification for Straight-Beam Ultrasonic Examination of Rolled
Steel Plates for Special Applications
ASTM E 94 Practice for Radiographic examination
ASTM E-165 Practice for Liquid Penetrant Inspection Method
ASTM-E-381 Standard Method of Macro etch Testing Steel Bars, Billets, Blooms, and
Forgings
Manufacturers Standardisation Society
MSS-SP-25 Standard marking systems for valves, fittings, flanges & unions.
MSS-SP-97 Integrally Reinforced Forged Branch Outlet Fittings –Socket Welding,
Threaded, and Butt welding Ends
Bureau of Indian Standards
IS-302 General And Safety Requirements For Household And Similar Electrical
Appliances
IS: 816 Code of practice for use of metal arc welding for general construction of mild
steel.
IS : 817 Code for practice for training & testing of metal arc welders.
IS: 822 Code of procedure for inspection of welds.
IS-2062 Hot rolled medium and high tensile structural steel - specification
NETA/MTS-1997 Electrical insulation testing
American Welding Society (AWS) Standard
Standards of Tubular Exchange Manufacturers Association (TEMA)

In event of conflict between the above standards and this technical specification, this specification
shall govern.

6 DESIGN DRAWINGS
The design drawing of each component is attached and discussed in respective annexures. The
vendor/ manufacturer should note that the drawing provided along with this specification is a design
drawing. On placement of the order, vendor is required to prepare and submit to the purchaser,
detailed fabrication drawings for approval. Fabrication/manufacturing shall commence only after
approval of fabrication drawings by purchaser.

7 BRIEF TECHNICAL SPECIFICATIONS

Technical specifications of each component is attached and discussed in respective annexures.

8 GENERAL REQUIREMENTS
The construction of all above equipment design and construction of supports shall be done in
accordance with the latest editions of codes and standards specified in Table-3 (Page-3). Certain
requirements in this specification may be in excess of the above.
8.1 Material and workmanship
Material and standard parts which are not specifically designated herein shall be of good quality and
in accordance with the best practice in the manufacturing of pressure vessels. Used materials/ recycled
items/ repaired items will not be acceptable and will be rejected.
Workmanship shall be in accordance with the best practice and at least adequate to ensure satisfactory
operation and service life for the conditions stated herein.

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8.2 Subcontracting
Majority of the work should be done in the premises of vendor/manufacturer’s with which the
purchase order is placed. For some specialized procedures or components subcontracting may be
allowed. Subcontracting/ outsourcing are allowed subject to approval of purchaser. No work in this
order may be subcontracted without purchaser’s approval. The responsibility that the work performed
by subcontractor is in conformance with this specification lies with the vendor/manufacturer on which
purchase order is placed. The purchaser shall have access to the premises of the subcontractor for
inspection of the equipment and work carried out by the subcontractor.

9 RAW MATERIALS
No Free Issue Material will be provided by the purchaser. Material procurement and testing is in
scope of bidder. All materials specified in accordance with ASME/ASTM or IS Specification shall be,
as a minimum, tested as required by those Specifications. The requirement of this Specification are in
addition to such testing specified in material specifications. All the raw material shall be new. The
used and reconditioned raw material will not be accepted. Generally, all material shall be free of rust,
pits, shop dirt, grease and loose or heavy scale.

9.1 Bolting Materials

All screws, studs, bolts and nuts used in the vessels and their supports shall conform to the
requirements of tender drawings. All nuts shall be provided with corrosion resistant positive locking
devices/nuts. Bolting materials are indicated on Vessel Specification Sheets and drawings. Materials
intended for use in the vessels shall be examined by magnetic particle or liquid penetrant methods.
Bolting materials shall be visually checked and shall be free from obvious defects such as crossed
threads, deep surface imperfections and other damages.
9.2 Gaskets
Spiral wound metallic gaskets with flexible graphite packing conforming to ANSI B36.10 shall be
used. Gaskets shall be of good quality and free from imperfections.
9.3 Testing of materials

9.3.1 The material shall be offered to the purchaser or his representative for inspection prior to
fabrication/manufacturing by the vendor. Material procurement and testing is responsibility of the
vendor/ manufacturer.

9.3.2 Raw material dimensions must conform to the required nominal dimensions. The allowable tolerance
in standard components like tubes, pipes, plates, flanges, end caps, pipe fittings etc. must be as per the
relevant material specifications.

9.3.3 All tests shall be carried out by the National Accreditation Board for Testing and Calibration
Laboratories (NABL) approved test laboratory. Except as indicated in 9.3.5, Material Test Certificate
submitted by the vendor/manufacturer in lieu of additional test is not enough and will not be accepted.
Testing charges and sample cost shall be included in the rate quoted. Following tests indicated in shall
be carried out on the collected sample.

9.3.4 From the lot of pipes, tubes, plates, studs, bolts etc., 10% (randomly chosen) of the components of the
lot having the same heat number will undergo mechanical testing (Yield Strength, UTS, % reduction in
cross section and % elongation and hardness test), Macro and Micro test, Etching test as per ASTM E-
381, Inter-granular corrosion test in accordance with the requirement of ASTM-A-262 Practice ‘A/E’,
and any other test mandated by the relevant material specification. One sample for each size of
pipe/plate will be randomly selected by the purchaser (or his representative) from each heat number
and same shall be tested for chemical composition at NABL accredited test lab.

9.3.5 In case of standard forged flanges and other standard forged fittings, chemical testing will be
performed per heat number. Co-relatable original mill test certificates are acceptable in lieu of other
destructive testing. Mechanical tests, IGC practice A/E and other tests mandated by relevant material

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 specification are however be required to be performed (on 10% per heat number or at least 1 no.) in
case mill test certificates are not co-relatable or the results of chemical test are not matching those
specified in mill test certificate.

9.3.6 Liquid penetrant examination in accordance with ASTM–E–165 shall be carried in each fitting and
flanges to check any gross defect like cracks, discontinuity. 10% sample from fitting and flanges, shall
be selected for Ultrasonic testing in accordance with ASME SA-745 to check any gross defect like
cracks, discontinuity and multilayer defects.

9.3.7 All plates and pipes must undergo 100% Ultrasonic testing in accordance with ASME SA-578 and
acceptance criteria shall be as per ASTM A 578 Level–B to check any gross defect like cracks,
discontinuity and multilayer defects.

9.3.8 Welding materials must be checked for delta-ferrite content. They should have a minimum of 5% delta
ferrite.

9.3.9 The material which will not conform to above requirements will be rejected.

10 WELDING AND JOINING REQUIREMENTS

All welding shall comply with requirements of ASME Boiler & Pressure Vessel Code Section VIII
div. 1 and Section IX. Electrode designations shall be as per AWS Standards. Configurations of all
weld joint preparation are to be shown on detail drawings by welding symbols as per AWS Standards.
Detailing of the grooves for weld edge preparation shall be done by the Supplier and shown in
welding procedures.
10.1 Welding Qualifications
The vendor shall establish the Welding Procedure and conduct all tests required by ASME Section IX
in order to qualify both the welding procedures and the performance of welders for the materials to be
used in the manufacture of the equipment. The Supplier shall maintain a record of the `Welding
Procedures' and `Welders' qualified in his shop. Welding Procedure Specification (WPS), Weld
Procedure Qualification (WPQ) and Procedure Qualification Record (PQR) shall be submitted to the
purchaser for approval. Only Purchaser’s approved electrodes and filler wires shall be used for
welding. In case vendor/manufacturer decides to use any electrode other than those approved by
purchaser, testing as required by appropriate specification of ASME section II part C must be
performed and it must be demonstrated that the electrode meets the specified criteria.

10.2 Tolerances of Weld Edge Preparation

Dimensions of the edge preparations of weld grooves shall not vary more than those shown in Table-4
(Page-6)
Table 4: Tolerances on weld edge preparation
Root face of joint ± 1.5 mm
Root opening of joints without steel  1.5 mm
backing
Root opening of joints with steel backing + 3.0 mm, – 1.5 mm
Groove angle of joint  5 deg.
Radius of `J'&`U' grooves + 3 mm
10.3 Welding Procedure

10.3.1 The root pass for all welds is to be performed by Gas Tungsten Arc Welding (GTAW) process with an
inert gas backing. The remaining runs can be made by Submerged Metal Arc Welding (SMAW). The
welding electrodes should be baked before use to ensure complete removal of moisture. The Welding
Procedure shall be such as to assure full root penetration & through fusion in the lands of the root &
in the entire weld preparation.

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10.3.2 Each layer of weld metal in a multi-layer welding shall be cleaned before applying the next pass.
Liquid penetrant & radiographic inspection shall be carried out on all the butt welds. All the butt-
welded joints shall be fully radiographed with at least ten percent overlap & radiography films shall be
submitted for approval during inspection.

10.3.3 Liquid penetrant examination must be performed on each weld twice; after root pass and after final
pass.

10.3.4 The welding procedure & performance shall comply with requirements of ASME BPVC section VIII
division 1 and qualify as per ASME BPVC section IX.

10.3.5 All the flanges, wherever applicable, shall be welded to the pipes using full penetration butt weld. The
welding distortion shall be controlled to a minimum by using suitable clamps & fixtures.

10.3.6 The methods used to prepare the base metal shall leave the weld preparation with reasonable smooth
surfaces. The surfaces for welding shall be free of cracks, deep indentations, scale, rust, oil, grease &
other deleterious material. The work shall be protected from deleterious contamination, from rain &
wind during welding. The welding shall not be performed on wet surfaces.

10.3.7 The specification of electrodes, voltages, welding speed, current & polarity should be as specified in
approved welding procedure. Any deviation from the welding procedure will be treated as
objectionable & may disqualify the procedure & the welder or welding operator.

10.3.8 The parts that are to be joined by welding may be fitted, aligned and retained in position during
welding by the use of bars, jacks, clamps, tack welds or temporary attachments. All the tack welds shall
be removed before the commencement of final welding. All these used to secure alignments shall be
completely removed after completion of welding and stress relieving. Offset, angular deviation and
distortion of parts being joined shall be strictly controlled to achieve the dimensions indicated on the
component drawings.

10.3.9 The welding should be done with the best practice to ensure no requirement for repairs. If however,
such a requirement arrives upon examining the radiographic film or after failure in hydrotest, same
may be carried out according to provisions of Sec. VIII div. 1 UW-38. All rectification work shall be
carried out without any cost implications to the purchaser.

10.3.10 The inspector/ purchaser’s representative has the authority to reject any unsatisfactory process or
operation or workmanship, not complying to approved QAP, at any stage of fabrication.
10.4 Quality of Welds
The welding method for all butt welds should be commensurate to warrant a joint efficiency equal to
1(one). All butt welds will undergo 100% radiographic examination by qualified QA personnel
(purchaser or his representative). The costs of all inspection and testing need to be borne by vendor/
manufacturer.
Groove welds shall be free from lack of fusion, undercuts, overlaps, abrupt ridges and valleys. The
surface of fillet welds shall be free from coarse ripples or grooves, undercuts, overlaps, abrupt ridges
or valleys etc. and shall merge smoothly with the surfaces of members being joined. All fillet welds
must be inspected by liquid penetrant technique.

10.5 Stress Relieving

Preheat, post weld heat treatment, annealing/stress relieving after forming operation must be provided
wherever required as per ASME Sec. VIII div. 1.

11 SUPPORTING ARRANGEMENT, ATTACHMENTS AND LUGS

Attachment shall be provided on all the equipment assembly in accordance with pertinent drawings
and shall be attached by full penetration welds. Suitable lugs for handling and transportation should

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be put on the equipment/vessel by the manufacturer after getting approval on manufacturing
drawings.

11.1 The design and fabrication of structural support for Horizontal Steam Generator and Air Cooled Steam
Condenser is the responsibility of the vendor. Support design for Pressuriser has been provided by the
purchaser. However, Fabrication of support of the pressuriser is in the scope of the vendor. Upon
placement of the purchase order, the vendor/ manufacturer should submit along with the drawings, the
support design for purchaser’s approval.
11.2 The support should be designed to withstand twice the filled load of the corresponding equipment.
Horizontal SGs and pressuriser vessel will be located indoors at the purchasers’ premises and there will
be no significant wind loads at the location of installation. While air cooled steam condenser assembly
shall be installed outdoors and wind load (considering wind speed of 40 m/s at Tarapur site) shall be
considered for support design.
11.3 The vendor should provide adequate number of anchor bolts and other accessories which would be
required to secure the equipment.
11.4 The support design should ensure that all nozzles are easily accessible for welding and/or other
maintenance and fabrication activities.
11.5 The material used in beam, columns and bracing shall be of adequate strength and shall be true to the
form. The support material should conform to requirements of IS 2062:2011 E350(A) or equivalent.
11.6 Suitable lugs for handling and transportation should be put on all the equipment by the manufacturer
after getting approval on manufacturing drawings. Attachment shall be provided on each equipment in
accordance with drawings (approved by purchaser) and shall be attached by full penetration welds.
11.7 Welding of these items shall be inspected according to the requirements of ASME section VIII div. 1.
All bolt holes shall be drilled. Flame cutting of such holes will not be permitted.

12 TESTING DURING AND AFTER ASSEMBLY

12.1 Inspection will be performed during and after critical manufacturing and assembly operation which
include, assembly requirements, dimensional checks for critical components etc. In case of non-
conformance to this specification, equipment will be rejected.
12.2 The completely assembled equipment shall be examined to determine its conformance with respect to
material dimension, provision for all nozzles specified in purchaser approved drawings, workmanship,
cleanliness & test requirements.
12.3 Positive Material Identification (PMI) test will be carried out after fabrication and final assembly, if
required. Those parts which are not accessible after assembly will be checked prior to assembly.
12.4 Hydrostatic Testing

12.4.1 The equipment constructed under this specification shall be hydrostatically tested in the presence of the
purchaser or their representative as per the requirement of ASME section VIII, division 1 at the
pressure specified in respective annexure.

12.4.2 The manufacturer shall close all the openings by using blind flanges/plugs/caps/plates for hydro test.

12.4.3 The manufacturer shall close all threaded openings by using SS304 threaded plugs. These plugs shall
not be removed after hydrotest.

12.4.4 All mechanical & welded joints shall be left exposed for examination during the test.

12.4.5 The test medium shall be demineralised water.

12.4.6 Test pressure shall be maintained for a minimum of 10 minutes prior to conducting the examination for
the leakage.

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12.4.7 There should not be any leakage from the assembly; test procedure shall conform to ASME section VIII
division 1.

12.4.8 Examination for leakage (or sweating) shall be made at all joints, connections & of all regions of high
stress such as regions around openings & thickness transition section.

12.4.9 In the event of failure of the test section or any part thereof, the vendor shall notify the purchaser. The
vendor shall obtain written permission from purchaser before repair & subsequent use of any part. If
the repairs are likely to affect the results of examination & test or work previously completed,
appropriate re-examination, re-inspection & re-testing shall be conducted.

12.4.10 Blind plates/caps which were used to block any pipes during hydrotest must be removed after
completion of the hydrotest.
12.5 If fabrication, examination, inspection & testing are not in conformance to the requirements of this
specification, the fabricated components will be rejected.
12.6 The empty and filled weight of all the equipment should be measured and recorded.

13 PROTECTIVE COATING/ SURFACE TREATMENTS

13.1 Protective coating/ surface treatment / painting shall be done after hydro-static performed test to
satisfaction of the purchaser.
13.2 All surfaces to be coated/ treated as above shall be clean and free of loose scale, rust, grease, oil and
moisture.
13.3 All stainless steel surfaces should be pickled and passivated as per ASTM-A-380.
13.4 All carbon steel surfaces will be given one coat of primer and paint (epoxy paint) of 60-80 micron Dry
Film Thickness (DFT).

14 QUALITY SURVEILLANCE
14.1 Upon placement of purchase order, a Quality Assurance Plan (QAP) listing the important Control points
and Tests required during the manufacture of the equipment shall be prepared by the vendor/
manufacturer and submitted to purchaser for approval. The purchaser reserves the right to witness,
stamp, review or put hold points at any of the steps of the QAP and add or modify points to make the
QAP conformant with this technical specification.
14.2 Vendor shall perform, at his cost, all inspection and testing etc. specified in this specification and the
drawings to the satisfaction of the Purchaser. The vendor shall arrange and/or provide all testing and
inspection (gauges, instruments, equipment etc.) facilities required during manufacture of the
components, assembly and shop testing. Wherever purchaser witness/stamping/testing etc. is involved,
according to approved QAP, the vendor/manufacturer should give an inspection call to the purchaser at
least 10 days in advance of inspection. The vendor/manufacturer should however plan fabrication and
QA activities in a manner such that similar items are clubbed and number of purchasers’ visits are
reduced. In this regard, the vendor/manufacturer must also supply along with the QAP, the
manufacturing and assembly plan.
14.3 Testing procedures shall be prepared by Supplier and submitted to purchaser for approval. All
observations and readings shall be permanently recorded and submitted to Purchaser in the history
docket.
14.4 The vendor/manufacturer must at all reasonable times allow free access to the purchaser or his
representative to his shop floor/ subcontractor premises where the work for pressure vessel and heat
exchangers with supports is in progress.
14.5 All testing and QA activities which are performed should be recorded in the format specified by ASME
Sec. VIII div. 1.

15 REPORTS
The detailed reports and data on all aspects of planning, procurement, procedure qualification,
fabrication, inspection, testing and supply of pressuriser, steam generators and air cooled condenser

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with support as listed below shall be compiled and furnished by the Supplier. These reports shall be
signed by a responsible authorized technical representative of the Supplier. Two hard copies and a
soft copy of all the documents including following must be provided along with the supply.
15.1 Technical specifications
15.2 Deviation list (if any)
15.3 Approved Quality Assurance Plan (QAP)
15.4 Approved fabrication drawing(s)
15.5 Approved support design report
15.6 Fabrication plan
15.7 Material procurement, inspection and testing reports
15.8 Fabrication procedures, procedure qualification records, Weld and welder qualification records
15.9 WPS, WPQ and PQR reports
15.10 Heat treatment records
15.11 Inspections, tests and checks carried out during fabrication and assembly-procedures and reports
15.12 Air leak test-procedure and report
15.13 Hydrotest-procedure and report
15.14 As built drawing(s)
15.15 Packaging and shipping details
15.16 Tightening torque and locking for fasteners for flange sizes above 6”.
15.17 Certificate of Compliance to the specifications
15.18 Guarantee certificate

16 PACKING AND SHIPMENT

After completion of all shop tests and acceptance by the Purchaser, the equipments shall be
thoroughly cleaned, dried, protected from dirt, corrosion and any other damage. Each equipment
should be provided with a corrosion resistant identification tag secured to the outer surface of the
support indicating. The tag should indicate at least the following:
1. Name of manufacturer
2. Name of equipment
3. Purchase order number
4. Month and year of manufacture
5. Design pressure and temperature for primary and secondary sides
6. Material of construction
7. Empty weight
8. Filled weight
16.1 Packing
The equipments shall be crated suitably and shipped to NPCIL R&D Centre, Tarapur Maharashtra
Site, Tarapur, Maharashtra-401502. The Supplier shall be fully responsible for the proper care and
handling of the assembly during packing and shipment to ensure their arrival at destination without
damage to any part. At all stages of handling, the component / equipment shall be properly supported
to prevent deformation. All loose parts of the assembly shall be positively locked. The vendor shall
design, fabricate and supply robust shipping frames (transportation crates) to prevent distortion and
damage during handling and transportation of Equipments. The vendor should also ensure, by
providing proper covering, that the equipment is protected from rain and dust during transit.
All machined faces and threaded and machined holes shall be protected from corrosion/damage. All
important machined surfaces and protruding nozzles shall be protected with thermocole or plywood
sheets. All openings shall be closed by plugs to prevent ingress of foreign material. All bare threaded

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holes shall be closed by stainless steel plugs. Special packaging care should be taken for nozzles
extended from the vessel so as to ensure safe delivery to site.
The packaging and shipment protection against corrosion, damage or loss shall be adequate for all
climatic conditions encountered during shipment and erection at Supplier’s works.
The package shall be clearly and legibly marked in a suitable permanent manner on top and sides with
the information listed below:
a) Equipment Name
b) Gross Weight of the package
c) Dimensions of the package
d) Purchase Order number
e) Number of package in shipment
The identification marking shall neither be obscured by the protective coatings and wrappings nor
shall the identification be destroyed upon removal of such coatings and wrappings.

16.2 Delivery
Delivery of Equipments shall be made only after obtaining clearance from Purchaser or his authorized
representative. The responsibility of safe delivery of the equipments lies with the vendor/
manufacturer. The purchaser will not be responsible for any loss in transit.

17 GUARANTEE / WARRANTY
The equipment shall be guaranteed for a period of 18 months from the date of delivery at Purchaser’s
works. The guarantee shall be against the failure of any part or the equipment as a whole due to faulty
fabrication (e.g., poor welding etc.). Since the support design is the responsibility of the vendor,
complete guarantee for adequacy of the supporting structure rests with the vendor.

18 MILESTONES AND PAYMENT

The work involved will be monitored during all stages by the purchaser according to the approved
QAP. No request for advance payment is acceptable.

19 ESSENTIAL INFORMATION REQUIRED IN THE BID

The quotation should be for the complete work i.e., procurement of raw materials, fabrication,
assembly, inspection and testing, packing and delivery and guarantee. If quotation is made for only
some part of the work and not others, it will be declared invalid.
The following must be mentioned in the quote:
19.1 Documentary evidence of mandatory requirements as given in section 4 (page-3).
19.2 The time required (from the date of placement of purchase order) for completion of work specified
herein.
19.3 Deviations if any, from the specifications herein must be clearly listed.
19.4 A table mentioning the documents/ drawings which will be prepared by the vendor/ manufacturer on
placement of purchase order.
19.5 Details of manufacturing, fabrication and inspection facilities pertinent to this specification, available
with the vendor. This should also mention what processes will be outsourced and what will be done in-
house. Details of the potential subcontractor shall be provided in the bid.
19.6 Details of organizational structure, manpower on rolls in different departments viz., design, fabrication
and machining, QA, finance etc.
19.7 Details of turnover and similar orders executed along with the time frame of delivery, delays in delivery
shall be clearly mentioned (refer 4.1b, 4.1c & 4.2k page-2).
 

20 ACCEPTANCE AND REJECTION CRITERIA

The acceptance and rejection criteria for various items/activities have been mentioned earlier in the
technical specification. These are compiled in a tabular form in Table-5 (Page-12). Any criteria

11 
 
mentioned in this specification but missed in Table-5 (Page-12) will apply. The supplier must thus
read this specification in completeness along with Table-5 (Page-12)
Table 5: Acceptance and rejection criteria
Sr. No. Acceptance criteria
Bid evaluation Conforming to mandatory
criteria of section 4 (page‐2)
Raw materials Raw materials should conform
to respective material
specifications as in drawing.
This conformation will be done
as per section 9 (page-4) and
respective annexure.
Ultrasonic testing Should be performed as per
ASME Sec. V art. 5
As per ASME SA-388
Support design All criteria mentioned in section
11 (page 11-12) should be met.
Welding and other fabrication Work should be as per approved
activities QAP, WPS, PQR etc.
Liquid Penetrant Examination Should be performed as per
ASME Sec. V art. 6
As per ASME Sec VIII div. 1
MA-8
Weld radiograph Should be performed as per
ASME sec V art. 2
As per ASME Sec VIII Div. 1
UW-51
Dimensional and assembly Should be within the specified
inspection tolerances as in approved
fabrication drawing
Air leak test Ability to hold pressure of
2kg/cm2 for 10 minutes, no
observable leakage
Rejection criteria
Non-conformance to any of the
mandatory criteria of section 4 
(page‐2).
Non-conformance to material
specifications or any of the
criteria mentioned in section 9
(page-4) and respective
annexure.
Not performed as per ASME
Sec. V art. 5
As per ASME SA-388
Nor conformance to any of the
criteria of section 11 (page 11-
12).
Deviation from approved QAP,
WPS,WPQ, PQR etc.
Not performed as per ASME
Sec. V art. 6
As per ASME Sec VIII div. 1
MA-8
Not performed as per ASME
sec V art. 2
As per ASME Sec VIII Div. 1
UW-51
Deviation from approved
fabrication drawing
Fall in pressure is more than 0.5
kg/sq. cm. in 10 minutes.
Flange/threaded joint leaks
must be rectified and air leak
test re-done.
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Hydrotest Ability to hold hydro-static test
pressure (as specified in
respective equipment annexure)
for 10 minutes, no observable
leakage or sweating in welds or
material
Fall in pressure is more than 2
kg/sq. cm in 10 minutes.
Or
Observable leakage/sweating in
welds or material.
Flange/threaded joint leaks will
be rectified and hydrotest re-
done.

Receipt at site All nozzles/openings/ Visible damage to

protruding parts should be
properly packed and prevented
from damage
nozzles/threaded parts/
protruding parts etc. due to
transit may lead to rejection if
these damages cannot be
repaired to as shipped condition
by the vendor/ manufacturer

21 RESPONSIBILITY OF THE VENDOR AFTER PLACEMENT OF ORDER

21.1 The vendor is required to prepare detailed fabrication drawings and indicate in a separate sheet, the
deviations (if any) from the specifications herein. These are required to be submitted to the purchaser for
approval.
21.2 Materials shown in Bill of Materials (BOM) of the drawing are tentative only. During preparation of
fabrication drawings/manufacturing, if some of the items need to be added for complete functioning,
those should be added in BOM.
21.3 Deviations not explicitly listed will not be recognized even if they are shown in the approved fabrication
drawings. The specification and drawings herein will govern in that case.
21.4 Preparation of a detailed Quality Assurance Plan (QAP) and getting it approved by the purchaser.
21.5 Procurement of raw materials and other standard components required for fabrication, assembly and
testing of Equipments. No Free Issue Material (FIM) will be supplied from the purchaser. All
materials required for equipment as well as their guarantee shall be in vendor’s scope of work which
involves procurement, relevant testing as specified in the codes and specification, supply, fabrication and
acceptance testing.
21.6 Fabrication/manufacturing and QA of Equipment (and its components) as per the purchaser approved
drawings and this technical specification.
21.7 Design and fabrication of adequate support for installation of the Equipment.
21.8 Hydro test of Equipments as per this technical specification: All utilities (pump, compressed air, DM
water, valving system and pressure gauges etc.) required for Hydro test shall be in vendor’s scope.
21.9 Surface treatments as specified herein (section 13, page 9), safe packaging and delivery to purchasers’
desired location as specified here.
21.10 Preparation and submission of documents like as built drawings, support design report, fabrication and
assembly reports, inspection and testing reports, history docket, any further relevant notes etc. These
documents should be submitted in both soft and hard format. Two hard copies are required to be
submitted to purchaser.
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 ANNEXURE-1: DETAIL TECHNICAL SPECIFICATION OF PRESSURIZER

1. Scope
This annexure must be read in conjunction with the parent specification. The information specified in
this annexure is additional requirements specific to Pressuriser design and supply with installed
immersion heaters. The vendor must submit detailed design of the heaters to the purchaser for
approval before manufacturing the heaters. The procedure of welding the heaters should be
established in the mock up and approved by the purchaser.

2. Design Drawings
The schematic design drawing of pressuriser is provided as drawing no. A0-01422-M-1003. The
vendor/ manufacturer should note that the drawing provided along with this specification is a design
drawing. On placement of the order, vendor is required to prepare detailed fabrication drawings for
fabrication with purchaser’s approval.

3. Specification for Pressurizer:

The summary technical specifications of Pressuriser and tests required are given in Table-A1 (Page-
15). These tests are in addition to those specified by ASME Sec. VIII div. 1 and further elaborated
later in this specification.
Major raw material for the pressurizer vessel:
a) Seamless Stainless Steel (S.S.) pipes conforming to the material specifications of ASTM-A-312
Grade TP 304L. Dimensional tolerances shall confirm to ASTM-A530.
Size : 300 NB SCH 160
OD of Pipe : 323.8 mm
Thickness : 33.32 mm
Length : 6 meter
b) Standard ellipsoidal end cap for above mentioned pipe
c) 300 NB Weld Neck Raised Face Flange SS304L, 2500 lbs along with hexagonal head bolt, nut,
washer and Spiral wound metallic Gasket or along with stud, two nuts, two washers and Spiral wound
metallic Gasket
d) 300 NB Blind Flange, 2500 lbs rating SS304L
e) Spray Nozzle : 40NB sch 160. It is provided to spray the cold water in the vessel. It should be
designed with minimum pressure drop (< 3kg/cm2) and droplet of size <3mm (tentatively).
f) All the nozzles are to be provided with globe valve (for isolation) as specified in drawing no. A0-
01422-M-1003.
g) Pressurizer is equipped with 10nos /15 nos of immersion heaters of 9kW /6 kW capacities (total
capacity of 90kW, refer A0-01422-M-1003) each. The sheath of these heaters should be SS 304L.
The heaters should bear an external pressure of 265 kg/cm2 and temperature 400oC.

Table-A1 Specification for pressurizer

BHABHA ATOMIC RESEARCH CENTRE
TECHNICAL DATA SHEET OF PRESSURISER VESSEL
S. No. EQUIPMENT UNITS PRESSURISER VESSEL To Be Filled By
Contractor

1 Equipment location 4 m elevation resting

2 Applicable Standard ASME SEC VIII, DIV I

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3 Design Conditions

3.1 Design Pressure kg/cm2(g) 165

0
3.2 Design Temperature C 350

3.3 Immersion Heater capacity kW 90 (10 nos /15 nos heaters of 9

kW /6 kW rating)

4 Operating Conditions

4.1 Pressure kg/cm2 150

0
4.2 Temperature C 325

4.3 Fluid Medium DM Water/Steam

5 Other Data

5.1 Fluid hold-up volume m3 0.325

5.2 Materials used ASME-SA 312 (SS 304L)

5.3 Geometry /support Vertical Vessel/Lug Support

5.4 Dimension As shown in drawing no.  A0-

01422-M-1003

5.5 Approx. Weight (with Fluid) Ton 3.0

6 Shop Tests

6.1 RT & DPT of all butt welds 100% RT for butt weld and
100% DPT for all weld joints

6.2 Dimensional Check Required 100%

6.3 Hydro test kg/cm2(g) 265.0

6.4 Testing of immersion heaters As per the procedure described

in section 5.2 (Page-17)

3.1 Specifications of immersion heaters:

a. Power rating: 9 or 6 kW each at 240 volts±10%, 1-phase, 50 Hz ± 3%, AC
b. Nos. of heaters: 10 nos or 15 nos
c. Total power of heater bank: 90 kW (15× 6 kW or 10 x 9 kW)
d. Temperature: 400⁰C
e. Sheath material: Stainless steel 304L seamless tube
f. Heating element: KANTHAL/NICHROM.
g. Insulating material: 99.9% pure magnesium oxide compact to rock hard density.
h. Sealing: removable seal of silicon rubber & fixed seal thereafter.
i. Shape of heating element: Rod type
15 
 
 j. Length of heating element: such that the total heater bank height does not exceed 1300
mm+300 mm cold length.
k. Terminals: fiber glass copper wire (6 mm square) terminals 2 meter in length.
l. Thermocouples at the surface of heating elements: 1 no. on each, K type
m. Annealing: Annealing shall be done at 1000± 100⁰C for a period of 30 minutes after cold
working (Swaging)

4. Raw Materials and testing

Following requirement must be met in addition to those specified in section 8 (page-4) of parent
specifications:
4.1 Gaskets
Spiral wound metallic gaskets with flexible graphite packing conforming to ANSI B36.10 shall be
used for sizes flange size 8” and below. For flange sizes larger than 8”, cam profile gaskets with
SS304 core and flexible graphite sealing layer should be used. Gaskets shall be of good quality and
free from imperfections.
4.2 Welding and Joining Requirements
Following are additional requirements (apart from Section 9 (page 5-6) of parent specification)
specific to Pressurizer.

Procedure for welding the sleeve for installing heaters

4.2.1 Drill the hole of 14 mm in the blind flange upto a depth of 50 mm and rest of 10 mm
(heater pin OD) for the rest of the flange depth.
4.2.2 Insert the solid rod (length 60 mm) in the hole of 50 mm and weld it with the flange.
4.2.3 Make a hole of 10 mm (pin OD) in the sleeve and insert the heater in that hole and weld it
with the sleeve at outside.
The procedure of welding the heaters should be established in the mock up and approved by the
purchaser.
5. Testing During and After Assembly

5.1 Hydrostatic Testing:

The pressuriser constructed under this specification shall be hydrostatically tested in the presence of
the purchaser or their representative as per the requirement of ASME section VIII, division 1 at the
pressure specified in Table-A1 (Page-15). Other requirements for hydro test will be as per the parent
specification.
5.2 Testing for Immersion heaters:
The heating element shall be subjected to ‘routine test’ & ‘type test’ in accordance with IS-302 and
NETA/MTS-1997. The inspection & testing of the heaters shall be subjected to ‘routine tests’ and
‘type test’ as per section 5.2.1 and 5.2.2 given below:
5.2.1Routine test:
These tests shall be carried out on every heating element by the manufacturer and data shall be
recorded for purchaser approval.
a) Dimensional check for the following:
i) Outer diameter
ii) Overall length
b) Electrical resistance of heating element at ambient conditions
c) Insulation resistance (IR) test at 500 Volt DC for 1 minute. IR value shall be minimum 50
MΩ at room temperature as per NETA/MTS-1997.
d) High voltage withstand test at room temperature at 1500 Volts AC, 50 Hz for one minute

16 
 
 5.2.2Type test:
Heating elements shall be subjected to following tests by the manufacturer and data shall be recorded
for purchaser approval
a) Radiographic examination (as per ASTM E 94-04(2010)) over the full length at 90⁰C to
determine the concentricity of heating coil within the sheath.
b) Moisture resistance test followed immediately by IR test at 500 volt DC and high voltage
with stand test at 1500 Volts AC for one minute. IR value shall be more than 10 MΩ.
c) Leakage current test: this test is to be carried out as per IS: 302. One thermocouple shall
be brazed with the outer S.S. sheath.
d) Rated voltage test: The rated voltage of 240 volts will be applied to the heating element
and the temperature at the S.S sheath will be monitored till it stabilizes. The sample will
be kept at this stabilized temperature for 6 hours and the failure if any will be noted. The
above test will be done in water.
e) These heaters shall bear the hydrotest pressure (external pressure) of 265 kg/cm2.
6. Structural supports
Adequate support need to be provided for installation of the pressurizer. The type of the support will
be lug type, welded at two location (2 m and 4m from the ellipsoidal head) along the axis. Besides,
lifting lugs need to be provided.

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17