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NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A GOVERNMENT OF INDIA LIMITED)

SPECIFICATION NO. : PC-E-1044

REV NO. : 0 1

DATE OF ISSUE

(MONTH/YEAR) : OCT., 2014 JULY, 2015

TOTAL NO OF PAGES

(Including Cover Sheet )

: 4+50 8+50

TECHNICAL SPECIFICATION

FOR

PHT SYSTEM HEAVY WATER HEAT EXCHANGERS FOR 700 MWe

PHWR PROJECT

REF. USI NO. : 33000

NAME Designation SIGNATURE DATE

PREPARED

BY

Lokesh Dwivedi SEE Sd/- 27/10/2014

R Babu EE Sd/- 29/10/2014

CHECKED BY

Babita Gupta

ACE Sd/- 30/10/2014

Braham Parkash

ACE Sd/- 30/10/2014

S.B.Dharmadhikari

SEE Sd/- 30/10/2014

REVIEWED

BY

T.K.Kandar ACE Sd/- 31/10/2014

K.K.De ACE Sd/- 31/10/2014

S.Ramesh ACE Sd/- 31/10/2014

APPROVED

BY

Suma Nair AD Sd/- 31/10/2014

(For Revisions see Revision Control Sheet )

File Name : PC-E -1044-R1

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NPCIL PROPRIETARY

This document contains confidential and protected information and that the

same are the intellectual property of Nuclear Power Corporation of India

Limited (NPCIL). No part of this document including notably any editorial

element, verbal and figurative marks and images including herein, shall be

reproduced or transmitted or utilized or published or stored in any form or by

any means now known or hereinafter invented, electronic, digital or

mechanical, including photocopying, scanning, recording or by any

information storage or retrieval system, without prior written permission

from NPCIL, by any person or entity. Unauthorized use, disclosure or

copying is strictly prohibited and may constitute unlawful act and can attract

legal action.

TABLE OF CONTENTS

S. No Description Pg. No

1 Scope 1

2 Contents 1

3 Applicable specifications, codes, standards and drawings 2

4 General Description 4

5 General Requirements 7

6 Fabrication Requirements 11

7 Examination, Inspection and Testing 20

8 Foreign Material Exclusion. 27

9 Preparation for shipment 27

10 Submittals 31

11 Heat Exchanger Drawing List Annexure-1

12 Data sheets Annexure-2

13 Requirement of Dust Free Enclosure (DFE) Annexure-3

14 Paint Specification Annexure-4

15 Mandatory Spares Annexure-5

NUCLEAR POWER CORPORATION OF INDIA LTD ATOMIC POWER PROJECT


FOR

PHT SYSTEM HEAVY WATER HEAT

EXCHANGERS FOR 700 MWe PROJECTS

Page No. : 1 of 50

Rev.

No. : 1

1.0 Scope

This specification covers the technical requirements for procurement of raw material,

fabrication, examination, inspection, testing, documentation, packing and delivery of

Primary Heat Transport (PHT) System Heavy Water Heat Exchangers (Shell & Tube

type) for 700 MWe PHWR units.

This specification is applicable for following Heat Exchanger Equipments of 700

MWe Projects beyond RAPP# 7&8.

Sr

No.

Name of the Heat Exchanger Tag Number

1. Regenerative Cooler 3331-HX-1

2. Bleed Cooler 3332-HX-1

3. Shutdown Cooler 3341-HX 1,2,3,4

4. Fuelling Machine Recirculation Cooler 3337-HX-1

5. Fuelling Machine Return Cooler 3337-HX-2

6. Inventory Addition and Recovery System

(IARS) Heat Exchanger

3333-HX-1

2.0 Contents

The requirements of this specification are presented under the following headings:

DESCRIPTION SECTION

Scope 1.0

Contents 2.0

Applicable specifications, Codes, Standards and Drawings 3.0

General Description 4.0



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DESCRIPTION SECTION

General Requirements 5.0

Fabrication Requirements 6.0

Examination, Inspection and Testing 7.0

Foreign Material Exclusion 8.0

Preparation for shipment 9.0

Submittals 10.0

Heat Exchanger Drawing List Annexure-1

Data sheets Annexure-2

Requirement of Dust Free Enclosure (DFE) Annexure-3

Paint Specification Annexure-4

Mandatory Spares Annexure-5

3.0 Applicable Specifications, Codes, Standards and Drawings:

3.1 General

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

tendering document apply as specified herein. The requirement of codes,

standards, drawings and specification referred in the sections hereunder shall be

deemed to be minimum requirements. In case of doubt, the stricter of them shall

apply. For cases not covered by this specification, the ASME Boiler and Pressure

Vessel Code Section-III NB /NC/ND and NF as relevant shall be applied. All the

relevant procedures required as per this specification are to be submitted by the

manufacturer to NPCIL for approval, and the same shall be used by the

manufacturer, only after approval by NPCIL.



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3.2 Applicable General Codes and Standards (Latest edition at the time of

tendering):

STANDARDS/ CODES DESCRIPTION

ASME BPVC

Section – II

Section – III

Section – V

Section – IX

Boiler and pressure vessel code.

Material specification.

Nuclear Power Plant Component including

Appendices, Sub sections NB/NC/ND & NF.

Non-destructive Examinations.

Welding and Brazing Qualification.

TEMA Standard of the Tubular Exchanger Manufacturer’s

Association, Class-C.

ANSI B 1.1 Unified Screw Threads.

ASTM-E-94 Recommended practice for radiographic testing

ASTM-E-213 Recommended practice for Ultrasonic testing

ANSI B 16.25 Butt Welding Ends.

ANSI B 16.5 Steel pipe Flanges and Flanged Fittings.

ISO International Standard Organization

(Dimensional standards for pipes and BW fittings and

Metric screw threads).

ASTM Appropriate Publication for Material Testing.

3.3 Applicable NPCIL’s Specifications:

SPECIFICATION

NO.

DESCRIPTION

PC-E-923 Specification for Annealed Nickel-Iron-Chromium alloy (Incoloy-

800) Tubes for Heat Exchangers.

PC-M-1108 Carbon steel forging for heat exchangers.



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SPECIFICATION

NO.

DESCRIPTION

PC-M-288 Carbon Steel Seamless Pipe Fittings and Piping Components for

primary system. (To be only used in case the equipment is Class-1

NB component, elsewhere applicable ASME codes will apply).

PC-M-1109 Inconel Welding Consumables and Overlay Cladding for PHT

system Heat Exchangers.

PC-P-192 Procedure for Tube sheet and Baffle Drilling of Heavy Water Heat

Exchanger.

PC-P-193 Procedure for Tube to Tube sheet Welding of Heavy Water Heat

Exchanger.

PC-P-194 Procedure for Tube Expansion.

PC-P-255 Procedure for Hydrostatic Test of Heavy Water heat Exchanger.

PC-P-257 Quality Assurance Plan for Heavy Water Heat Exchanger.

PC-P-258 Procedure for Ball Passage Test of Heavy Water Heat exchanger.

PP-P-1962 Procedure for Eddy current testing of Heat Exchangers

PP-E-2384 Specification for Helium leak testing in vacuum mode

3.4 Drawings

Applicable Drawings related to individual Heat exchanger equipments are listed

separately in Annexure-1

4.0 General Description

Regenerative Cooler (3331-HX-1)

Regenerative Cooler is a shell and tube Heavy water to Heavy water heat exchanger,

located in pump room at 115.5 M Fl. El. Hot bleed from Bleed Condenser is cooled by

feed flow (tube side) from the Primary Pressurizing Pumps, thus heating up the feed



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going to PHT main circuit. This scheme enables to recover system heat which

otherwise would have been lost in bleed cooler and also minimizes thermal stresses at

feed line - main circuit junction. Physically Regenerative Cooler is divided into two shells

and both heat exchangers are in series on tube side as well as shell side. The design

parameters and operating conditions are given in Regenerative Cooler data sheet attached

in Annexure-2.

Bleed Cooler (3332-HX-1)

Bleed Cooler is designed to cool bleed from Bleed Condenser outlet condition to near

ambient temperature. Bleed Cooler is also a shell and tube heat exchanger, located in

pump room at 115.5 M Fl. El. Hot bleed (Tube side) is cooled by Active Process Water

system (shell side). Physically Bleed Cooler is split into two heat exchangers which

are in series on tube side (Heavy Water side) and are also in series on shell side

(Active Process Water side). The design parameters and operating conditions are given in

Bleed Cooler data sheet attached in Annexure-2.

Shutdown Cooler (S/D) (3341-HX 1, 2, 3, 4)

The Shutdown Cooler is provided in the shutdown cooling system to cool the PHT heavy

water to below 150ºC and hold it cold enough for carrying out maintenance work. The

designed heat removal rate is in parity with the decay heat generation and hence ensures

that the specific design limits of the fuel are not exceeded during shutdown. Each PHT

loop has 2 x 100% S/D cooling pumps and 2 x 100% S/D cooling heat exchangers. S/D

cooling heat exchangers are located at 109 m of Reactor Building. The design parameters

and operating conditions are given in Shutdown Cooler data sheet attached in

Annexure-2.



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Fuelling Machine (F/M) Recirculation Cooler (3337-HX-1)

This heat exchanger is provided to cool the bypassed Heavy Water from F/M valve

station. The design parameters and operating conditions are given in F/M Recirculation

Cooler data sheet attached in Annexure-2.

Fuelling Machine (F/M) Return Cooler (3337-HX-2)

F/M Return Cooler cools down hot Fuelling Machine return flow to near ambient

temperature, before it is returned to storage tank/pump suction via purification. The

design parameters and operating conditions are given in F/M Return Cooler data sheet

attached in Annexure-2.

Inventory Addition & Recovery System (IARS) Heat Exchanger (3333-HX-1)

The IARS heat exchanger is provided to cool the spilled inventory collected in IARS tank

before pumping to D2O Storage tank 3333-TK-1 via purification circuit. The design

parameters and operating conditions are given in IARS Heat Exchanger data sheet

attached in Annexure-2.

4.1 Design Conditions

The design conditions and operating parameters of these Heat exchangers are given in

Annexure-2.

4.2 All these Heat Exchangers are designed in accordance with ASME Section- III

NB/NC/ND & NF (as applicable), TEMA Class-C for tube side and shell side and Heat

Exchanger Data Sheets (Annexure-2).

4.3 Seismic design criteria

The heat exchangers are designed for Safe Shutdown Earthquake (SSE) and Operating

Basis Earthquake (OBE) level earthquake as enumerated in respective Heat Exchanger

data sheets (Annexure-2).



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4.4 Nozzles and Supports

The loads and moments on the Heat exchanger nozzles and its supports due to piping

reactions from dead weight, thermal and seismic considerations are considered in the

design of the respective heat exchanger supporting structure

5.0 General Requirements

5.1 The Heat Exchanger’s shall be fabricated, inspected and tested to meet the requirements

of the ASME Boiler and Pressure Vessel Code, Section III, Nuclear Power Plant

Component under which parts of heat exchanger containing heavy water are classified as

Class-I/Class-II/Class-III components (as specified in relevant Heat Exchanger Data

Sheet Ref Annexure-2) and those parts containing Water are Class-III components.

However, the hub integral with the tube sheet shell side face shall be treated as Class-I if

the same is specified for tube side (Regenerative Cooler, Bleed Cooler and Shutdown

Cooler). The heat exchanger shall further meet the requirements of the standards of the

Tubular Exchanger Manufacturer’s Association (TEMA) Class-C. All the requirements

for heat exchangers, stated in individual data sheet, fabrication drawings approved by the

NPCIL and NPCIL’s tendering drawings shall be fully complied with. Material and

standard parts which are not specifically designated herein and which are necessary for

the fulfillment of this specification shall be of good quality and in accordance with the

best practice pertinent to the manufacture of heat exchanger.

In compliance with or supplementary to the ASME code, certain procedure shall be

qualified and the product shall meet the requirements stated herein. The inspection and

testing, whether required by the ASME code or specified herein shall be performed as

specified and the product shall meet the requirements stated herein.

5.2 Manufacturer shall be responsible for the preparation of shop fabrication drawings,

preparation and qualification of all procedures for fabrication/examination/ testing, data

accumulation/evaluation and reporting, procurement of raw material, performing all



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examinations and testing, final documentation, cleaning, drying and preparation for

shipment, shipment and full compliance with this specification.

5.3 The manufacturer shall accept full responsibility for his work and for the compliance

with this specification. Approval of drawings and documents by the NPCIL does not

constitute acceptance of any designs, materials or equipment, which will not fulfill the

requirements established by the purchase contract.

5.3.1 Sub-contractors:

In the event of the Manufacturer, sub-contracting part of the Heat Exchanger

component, the sub-contractor shall be approved by NPCIL before award of the work or

placement of the Purchase order. The subcontractor will be evaluated first by the

supplier and relevant reports should be submitted along with the proposal to NPCIL.

The sub-contractor shall not further sub-contract any part of work given to them.

Relevant technical specifications required by the subcontractor shall be handed over

only after obtaining written permission from NPCIL. The manufacturer shall be

responsible for ensuring that the sub-contractor makes the components as per relevant

codes, standards and specifications as enunciated in this specification by NPCIL. The

manufacturer shall be responsible for preparing uniform plans, lists and other documents

and for documentation by sub- contractor as per this specification.

All manufacturing documents prepared by the sub-contractors should be reviewed and

accepted/approved by the main contractor and the same shall be submitted to NPCIL

before the start of manufacture for review and approval.

5.4 Material

5.4.1 All raw materials shall be procured by the manufacturer. The material shall be

purchased with valid original test certificates. In absence of co-relating Mill certificates,

samples shall be drawn as per relevant specification in presence of NPCIL and check

test shall be carried out. Testing shall be done in NPCIL approved labs. The material test

certificates/reports will be further reviewed and accepted by NPCIL before use.



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All welding consumables for fabrication are to be procured by the manufacturer. The

welding consumables shall be procured from NPCIL’s approved vendors and shall be of

approved brand name.

5.4.2 The materials should be as per the tender drawings and should meet the corresponding

raw material specification. The Cobalt content shall be limited to 0.03% for SS material

and 0.02% for those CS material which are coming in contact with Heavy Water (D2O)

5.4.3 All SS material shall be Solution Annealed and Inter Granular Corrosion (IGC) tested as

per relevant material specification.

5.4.4 Materials, which are not specified herein or in drawings, shall be selected by

manufacturer in accordance with ASME B&PV code, Section-III NB/NC/ND (as

applicable) & Section-II with the approval of the NPCIL.

5.4.5 Any components/materials (tubes/shell/channel head/ tubesheet/nozzle) imported for use

in Heat Exchanger equipment shall have valid test certificate and compliance (to

specification) certificate duly certified by NPCIL approved inspection agency. Any

other imported raw material (to be used in Heat Exchanger) shall be duly tested in India

at NPCIL approved labs for certificate verification.

5.5 Nozzle End Connections

All connections to the heat exchanger vessel shall be in accordance with the requirement

of this specification and relevant drawings.

All connections shall terminate with end preparations for butt welding in accordance

with drawing no. NPCIL/01006/2232/SK (butt welding with “Y” type consumable

inserts) preferably.

In general, the following nozzle end connections, if not specified in the drawings, shall

be 150 mm long and free end shall be prepared for butt-welding to 20 mm NB x 4 mm

wall thickness pipe.

a) Vent and drain connections at the highest and lowest points respectively on shell

side.



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b) Vent and drain connections at the highest and lowest points respectively on tube

side each located in the channel cover.

c) Leak off connections for the space between the double gaskets, between channel

cover and tube sheet and any other double gasketted joint as applicable.

5.6 Threaded Fasteners

All threads shall conform to ISO ( Dimensional standard for metric threads ) or ANSI- B

1.1. All threaded fasteners shall be provided with corrosion resistant locking device. No

Frictional-locking device shall be used. Positive (non-friction) locking devices such as

castellated nuts with pins shall be provided on the bolts for channel cover – tube sheet

gasketted joints as given in respective heat exchanger drawings.

Bolting up of pressure boundary gasketted joints shall be done preferably by means of a

hydraulic tensioner. This is because of the uncertainty in estimating the actual bolt

tension values achieved by the conventional coefficients. Otherwise, if torquing is

adopted due to non-availability of hydraulic tensioner, suitable graphite based lubricant

shall be applied on the rubbing and bearing surfaces of the nut, bolt and flange surfaces.

In both cases, bolting up procedure of the gasketted joints shall be approved by NPCIL.

However, these requirements are not applicable to temporary nuts/bolts and gasket

arrangement used during post weld heat treatment of the vessel.

The bolts for spiral wound gasketted joints shall have unthreaded reduced shanks for

resilience. Suitable arrangement for mounting bolt elongation monitoring/measurement

device (while bolts are being tensioned) shall be indicated by the manufacturer. The

bolting up procedure shall include progressive step-wise application of bolt load and

measurement of corresponding bolt extensions, gasket compression and mating flange

deflections. All material required for fasteners shall be tested as per applicable

specification/ drawings/ approved material sampling and testing plans.



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6.0 Fabrication Requirements

6.1 Workmanship

Workmanship shall be in accordance with the best practice and adequate to ensure

satisfactory operation, ease of maintenance and service life of at least 40 years in

accordance with the provision of this specification.

6.2 Procedure

The manufacturer, before taking up the fabrication, shall submit all documents and

drawings as specified in section no. 10 for NPCIL’s approval. Results of exploratory

trials and tests to establish procedures are desirable evidence may be also submitted to

the NPCIL for information.

6.3 Heat Treatment

Heat-treatment shall be carried out in duly calibrated furnace only and evidence of

temperature distribution in the furnace is to be supplied to NPCIL for the furnaces

employed. Furnace shall be electrical/gas fired.

Heat Treatment Plan

The tube sheet after cladding and other components when required shall be heat

treated for stress relieving. For all heat treatment intended to be performed on

component or heat exchanger, heat treatment plan shall be established. The detailed

procedure shall be submitted to NPCIL for approval, prior to start of process.

6.4 Material Cutting

Carbon steel material may be cut to size and shape by flame cutting provided all

accumulation of slag oxides is removed from the cut surface. All flame cut edges shall

be machined or ground back to a minimum 3 mm past the deepest indentation.



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The local preheat for cutting may be used if required. The preheat temperature for

cutting shall be same as that for welding.

6.5 Tolerances and Surface Finish

The manufacturer shall be responsible for compliance with prescribed final

dimensions and tolerances. The dimensions for wall thickness of base material

given in the drawings are the minimum prescribed values and manufacturer

shall procure with positive tolerance only.

All welds and surfaces to be examined must be finished in such a way that a precise

coupling of such units is ensured during Ultrasonic examination. The requirements of

the corresponding specifications shall apply in such cases. All welds shall be ground

smooth. If the weld edges are dislocated either on the inside or outside within the

manufacturing tolerances, the transition shall be brought upto an angle of maximum 5º

and shall have a radius of minimum 250 mm. Written approval of NPCIL should be

taken for such welds, which shall be properly recorded.

6.6 Cleanliness

Tube sheets and baffles shall be maintained in a clean condition. Scrupulous attention

to cleanliness is essential for the satisfactory tube-to-tube sheet welds. Just before

closing of the channel side by assembling the cover, each tube shall be cleaned and

purged with clean oil free compressed air. Prior to carrying out eddy current

examination of tubes by ID probes to establish base line data for reference for future

health assessment as part of In Service Inspection (ISI), the manufacturer shall clean

each of the tubes by acetone soaked felt plugs driven by clean oil free compressed air.

All internal surfaces of the Heat Exchanger shall be clean to the degree that wiping

with clean white cloth results in no significant coloration of the cloth. The Heat

Exchanger shall be examined visually at appropriate stages of fabrication to ensure

that cleanliness is maintained.



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All stainless steel surfaces and outer edges shall be protected from contamination by

injurious and undesirable foreign matter at all stages of manufacture. Chemicals, oil,

grease and cleaning agents where used, shall be subject to NPCIL approval.

Chemical cleaning procedure shall be approved by NPCIL prior to start of cleaning

operations. Only certified and approved cleaning agents shall be employed. After

cleaning, the surface shall be free of chlorides and other injurious contaminants such

as Iron, Lead, Sulphur. Water with halogen content not exceeding 25 ppm shall be

used for flushing. All pickled surfaces shall be passivated as per NPCIL approved

procedures.

6.7 Forming and Bending Process

Any process may be used for forming or bending (hot /cold) of any pressure retaining

materials for component, provided the required tensile and impact properties are not

reduced below the minimum required values (as per material specification) or they are

effectively restored by heat treatment following the forming/bending operation.

Qualification of Forming and Bending Process

When required, procedure qualification test shall be conducted on specimens taken

from coupons of the same material specification as employed for the portion of the

component involved. The applicable tests shall be conducted (on coupons) to

determine that the required tensile and impact properties are met. The procedure is to

be submitted to NPCIL for approval prior to carrying out the qualification. If the

manufacturer has already conducted tests on similar materials, he shall submit the

relevant data to NPCIL for review and approval.

6.8 Welding

6.8.1 General

Welding operation shall be conducted under sheltered conditions. Welding work,

workshop facilities, the employment of welders and supervisory personnel must be



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available in accordance with the requirements of ASME. The general welding

qualification standard with above specification requirements shall be submitted for the

approval of NPCIL.

All welding shall be planned and conducted to minimize warping or undue distortion

of the assembled units. Machined surfaces and threads shall be protected against weld

splatters and restrained against warping.

Welding Equipments

A list of welding equipment to be used with model designation, control characteristics,

construction year and registration numbers and latest calibration certificate shall be

submitted to NPCIL. In addition to this, NPCIL shall be notified of the control

equipment and welding machines that are to be monitored and calibrated (random

parameter check shall be carried out by NPCIL).

Data of welding speed and wire feed rates (by recording or indicating instruments) are

required for automatic welding. Welding current and voltage must be documented on

continuous-recording devices. The agreement of NPCIL is required for exceptions to

these for cogent reasons. All welding equipment shall be maintained in a perfect

condition and checked regularly. Opportunities for verification shall be afforded to

NPCIL.

Requirements and functions of supervisory and welding personnel shall be clearly

defined. The supervisory personnel shall be responsible for the quality of the welding

work. The welding supervisory personnel shall not be engaged directly in welding.

6.8.2 Welding operation on the component shall only be commenced if:

a) Approved and released manufacturing plan and welding plan is available and

welds are covered by valid welding procedure qualification tests approved by

NPCIL.

b) The welding material (batch of electrodes, melts of wire/strip or flux batches and

combination thereof) have been released for welding by NPCIL (QA).



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6.8.3 Welding material shall meet relevant specification listed in part C of ASME Section II

except inconel consumables which are required to be procured as per NPCIL

specification (PC-M-1109).

6.8.4 Welding procedures used in the fabrication shall be qualified in accordance with

Section-III and Section-IX of ASME code. The welding procedure qualification test

shall be conducted in the presence of NPCIL (QA). The respective documents

(WPS/WIP) must be submitted to NPCIL for the approval of welding plan. The welds

shall be uniform throughout and shall blend smoothly into the parent metal. For each

welder, the appropriate approved welding procedure plan must be available.

During all welding operation, the welding parameters laid down in the welding

procedure specifications (WPS) shall be complied with and the same shall be ensured.

6.8.5 The copper nozzle (welding tip) of the welding equipment must be marked before use.

Upon completion of the work, the nozzle must be presented for checking. If a nozzle

melts into the weld during welding, the welding processes must be stopped

immediately, the occurrence noted down in the welding report and NPCIL be

informed. Only after being appraised by NPCIL and subsequent removal and

examination of the weld affected location, welding process may be continued using a

new nozzle.

6.8.6 Carbon electrodes without copper coating are only permissible for back gouging.

6.8.7 Welding Plan

A welding plan shall be established for each weld joint and repair. Tack welds shall

be included in the plan. In particular the welding procedure qualification must also be

listed. The welding plan requires the approval of NPCIL before the start of welding.

6.8.8 For all welding parameters (including preheat, weld inter-pass and post-heat treatment

temperatures) the allowable tolerance range established in the welding procedure

qualification test shall be specified. Following definition apply to pre-heat weld inter-

pass and post-heat treatment temperature.



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Pre-Heat Temperature

Temperature of work piece in weld zone (100 to 300 mm on either side of weld) at the

start of welding.

Caution

Local preheating shall be avoided as it could produce permanent deformation in final

as welded condition.

Weld Inter-pass Temperature

Temperature of the work piece, measured (100 to 300 mm on either side of weld) in

front of the welding location at or directly adjacent to the groove face. It shall not be

lower than the lowest pre-heat temperature and not higher than the maximum weld

inter-pass temperature given in the welding plan.

Post Weld Heat Treatment Temperature

Temperature of the work piece in the welding region during soaking as indicated in

the welding and heat treatment plans.

6.8.9 Stainless steel welds shall be cleaned with stainless steel wool or stainless steel

brushes before adding the next bead and following the final bead to facilitate

inspection. The light oxide discoloration, which forms on the weld surface, need not

be removed.

6.8.10 Welds shall be cleaned of slag and flux between passes and following the final

deposit.

6.8.11 Root passes of the welds, not accessible from both sides shall be made preferably by

using welding insert and/or by inert gas tungsten arc (GTAW) process.

6.8.12 All welds, unless otherwise specified, shall be full penetration welds.

6.8.13 All surfaces to be joined shall be thoroughly cleaned to prevent weld contamination

and all weld preparations shall be machined smooth and PT tested.

6.8.14 All weld surfaces shall be ground smooth with maximum reinforcement of 1.5 mm

and shall be free from any crevices or undercuts.



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6.8.15 Any cracks, blow holes or other defects which appear on the surface of weld beads

shall be removed by machining, chipping, grinding or arc gouging. Austenitic weld

repairs, if arc gouged, shall be followed by grinding. Austenitic welds shall not be

peened. Ferritic welds may be peened with the approval of NPCIL.

6.8.16 Temporary welds on the base material of the heat exchanger shall be located where

possible on the edges and areas that will be trimmed off. Temporary attachment, must

be made of killed steel. Cutting off shall be done mechanically as far as possible. If

flame cutting gauging is performed, the cut off location must be sufficiently far away

from the surface of the work place to avoid the part being metallurgically heat

affected. Cut off location must be ground flush to the surface and subjected to PT and

hardness test (if needed in specific case).

6.8.17 Wide welds to overcome poor fit are not permissible. Poor fits shall be remedied by

suitable means such as re-grooving and shall be subject to approval by NPCIL. Except

for small cavities, the manufacturer shall not correct a plate edge deficiency unless

approved by NPCIL and NPCIL may require that welding to correct a plate edge

deficiency be subjected to radiographic or other approved methods of examination.

6.8.18 Use of backing ring except in case of closure joint between tube sheet and secondary

shell, will be permitted only if the ring is removed after welding and the weld root is

subjected to and passes liquid penetrant examination.

6.8.19 Chemical composition of backing ring shall conform to that of base metal. If

consumable inserts are used, their composition shall conform to that of the filler metal

used in welding the joint.

6.9 Tube sheet Cladding

The tube sheet shall be procured as per NPCIL specification PC-M-1108.

6.9.1 The Inconel overlay cladding on the production component shall be done using

qualified heat/lot/batch of welding consumables, in accordance with qualified overlay



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cladding procedure by qualified welders/welding operators as specified in the NPCIL

specification PC-M-1109.

6.9.2 The tubesheet after cladding shall be stress relieved as per the requirements of ASME

section III and at a temperature of 600 +/- 10

degree C. The soaking time will depend on

tube-sheet thickness and the same shall be approved by NPCIL.

6.9.3 The tube sheet prior to cladding and after cladding & stress relieving shall be

subjected to liquid penetrant examination and Ultrasonic examination.

6.10 Tube sheet and Baffle Drilling

Tube Sheet and Baffles shall be drilled in accordance with NPCIL specification no.

PC-P-192: “Procedure for Tube sheet and Baffle Drilling ". Before taking up

production drilling, procedure shall be qualified. The CNC controlled single

spindle/multiple spindle drilling machine used for this purpose shall be in a technically

perfect condition. A continuous checking of drilling parameters and measurement

shall be ensured. The details of the drilling machine shall be made available to

NPCIL, prior to taking up the work. The drilling work shall be carried out only by

trained and qualified personnel, who have prolonged experience on similar job. All

work shall be carried out under the supervision of responsible persons of the

manufacturer. In order to perform the work, clear written operating instructions

indicating all important details shall be made available to the operating personnel. By

means of conducting a trial on qualification test specimen, the manufacturer shall

prove that the job could be carried out successfully using his CNC machine. He shall

also establish optimum drilling parameters through the trial.

6.11 Tube Bundle Assembly

6.11.1 Tube bundle assembly shall be carried out in clean room/Dust Free Enclosure (DFE).

The requirement of Dust Free Enclosure (DFE) is attached as Annexure-3.



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6.11.2 The Tube bundle skeleton assembly shall be checked for dimensional compliance

before inserting the tubes. Tubes ready for insertion, shall be thoroughly cleaned all

over by suitable cleaning solvent.

6.11.3 Burrs, drilling particles, all traces of grease, oil, machining lubricant, marking crayons

or any other foreign matter or contamination shall be removed from both sides of

baffles, tube sheet and from the interior of each hole prior to insertion of tubes.

6.11.4 All handling of the tubes, tube sheet and baffles shall be done with clean gloves.

6.11.5 Each tube after insertion shall be checked visually to ensure that surface is free of

scratch marks.

6.11.6 Cleanliness of tube bundle assembly shall be maintained throughout the operation.

6.12 Tube end Rolling

The tube ends shall be given a light rolling (contact rolling) to close clearance between

tube-sheet hole and tube OD. The length of tube end rolling shall be up to 3 to 4 mm

inside the tube-sheet, from the tube-sheet channel side face.

Tube End Rolling shall be in accordance with NPCIL procedure no. PC-P-194

" Procedure for Tube Expansion ". However, before taking up production tube end

rolling, procedure qualification shall be carried out.

6.13 Tube-to-Tube sheet weld

6.13.1 The tube to tube sheet weld joint shall be recessed type as shown in the tender

drawings and Semi automatic welding machine shall be used.

6.13.2 The welding shall be carried out in accordance with the NPCIL procedure no. PC-P-

193: “Procedure for Welding of Tube to Tube Sheet Joints”. However, before taking

up Production Tube to Tube sheet Welding, procedure qualification and operator

qualification shall be qualified as per above mentioned NPCIL specification.



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6.14 Expansion of Tubes in Tube-sheet

After Helium leak testing of tube to tube-sheet welds, all the tubes shall be

protractively expanded in the tube sheet using mechanical expanders. The rolling shall

begin at a point inside the tube sheet 15mm from its tube side face and shall terminate

at 2+1/-0

mm from the shell side face of the tube sheet. The expansion length/number of

stages will be as per the approved drawings. The manufacturer shall submit the

tube/tubesheet expansion procedure for approval of NPCIL.

The percentage reduction in the tube wall thickness due to rolling shall be 3 to 6

percent of nominal tube wall thickness.

Tube expansion shall be carried out in accordance with the NPCIL specification no.

PC-P-194 : “Procedure for Tube Expansion ". Before taking up Production rolling,

procedure qualification shall be carried out in accordance with the above mentioned

specification. Production control of expansion of Tubes into Tube sheet shall also be

carried out as per the requirements stated in the above specification.

7.0 Examination, Inspection and Testing

7.1 General

The manufacturer shall be responsible for and shall provide for and perform all the

examination, inspection and testing specified herein. The Heat Exchanger shall be

carefully examined during manufacture and after completion to determine its

conformance with this specification with respect to material ,workmanship, finish,

marking and dimension. Manufacturer shall also assess conformance with other

requirements stated or reasonably implied and not covered by specific examinations

and tests. The examination, inspection and testing shall be conducted in a manner

satisfactory to and shall be subject to the approval of the NPCIL. The NPCIL or his

authorized agencies shall have access to the Manufacturer’s premises at all reasonable

times to the extent necessary to assess compliance with the provision of this



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specification. Examination, inspection and test reports shall be submitted by the

manufacturer to NPCIL periodically.

NPCIL shall have the right to conduct at his own expense any additional examination,

inspection or testing as deemed necessary. At the request of the NPCIL, the

Manufacturer shall re-examine, re-inspect or re-test any component of the equipment.

Defects so revealed which do not meet the requirements of this specification shall be

cause for rejection of the component, or alternatively for repair and subsequent re-

examination, re-inspection and re-test. If defects are revealed, all such re-

examination, re-inspection and re-testing both before and after repair shall be at the

expense of the Manufacturer. If no unacceptable defects are revealed, re-examination,

re-inspection and re-testing requested by the NPCIL shall be at NPCIL's expense.

7.1.1 Quality Assurance

The quality assurance plan (QAP) shall ensure the quality control of raw materials,

welding filler metals/auxiliary materials, fabrication process etc. Suggested QAP is

indicated in NPCIL specification No. PC-P-257. Manufacturer shall prepare detailed

QAP for NPCIL approval based on suggested QAP.

7.1.2 Examination and Inspection on Test Failure

In the event of failure of the equipment of any part thereof to meet examination,

inspection or test requirements specified herein, the Manufacturer shall notify NPCIL.

The Manufacturer shall obtain permission from NPCIL before carrying out repair or

subsequent use of such equipment or part thereof. If the repairs, including redesign,

are likely to affect the results of examination, inspection and tests or work previously

completed, appropriate re-examination, re-inspection and re-testing shall be

conducted.

7.2 Material Examination and Tests

All materials designated as in conformance with ASME Section-II standard shall be

tested as required by such standard and examined and tested as per the requirement of



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ASME Section-III NB/NC/ND or NF as applicable and any special additional

requirements of this specification. The material toughness properties, when required

by ASME Section-III NB/NC/ND or NF shall be such that the RTNDT shall not be

higher than -15 oC. The lowest service temperature value used for impact testing shall

not be higher than +18 oC at which the Charpy V-notch energy and / or lateral

expansion values specified in ASME Section-III are to be met. Proof in the form of

certified examination and test reports or mill certificates that the required

examinations and tests have been carried out at the source will be acceptable, but if

they are not available, these examination and tests shall be performed by the

Manufacturer. However acceptance of material certificates is subject to satisfaction of

NPCIL and if required NPCIL may ask for retesting of material to conform to the

specification requirements.

7.3 Non-destructive Examinations

7.3.1 Liquid Penetrant /Magnetic Particle Examination (PT/ MT)

Liquid Penetrant/Magnetic Particle examination shall be performed in accordance with

ASME Section -V and Section-III NB/NC/ND/NF as applicable. Additional

requirements are as follows:

7.3.1.1 Liquid Penetrant Examination (PT)

a) Penetrant, developers and cleaning agents, shall preferably halogen free.

Halogen content in the penetrant, developer and cleaners to be used on

stainless steel material and sulphur in the penetrant, developer and cleaners to

be used on the nickel based alloy shall not exceed 1% of the residue weight as

determined by Article-6 of ASME Section V and respective ASTM standards.

Only NPCIL approved penetrant and developer agent shall be used.

b) Application of penetrant and developer from Aerosol type spray cans is

preferred.

c) The temperature of area to be examined shall be between 16ºC and 52 ºC.



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d) All traces of penetrant and of developer shall be removed from the work

immediately after the completion of examination.

7.3.1.2 Magnetic Particle Examination (MT)

a) Surface shall be prepared for examination by removal of scale (not just loose

scale). Scale shall be removed by a method, which will not obscure defects (shot

peening shall not be used as it obscures defects).

b) The indicating material shall be removed on completion of examination.

c) Demagnetization is required to achieve residual magnetism to less than 20 gauss or

equivalent.

Table- I below describes the requirements of MT/PT examinations.

7.3.2 Ultrasonic Examination (UT)

7.3.2.1 Ultrasonic examination methods shall be in accordance with the requirements of

Section-III NB/NC/ND/NF (as applicable) and Section-V of the ASME code.

Table- I below describes the requirements of UT examination.

7.3.3 Radiography Examination (RT)

7.3.3.1 Radiography examination methods shall be in accordance with the requirements of

Section-III NB/NC/ND/NF (as applicable) and Section V of the ASME Code.

Radiographic technique shall be in accordance with ASTM E-94.

The quality level of the radiographic examination shall be 2-2T as defined in SE-94 of

section V of ASME code.

Table- I below describes the requirements of RT examinations.



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TABLE-I

Nondestructive Examination Requirements

Type of

Examin

ation

Item Extent of examination Acceptance Criteria

MT or

PT

Raw material like

Forgings for Class-I

components.

ASME section III –NB &

NPCIL’s Specification

ASME section III –NB &

NPCIL’s Specification

U Tubes Covered in tube

specification PC-E-923

Covered in specification

PC-E-923

Finish machined surfaces

of all components

100% ASME section-III NB/

NC/ND or NF as

applicable

All weld edge

preparations


NC/ND or NF as

applicable

Final pass of all welds +

backchipped weld joints


NC/ ND or NF as

applicable

Tube sheet Cladding

a) as deposited condition

b) after heat treatment

c) after final machining

100% Free from any

discontinuity indications.

Tube to tube sheet welds 100% Any indication of any

shape and size shall be

unacceptable.

UT Raw material like Plates,

Forgings etc.

As per ASME section III –

NB/NC/ND/NPCIL’s

specification.

ASME section III –

NB/NC/ND/NPCIL’s

specification.



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Type of

Examin

ation

Item Extent of examination Acceptance Criteria

Tube sheet cladding

before and after stress

reliving

NPCIL Specification No.

PC-M-1108

NPCIL Specification No.

PC-M-1108

Welds ASME section-III NB/

NC/ND or NF as

applicable

ASME section-III NB/

NC/ND or NF as

applicable

U Tubes Covered in tube

specification PC-E-923

Covered in specification

PC-E-923

RT All Pressure retaining

Welds (Wherever RT is

not feasible UT should

be carried out.)

100% ASME section III NB/

NC/ND or NF as

applicable

7.4.0 Helium Leak Testing

7.4.1 Helium leak testing shall be performed in vaccum mode as per NPCIL approved

procedure. Manufacturer shall refer specification no PP-E-2384 for preparation of

helium leak testing procedure. Leak detection shall be by means of any approved leak

detector set up to detect actual leakage rate of 1 x 10-7

Std. cc per second or better

from a single leak site on the job using appropriate technique.

7.4.2 Stages of Test and Test Coverage

a) During procedure qualification of tube-to-tube sheet weld, including repair

qualification.

b) The Helium leak test shall be conducted on every Heat Exchanger at the

following stages:



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i) After completion of tube-to-tube sheet welding, but prior to tube expansion

and rolling. This shall cover the tube-to-tube sheet welds and leak, if any, in

the tubes.

ii) Inter gasket space Helium leak test on tube side after tube and shell side

hydro test.

iii) Tube side Helium leak test after tube side hydro test and drying. This shall

cover the tube-to-tube sheet weld, tubes and welds in the pressure boundary

of channel side, channel cover to channel shell gasket joint and entire

channel side pressure boundary.

iv) Shell side Helium leak test to be done after shell side hydro test for only

those Heat Exchangers having D2O on shell side (Regenerative Cooler).

Note: The manufacturer shall submit detailed drying procedure to ensure proper

and meaningful helium leak test.

7.4.3 Acceptance

a) Leak rate shall not exceed 1x10-7

std. cc /sec. of helium from a single leak and

1x10-6

std. cc/sec. of helium for global.

b) For gasket joint: Leak rate shall not exceed 1x 10-4

std.cc/sec. of helium.

7.5 Hydrostatic Test

7.5.1 The shell and tube sides of the completed Heat Exchanger shall be hydrostatically

pressure tested as per NPCIL approved procedure. Manufacturer shall refer NPCIL

procedure specification No. PC-P-255 for preparation of Hydrotest procedure. The

metal temperature anywhere shall be well above RTNDT + 60 deg. F (33 deg. C)

during the entire test.

7.5.2 Acceptance

a) There shall not be any recordable change in test pressure during testing.

b) There should be no leakage and distortion.



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7.6 Ball Passage Test

Ball Passage Test shall be carried out after hydro test of tube side using Teflon balls

which are shot through the U tubes by compressed Nitrogen gas. The test ensures that

no foreign material /part is left inside the tubes or any blockage and detects collapse of

tubes if any. The test shall be carried out as per NPCIL approved procedure. NPCIL

procedure specification No. PC-P-258 shall be referred for preparation of Ball passage

test procedure.

After Ball passage test and before final closing of primary side all tubes shall be

thoroughly cleaned as per approved procedure.

7.7 Eddy Current Testing

Eddy current examination of tubes by ID probes shall be carried out at

manufacturer’s shop after completion of heat exchanger fabrication in order to

establish base line data for reference for future health assessment. The procedure

for eddy current testing shall be submitted for approval of NPCIL prior to

carrying out Eddy current testing. NPCIL procedure specification No. PP-P-1962

shall be referred for preparation of Eddy current test procedure

8.0 Foreign Material Exclusion (FME)

All fabrication / manufacturing activities shall be carried out in a manner to ensure that

no foreign material (eg. loose metal pieces, weld spatter, tools & tackles etc.) is left in

any part of the Heat Exchanger. The manufacturer shall have a comprehensive FME

programme, duly approved by the Purchaser, to ensure the same. Before final boxing

up of the heat exchanger for shipment, a thorough inspection of HX internals shall be

carried out to ensure that no foreign material is left inside.



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9.0 Preparation for Shipment

9.1 Identification

Identification tag numbers are indicated on the heat exchanger data sheets. The

Manufacturer shall engrave the tag number on a thin rectangular metal piece

(made of SS 304 or equivalent material) and the same shall be securely attached to

the heat exchanger unit. The engraving font shall be of sufficient size so as to be

easily readable.

9.2 Heat Exchanger

Packaging for shipment shall be in accordance with the instruction outlined below:

The vessel and its accessories, if any, shall be thoroughly cleaned and dried

before shipment. The shell side and tube side shall be cleaned from inside and

outside. Shell side of Heat Exchanger shall be thoroughly dried by passing hot

air/Nitrogen. The tube side of all Heat Exchangers and both tube & shell side of

the Regenerative Cooler shall be thoroughly dried by passing dry Nitrogen gas

with a dew point checking of -10 oC. Drying procedure shall be submitted for

approval of NPCIL prior to carrying out drying.

All finished or machined external carbon steel surfaces shall be protected against

corrosion with a liberal coating of an approved, easily removable compound. The

compound shall be such that it will remain on the surface at temperatures

normally encountered during shipment, storage and operation. All machined

surfaces shall be protected against mechanical damage.

All external unfinished carbon steel surface shall be shot blasted and coated with

Inorganic zinc silicate primer and Epoxy paint (minimum dry film thickness of

250 microns including primer thickness of 50-75 microns) of aircraft gray colour

or high temperature (326°C) application paint (minimum dry film thickness 100-

150 microns including primer) as applicable to specific Heat Exchangers. NPCIL



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certified paints and suppliers are listed in Annexure-4. The paint brand and

application procedure shall be subjected to approval of NPCIL.

The vessel shall be purged of air and filled with dry nitrogen on both the shell and tube

sides to well above atmospheric pressure (0.3 kg/cm2 (g)) and sealed properly prior to

shipment. Two pressure gauges (duly calibrated with valid certificates) at highest

points of the heat exchanger shall be installed to ensure that inert gas pressure during

shipment and storage is maintained well above atmospheric pressure. Gauges shall be

protected/ secured such as to avoid any damage during transportation. Certificate of

Pressure gauges shall be forwarded along with the equipment.

All openings shall be adequately sealed. Flanged openings, if any, shall be covered

with blank flanges held in place with at least four bolts and sealed with blank gaskets

of natural rubber or equivalent. Butt weld openings shall be closed with fillet welded

slip-on type temporary covers.

Internally threaded pipe connections shall be plugged with a threaded metal plug and

sealed with tape. No thread lubricant shall be used. Externally threaded pipe

connections shall be similarly protected with caps and thread-tape.

The orientation of the heat exchanger unit during transportation shall be such that the

tube bundle gets support from the internal structural guide-cum-support. Manufacturer

shall ensure that the tube bundles do not get damaged during transportation due to

vibrations or jerks etc.

All components shall be tropical packed, suitably boxed, crated and protected from

damage in transit to site. Equipment shall be prepared for a period in transit exceeding

two months. The construction and lining of the box shall provide protection for its

contents. The packaging shall also include adequate cushioning, blocking, bracing,

skidding, hoisting and tie-down provisions. The packaging and preparation for

shipment shall be subject to NPCIL’s approval.



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9.3 Small Parts

All small and loose pieces, including fasteners, tools, gaskets, etc. shall be adequately

crated or boxed for protection during shipment. Parts subject to rusting shall be

suitably protected. All pieces shall be marked with the equipment piece number or

mark number specified by NPCIL

9.4 Spares

The spares supplied by the manufacturer under the contract shall be of best quality and

workmanship. The list of mandatory spare to be supplied with the Heat Exchangers are

given in Annexure-5.

9.5 Shipping weight and Dimensions

Estimated shipping weights and overall clearance dimension shall be supplied to the

NPCIL at least two months in advance before shipping.

10.0 Submittals

All submittals to NPCIL such as drawings, fabrication procedures, material

specification, test reports and other documents shall be in four hard copies.

10.1 Fabrication

Following shall be submitted to the NPCIL for Approval:

a) All fabrication drawings (Minimum submission size A1 )

b) Quality Assurance Plan (QAP) for following :-

i) Complete fabrication of Heat exchanger

ii) Materials in the scope of manufacturer like tubes, forgings ( tubesheet, channel

head, shell, dished end , nozzles etc), flanges , fasteners etc.

c) Fabrication/Operation Process Sheet

d) Heat Treatment Plans.



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e) Tube sheet cladding, Welding and weld repair procedures.

f) Any other Repair procedures.

g) Technical purchase specification for the materials in the scope of manufacturer.

h) Tube sheet/Baffle drilling Procedure.

i) Tube to tube sheet welding procedure.

j) Contact rolling and Tube expansion procedure.

k) Tube Bundle preparation and tube insertion procedure.

l) Hydro test procedure.

m) Helium leak test Procedure.

n) Draining and Drying procedure.

o) Ball passage test procedure

p) All Non destructive examination procedures (PT/MT/RT/UT/ECT).

q) Cleaning and preserving procedures, with chemical composition of solution or

agents.

r) Surface Preparation and Painting.

s) Packing procedure.

Any deviation from this specification and tender drawings is to be submitted for

NPCIL approval.

10.2 History Document

10.2.1 General Requirements:

a) The history document shall be prepared for each Heat Exchanger separately.

b) Two copies (One original+ one copy) of the history documents duly approved by

NPCIL’s inspection agency shall be put in properly identified hard cover bound

volumes and shall be submitted to the NPCIL.

c) Four sets of history documents shall be prepared on computer compact discs

(DVD) with appropriate software for indexing and search and shall be submitted

to the NPCIL.



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10.2.2 Contents

The history document shall contain following documents/drawings/certificates in the

same order as written below:

a) An index for history document.

b) Purchase Order (Main PO and un-priced sub PO including amendments if any)

c) Copy of Tender specification including technical specifications of all items of

equipment and support structure.

d) Copy of shipping release bearing the signature and seal of NPCIL’s inspector or

NPCIL’s authorized inspection agency.

e) All design concession records and Non conformity reports.

f) List of As built drawings.

g) One copy each of the following approved documents:

i) Detailed Quality Assurance Plans along with inspection reports.

ii) Manufacturing sequence plan.

iii) Heat treatment plan (if applicable).

iv) Ultra-sonic Testing procedure.

v) Radiographic Testing procedure.

vi) Magnetic Particle testing/Dye penetrant testing procedure.

vii) Hydro test and Helium leak test procedures.

viii) Drying procedure.

ix) Eddy Current test procedure.

x) Ball passage test procedure.

xi) List of welding consumables used, with consumable manufacturers name and

brand.

xii) All welding procedure specification including repair records.

xiii) Cleaning, preservation and packaging procedures.

xiv) Any other procedure approved by NPCIL.



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h) Certificates of the following tests / examination, signed by NPCIL’s inspector or

NPCIL’s authorized inspection agency:

i) Hydro test

ii) Heat treatment, if any.

iii) Helium leak test.

iv) Ball passes test

v) All Mechanical tests.

vi) All Non Destructive examinations.

vii) Record of dimension/inspection reports.

viii) Pre service base line information report ( ECT ).

i) All raw material/consumable identification reports and test certificates counter signed

by NPCIL’s inspector or NPCIL’s authorized inspection agency.

j) The as built General arrangement, tube bundle, channel head, baffles, fasteners and

the supporting structure drawings will be given in PDF and Autocad.

k) Rub off of stamping on nameplate.

l) Manufacturer’s compliance certificate indicating completeness of the job and

guarantee period.

m) Certificate of completeness of the history document duly signed by NPCIL’s

inspector or NPCIL’s authorized inspection agency.

Note: The history document shall not only be regarded as an evidence of specified

tests and examinations but also an instrument for fulfillment of contract.



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ANNEXURE-1

Sl.

No

Equipment Drawing title Drawing Numbers

A REGENERATIVE

COOLER (3331-

HX1A, HX1B)

1 General Assembly */33311/2001/GA

2 Tube Bundle and Shell Assembly * /33311/2002/DD

3 Anti Vibration Flat Assembly * /33311/2003/DD

4 Regenerative Cooler Supports */33311/2004/DD

5 Supporting Structure */33311/2005/DD

6 Channel head Assembly */33311/2006/DD

7 Tube Sheet Assembly */33311/2007/DD

8 Baffles */33311/2008/DD

9 U Tubes */33311/2009/DD

10 Material Specification Sheet */33311/2010/DD

11 Piping layout */33311/2011/DD

B BLEED COOLER

(3332-HX1A,

HX1B)

1 General Assembly */33321/2001/GA

2 Primary head Assembly * /33321/2002/DD

3 Shell assembly */33321/2003/DD


5 Tube bundle Assembly */33321/2005/DD

6 Anti Vibration Flat Assembly */33321/2006/DD

7 Flow Restriction Box */33321/2007/DD

8 U Tubes */33321/2008/DD

9 Heat Exchanger supports */33321/2009/DD

10 Support structure Assembly * /33321/2010/DD

11 Baffles */33321/2011/DD

12 Material Specification Sheet */33321/2012/DD

C

SHUT DOWN

COOLING HX

(3341-HX1 to HX4)

1 Shutdown Heat exchanger

Assembly HX2 & HX3

* /33411/2001/GA

2 Shutdown Heat exchanger

Assembly HX1 & HX4

* /33411/2002/GA

3 Tube Bundle Assembly HX2&HX3 */33411/2005/DD

4 Tube Bundle Assembly HX1&HX4 */33411/2006/DD

5 Shell assembly- HX2 & HX3 */33411/2007/DD

6 Shell assembly- HX1 &HX4 */33411/2008/DD

7 Tube sheet drilling plan */33411/2009/DD

8 Primary head assembly-HX2&HX3 */33411/2010/DD



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Sl.

No

Equipment Drawing title Drawing Numbers

9 Primary head assembly-HX1&HX4 */33411/2011/DD

10 Anti vibration flats assembly * /33411/2012/DD


12 Baffle and top Baffle */33411/2023/DD

13 Thermal Baffle */33411/2024/DD


D IARS HEAT

EXCHANGER

(SHELL & TUBE

TYPE ) (3333-HX1)

1 General Assembly */33331/2001/DD Sht1/ 6

2 Channel Head assembly */33331/2001/DD Sht 2/6

3 Shell assembly */33331/2001/DD Sht 3/6

4 Tube sheet And Baffles * /33331/2001/DD Sht 4/6

5 Tube Bundle Assembly * /33331/2001/DD Sht 5/6

6 Saddle supports */33331/2001/DD Sht 6/ 6

E F/M

RECIRCULATIO

N AND RETURN

COOLER (3337-

HX1 & 3337-HX2)

1 General Assembly

* /33371/2001/GA

2 Tube Bundle Assembly */33371/2002/DD

3 Shell assembly */33371/2003/DD

4 Tube Sheet * /33371/2004/DD

5 Tube End Box * /33371/2005/DD


7 Spacer tube with centering Device */33371/2007/DD

8 U-tubes */33371/2008/DD

9 Channel Head Assembly * /33371/2009/DD

10 Primary dished head */33371/2010/DD

11 Material Specification Sheet * /33371/2011/DD

F Weld detail

(Applicable to all

heat exchangers)

1 Butt welding with “Y” type

consumable inserts.

NPCIL/01006/2232/SK

(* represents project name)



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ANNEXURE-2

DATA SHEETS

1) REGENERATIVE COOLER (RGCL)

Sr

No

Parameter Description

1. Equipment Regenerative Cooler (RGCL)

2. Quantity/unit 1

3. Tag No. 3331-HX-1A &1B (2 Shells in series each

with following details).

4. Equipment Location Pump Room Floor (FL.EL.115.5 M)

5. Design Conditions Tube Side Shell Side

Design Pressure

Design Temperature

150 kg/cm2(g)

3260C

126 kg/cm2(g)

3260C

6. Design Classification

ASME Section- III

Class-I (NB) Class-I (NB)

7. Seismic Classification &

structural integrity

SSE & OBE SSE & OBE

8. Service Conditions Tube Side Shell Side

Fluid Heavy Water Heavy Water

Flow Rate, lpm 1200.0 2000.0

Flow Rate, kg/hr 79647.0 107875.5

Inlet temperature, oC 40.0 240.0

Outlet temperature, oC 224.72 106.34

Heat Load, kcal/hr. 14.74 x 106 (17.13 MWe)

No. of Passes 2 1

Pressure Drop, kg/cm2 0.284 4.46

The inlet and outlet temperatures specified are across the combined assembly of

two HX shells in series arrangement.

9. Shop Test

Testing Conditions Tube Side Shell Side

Air hold / leak test pressure 7.0 kg/cm2(g) 7.0 kg/cm

2(g)

Helium leak test Required Required



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Sr

No


Hydro test pressure, kg/cm2(g) 187.5 158

10. Field Tests (To be conducted at site. Not in manufacturers scope)


In circuit air leak test, kg/cm2(g) 7.0 7.0

In circuit hydro test, kg/cm2(g) 187.5 158

11. Inspection Requirements

Pre-service Inspection

Eddy current test data to be recorded as base

line data for all tubes.

In-service Inspection

Requirements

(To be conducted at site. Not in

manufacturers scope)

Volumetric examination of all pressure

retaining weld more than 1 NPS.

ECT of tubes.

12. Other Data

Equipment Weight – dry 10868 kg

Equipment Weight – operating 11698 kg

13. Fluid hold-up in

Channel

Tubes

Shell

130 Liters

220 Liters

480 Liters

14. Materials used

Shell

Forgings

Tubes

SA 350 LF2

SA 350 LF2

Incoloy-800 Annealed

15. Tube Size

No. of tubes

Tube pitch

Heat transfer area

12.6 mm OD x 1.15 mm Wt.

306

18 mm triangular (rotated)

209.17 m2

16. Applicable Drawings * /33311/2001/GA

* /33311/2002 to 2011/DD




FOR



Page No. : 38 of 50

Rev.

No. : 1

2) BLEED COOLER

Sr.

No


1. Equipment Bleed Cooler (BCR)

2. Quantity/unit 1

3. Tag No. 3332-HX-1A & 1B (2 Shells in series

each with following details).

4. Equipment Location Pump Room Floor (FL.EL 115.5 M)


Design Pressure

Design Temperature

126 Kg/cm2(g)

3260C

10.0 Kg/cm2(g)

2090C


ASME Section III

Class-1 (NB) Class-3 (ND)

7. Seismic Classification & structural

integrity

SSE & OBE SSE & OBE


Fluid Heavy Water Active Process Water

Flow Rate, lpm

kg/hr.

2000.0

107875.5

13360

797135.0

Inlet temperature, oC 240.0 34.0

Outlet temperature, oC 40 62.5

Rated heat Load 21875871.0 kcal/hr (25.43MWe)

No. of Passes 4 1


The inlet and outlet temperatures specified are across the combined assembly of

two HX shells in series arrangement

9. Shop Tests



2(g)

Helium leak test Required ----

Hydro test pressure, kg/cm2(g) 158 12.5



In circuit hydro test, kg/cm2(g) 158 12.5



FOR



Page No. : 39 of 50

Rev.

No. : 1

Sr

No



Pre-service Inspection

Eddy current test data to be recorded as

base line data for all tubes.

In-service Inspection Requirements.





ECT of tubes.

12. Other Data

Equipment Weight – dry 11,000 Kg. (approx)

Equipment Weight – operating 14,200 Kg. (approx)

13. D2O hold-up in

Channel

Tubes

130 Liters

270 liters

14. Materials used

Shell

Tube sheet, channel head

Tubes

SA 516 Gr.70

SA 350 Gr. LF2

Incoloy-800 (Solution Annealed)

15. Tube Size

No. of tubes

Tube pitch

Heat transfer area

12.6 mm OD x 1.15 mm Wt.

628 nos.


227.69 m2

16. Applicable Drawings

*/33321/2001/GA

*/33321/2002 to 2012/DD




FOR



Page No. : 40 of 50

Rev.

No. : 1

3). SHUTDOWN COOLER

Sr.

No


1. Equipment No. Shutdown Cooler

2. Tag No 3341-HX-1, HX-2, HX-3 & HX-4

3. Location 109.0 M EL. Floor Reactor Building

4. Quantity/unit 4

5. Design Condition. Tube Side Shell Side

Pressure 126 kg/cm2(g) 10.0 kg/cm

2(g)

Temperature 3260C 209

0C


ASME Section III

Class-1 (NB) Class-3 (ND)

7. Seismic Classification & Structural

Integrity

SSE & OBE SSE & OBE


Fluid Heavy Water Active Process

Water

Flow Rate – m3/hr 700 775

Inlet temperature, oC 54 35

Outlet temperature, oC 47 42

Rated heat Load 5.133 x 106 kcal/hr (5.97 MWe)


Number of Passes 2 1

9. Shop Test

Tube Side Shell Side


2(g)

Hydro-static test pressure 157.5 kg/cm2(g) 12.5 kg/cm

2(g)

Helium leak test Required ---

10. Field Test (To be conducted at site. Not in manufacturers scope)

In-circuit air hold/leak 7 kg/cm2(g) 7 kg/cm

2(g)



FOR



Page No. : 41 of 50

Rev.

No. : 1

Sr.

No


In-circuit hydro test pressure 157.5 kg/cm2(g) 15 kg/cm

2(g)


Pre-service Inspection.

Eddy current test data to be recorded as

base line data for all tubes.

In-service Inspection Requirements





ECT of tubes.

Heavy water nozzles made suitable for

in-situ ultrasonic examination

12. Other Data

Equipment Weight – dry 10,500 Kg. (approx)

Equipment Weight – operating 14,000 Kg. (approx)

13. D2O hold-up in

Channel

Tubes

490 Liters

360 liters

14. Materials used

Shell

Tube sheet, channel head

Tubes

SA 516 Gr. 70

SA 350 Gr. LF2


15. Tube Size

No. of tubes

Tube pitch

Heat transfer area

12.6 mm OD x 1.15 mm Wt.

864 nos.


209.23 m2

16. Applicable Drawings : */33411/2001-2002/GA

*/33411/2003 to 2025/DD




FOR



Page No. : 42 of 50

Rev.

No. : 1

1) F/M PUMP RECIRCULATION COOLER

Sr.

No


1. Equipment F/M Pump Recirculation Cooler

2. Tag No. 3337-HX-1

3. Quantity/unit 1

4. Equipment Location 104.5 M EL. Floor Reactor Building

5. Design Condition. Tube Side Shell Side

Design Pressure

Design Temperature

20 kg/cm2(g)

2100C

10.0 kg/cm2(g)

2100C


ASME Section III

Class-3 (ND) Class-3 (ND)


integrity

SSE & OBE SSE & OBE


9. Fluid Heavy Water Process Water

Flow Rate – lpm

kg/hr

300

19,530

1,970

117520

Inlet temperature, 0C 70.0 35.0

Outlet temperature, 0C 40.4 40.0

No. of Passes 4 1

Rated Heat load 586540 kcal/hr (692.0 KW)

10. Shop Test

Testing Condition Tube Side Shell Side


2(g)

Helium leak test

Required --

Hydro test pressure , kg/cm2(g) 25 12.5




.



FOR



Page No. : 43 of 50

Rev.

No. : 1

Sr.

No



Pre service Inspection Requirements.

Eddy current examination record to be

generated for all tubes




ECT of tubes.

13. Other Data

Equipment Weight – dry 2000 Kg. (approx)

Equipment Weight – operating 4300 Kg. (approx)


Tubes

Channel

69.0 liters

12.0 liters

15. Materials used

Shell,

Channel, Tube Sheet

Tubes

SA 333 Gr 6

SA 350 Gr LF2


16. Tube Size

No. of tubes

Tubes pitch

Heat Transfer area

12.6 mm OD x 1.15 mm WT.

106 nos.


32 m2 (approx)

17. Applicable Drawings */33371/2001/GA

*/33371/2002 to 2011/DD




FOR



Page No. : 44 of 50

Rev.

No. : 1

5) F/M RETURN COOLER

Sr.

No


1. Equipment F/M Return Cooler

2. Tag No. 3337-HX-2

3. Quantity/unit 1



Design Pressure 20 kg/cm2(g) 10.0 kg/cm

2(g)

Design Temperature 2100C 210

0C


ASME Section III

Class-III ND Class-III ND


integrity

SSE & OBE SSE & OBE


Fluid Heavy Water Process Water

Flow Rate – lpm

- kg/hr.

300

19,530

1,970

117520

Inlet temperature, 0C 70.0 35.0


No. of Passes 4 1

Pressure Drop, kg/cm2(g) 0.43 0.43

Rated Heat transfer rate 586540 kcal/hr. (692.0 KW)

9. Shop Tests



2(g)








FOR



Page No. : 45 of 50

Rev.

No. : 1

Sr.

No









ECT of tubes.

12. Other Data




Tubes

Channel

69.0 liters

12.0 liters

14. Materials used

Shell,

Channel, Tube Sheet

Tubes

SA 333 Gr. 6

SA 350 Gr. LF2


15. Tube Size

No. of tubes

Tubes pitch

Heat Transfer area

12.6 mm OD x 1.15 mm WT.

106 nos.

16 mm Triangular (rotated)

32 m2 (approx)

16. Applicable drawing numbers * /33371/2001/GA

* /33371/2002 to 2011/DD




FOR



Page No. : 46 of 50

Rev.

No. : 1

6) INVENTORY ADDITION AND RECOVERY SYSTEM (IARS) HEAT

EXCHANGER

Sr.

No


1. Equipment IARS Heat Exchanger

2. Tag No. 3333-HX-1

3. Quantity/unit 1



Design Pressure 20 kg/cm2(g) 10.0 kg/cm

2(g)

Design Temperature 1250C 65

0C


ASME Section III

Class-III ND Class-III ND


integrity

SSE & OBE SSE & OBE


Fluid Heavy Water Process Water

Flow Rate – lpm 500 3750

Inlet temperature, 0C 95 35.0


Operating Pressure, kg/cm2(g) 10.0 7.5

No. of Passes 4 1

Pressure Drop, kg/cm2(g) 0.01 0.13

Rated Heat transfer rate 1.6 x 106 kcal/hr (1.87 MWe)

9. Shop Tests



2(g)







FOR



Page No. : 47 of 50

Rev.

No. : 1

Sr.

No










ECT of tubes.

12. Other Data



13. Materials used

Shell,

Channel, Tube Sheet

Tubes

SA 516 Gr. 70

SA 350 Gr. LF2


14. Tube Size

No. of U-tubes

Tubes pitch

Heat Transfer area

12.6 mm OD x 1.15 mm WT.

157 nos.

19 mm Triangular (rotated)

52 m2 (approx)

15. Applicable drawing numbers */33331/2001/DD 1 to 6 sheets




FOR



Page No. : 48 of 50

Rev.

No. : 1

ANNEXURE-3

REQUIREMENT OF DUST FREE ENCLOSURE (DFE)

The DFE shall meet the following specific requirements of the Purchaser which shall be

documented in the form of an approved procedure.

1. All safety precautions shall be followed in DFE.

2. Separate enclosure having entry with double door.

3. Dust particle of size more than 5 micron shall not be allowed. The Clean Room should

conform to ISO 8 class or better as specified in ISO 14644-1 clean room standard.

This can be achieved by using proper air filters. Proper air flow (using fans and

filters) shall be maintained to achieve the uniform clean room quality. Testing shall

be carried out using instrument inside DFE at 10 locations spread across DFE.

Calibration of instrument should be done before start of the job and further after

every six months. In case of major maintenance of DFE, this test shall be carried out

before carrying out any further job in DFE.

4. Periodic monitoring of cleanliness shall be done to check the presence of any leakage

of undesirable dust

5. DFE shall be clean and under positive pressure.

6. Authorized and requisite Personnel shall only be allowed inside DFE.

7. Use of shoe covers and hand gloves is compulsory.

8. Sufficient space shall be provided to accommodate welding machines, argon gas

and other materials required for welding works.

9. Unnecessary material shall not be stored inside DFE.

10. Chloride contamination test shall be carried out every day before starting the job.

11. Cleaning inside DFE using mops shall be carried out on regular basis.

12. Vacuum cleaner may be used for cleaning.

13. Lighting should be sufficient for working.



FOR



Page

No. :

49 of 50

Rev.

No. : 1

ANNEXURE-4

RECOMMENDED EPOXY PAINTS FOR STEEL SURFACES

IN RADIATION AREAS

Sr. No.

Description Recommended System Manufacturer

1 Steel Surfaces DIMETCOAT–6

(Inorganic Zinc Silicate

Primer) +

AMERCOAT-90

(Epoxy Paint)

M/s. Goodlass

Nerolac

2. High Temperature

Applications (300 ºC)

iii) INTERZINC 1035


Primer) + INTERTHERM 50

M/s Akzo Nobel

Paints

3. Abrasive Blasted Steel

Surfaces other than

those mentioned in Sr.

No.1

i) APCOSIL 605

(85%) PC2119

(Inorganic Zinc Silicate Primer) +

APCODUR CF 641(Epoxy)

OR APCODUR CF 641-CS

(Epoxy)

ii) ZINC ANODE-304 NPC ( 85 % )


Primer) + PROTECTOMASTIC

(Epoxy)

iii) INTERZINC 1035 (Inorganic Zinc Silicate

Primer) +

INTERGARD 1054 (Epoxy)

iv) NEROSIL 118 NP

(Inorganic Zinc Silicate Primer) +

NEROMASTIC400NPK

(Epoxy)

M/s. Asian Paints (I) Ltd.

M/s. Berger Paints (I) Ltd.

M/s Akzo Nobel Paints

M/s Kansai

Nerolac paints



FOR



Page

No. :

50 of 50

Rev.

No. : 1

ANNEXURE-5

Mandatory spares required for PHT D2O Heat exchangers

Sr.

No. ITEM DESCRIPTION UNIT

Quantity

required per

Project

(consisting of -2

units)

ONE SET OF MANDATORY SPARES CONSISTS OF THE FOLLOWINGS

A Complete Gasket Sets for

1. Regenerative Cooler Sets 06

2. Bleed Cooler Sets 06

3. F/M Recirculation Cooler Sets 06

4. F/M Return Cooler Sets 06

5. Shut-down Cooler Sets 24

6. Inventory Addition & Recovery System Heat

Exchanger

Sets 06

B Studs along with two castle nuts, spherical washer and pins ( Same as

equipment drawing) for

1. M 64 X 615 L for Regenerative Cooler Nos. 06

2. M 64 X 685 L for Bleed Cooler Nos. 19

3. M 30 x 250 L for F/M Recirculation Cooler Nos. 19

4. M 30 x 250 L for F/M Return Cooler Nos. 05

5. M 72 x Shut-down Cooler Nos. 05

6. Inventory Addition & Recovery System Heat

Exchanger Nos. 08

C QC Block (50 mm thick) for qualification and

practice for tube plugging (each QC block shall

consists of 15 Nos. of tubes each 150 mm long, tube

to tube sheet welding and rolling completed and then

ready for use for qualification and practice for

plugging. The block shall be manufactured adopting

same manufacturing practice/procedure as that on

job.

Nos. 20

D Inconel 690 TT (Thermally Treated) plug material as

per tender drawing. Nos. 250

E Straight Tube Length of Incoloy-800. meters 2

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