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GOVERNMENT OF INDIA NUCLEAR RECYCLE PLANT SPECIAL EQUIPMENT DESIGN

NUCLEAR RECYCLE BOARD BHABHA ATOMIC RESEARCH CENTRE

TROMBAY, MUMBAI 400 085.

TENDER TECHNICAL SPECIFICATIONS

FOR

AUOMATED DIRECT FUEL TRANSFER SYSTEM

DOC NO : NRB / NRPSED / HEF / ADFTS / TTS / 2012 / 05 /

June, 2012

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CONTENTS --------------------------------------------------------------------------------------------------------- S.No. DESCRIPTION PAGE NO ---------------------------------------------------------------------------------------------------------

1. Introduction 3

2. Scope of work 3

3. Technical Specifications 10

4. Design / fabrication drawing 12

5. Materials 13

6. System operations 14

7. Design of equipment, design calculation and design basis report 15

8. Fabrication 17

9. Design requirements : (electrical) 20

10. Inspection, Testing and Fabrication record 23

11. Painting 27

12. Time Schedule 27

13. Vendors 27

14. Specific Instructions 28

15. Packing and transportation 29

16. Installation & commissioning 29

17. General requirements 29

18. Schedule of delivery 29

19. Guarantee 30

20. Document to be submitted 30

21. Annexure-A 31

22. Annexure-B 32

23. Annexure-C 40

24. Annexure-D 42

25. Annexure-E 43

26. Annexure-F 44

27. Annexure-G 45

28. Annexure-H 46

29. Annexure-I 47

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INTRODUCTION: Automated direct fuel transfer system is required for remote transfer of the spent fuel bundles from fuel pool of fuel

handling area (FHA) to dissolver cell in an automated way, eliminating manual operation, saving man hours,

eliminating dependency on skilled man power and minimizing man-rem consumption. Automation scheme is

selected for giving simplicity, remote maintainability and long service life.

This automation system has been proposed for the first time for nuclear recycle plants. The system is

designed with built-in safety margin giving high service life, redundancy (duplicated wire ropes and

sensors) giving high reliability and modular construction giving ease of maintenance. System design is

aimed at simplicity in system assembly, operation & maintenance.

1. SCOPE OF WORK :-

The scope of total work includes engineering design, preparation of design basis report &

engineering design drawing based on our reference design drawing, preparation of fabrication

drawings after obtaining approval on engineering design drawing, procurement of all material,

fabrication, inspection, assembly & testing at shop, dismantling of assembly & supply after

successful testing and installation & commissioning of automated direct fuel transfer system at our

site BARC, Tarapur. The scope of work also covers operational & maintenance contract for 1 year

after successful installation & commissioning of the above system at our site. The detailed scope of

work for the above equipment are as under mentioned.

1.1 Automated direct fuel transfer system along with drive unit & control system and its

supporting structures: Quantity - 5 nos lumpsum. (Refer design drawing no. IP1/102A/08058009/DWG/001/R-0)

The automated direct fuel transfer system comprises of two major sub-systems namely

Mechanical System and the Electrical System. The scope of work includes engineering design

based on design calculation of mechanical & electrical system, preparation of design basis

report & design drawing based on our reference design drawing, preparation of fabrication

drawings after obtaining approval on design report & design drawing, procurement of all

material, fabrication, inspection, assembly & testing at shop, dismantling of assembly & supply

after successful testing at supplier’s shop and installation, commissioning & testing of automated

direct fuel transfer system at our site BARC, Tarapur.

Prototype 1st unit will be tested for a number of cycles for a period of 6 months to establish

design and improvements required would be implemented on all remaining 4 units after

successful acceptance of prototype unit. Additional cost incurred during these changes would be

also quoted.

The description of mechanical & electrical systems are as under mentioned. 1.1.1 Mechanical System: (Qty. 5nos)

The mechanical system consists of Trolley and its driving unit sub-assembly, Trolley

locking/unlocking & front cover opening sub-assembly, X-Table sub-assembly, Single pusher

(Pusher-I from trolley to X-table) sub- assembly, Sensing sub-assembly for the bundle on the X-

table and Five pusher (Pusher-II from X-table to chopper) sub-assembly and its drive unit with

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control system as per attached technical specification & design drawing no.

IP1/102A/08058009/DWG/001/R0.

1.1.1.1 Trolley and its driving unit sub-assembly: (Refer design drawing no.

IP1/102A/08058009/DWG/005/R-0 & IP1/102A/08058009/DWG/007/R-0 ) The trolley carries five fuel bundles at a time (about 16 kgs. per fuel bundle). The trolley has

the fuel bundles spacing (pitch) of 117.4 mm, which is same as that of the trays for 11 fuel

bundles in case of fuel of 220 MWe PHWRs (Ф 82 mm dia). Trolley has four wheels and it

moves onto the rails. Two guide rails (one each side) are also provided at the top of the

wheels to prevent trolley from toppling over. The assembly is moved by the rope and pulley

driving system. One end of rope end is joined to front axle while other end of the wire rope is

joined to rear axle of the trolley sub-assembly.

The same trolley will be used for carrying five fuel bundles (about 24 kgs. per fuel bundle) of

540 MWe PHWRs (Ф 102 mm dia) having fuel bundles spacing (pitch) of 135 mm. Hence

design of trolley top platform has to be removable & replaceable type so that it can be change

over remotely from 220 to 540 MWe PHWRs and vice - versa.

The driving system of trolley consists of a wire rope, guide pulleys and a driving motor. Two

wire ropes are used from redundancy considerations. The driving ropes are kept under

tension by two independent floating pulleys and counter weight assembly ensuring system

operation as friction drive system. SS 316 having 10 mm diameter (8x19 construction IWRC;

Breaking strength of about 6000 Kgs.) wire rope is used.

The trolley is provided with a spring-loaded stopper on the cell side and a fixed stopper on

the pool-side to prevent the falling of fuel bundles.

Material of construction: SS 304L

Quantity: 5 nos. lumpsum

1.1.1.2 Trolley locking/ unlocking & front cover opening sub-assembly: (Refer design drawing no. IP1/102A/08058009/DWG/005/R-0) The trolley is locked in its end position in the cell, before pushing bundles from trolley to the

X-table. The spring loaded stopper plate on the cell side of the trolley is opened to enable

the transfer. Trolley locking (inside the cell) and movement of spring loaded stopper plate

are performed by two pneumatic cylinders. Trolley locking also results in actuation of a two

sets of duplicated limit switch (one on each side). Limit switch contacts are used for

generating the process interlock. The design of this assembly will suit for handling of 220 &

540 MWe PHWRs fuel bundles.

Material of construction: SS 304L

Quantity: 5 nos lumpsum

1.1.1.3 Single pusher (Pusher –I from trolley to x- table) sub-assembly :(Refer design drawing no. IP1/102A/08058009/DWG/004/R-0)

Pusher-I pushes fuel bundles from trolley onto the x-table. It consists of five pushers, LM

rails, LM guide blocks, ball screw assembly and the driving motor. Drive motor is kept

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outside the cell from ease of maintenance considerations. All the five pushers are connected

to a bracket, which is connected to the nut of ball screw assembly. Both ends of the screw

are supported through bearings. Screw is coupled to the motor shaft. Two sets of limit

switches are provided for end limits. Provision is kept for manual cranking of the driving

motor. This is used to bring back the pusher mechanism to its home position, in case of

motor failure. The design of this assembly will suit for handling of 220 & 540 MWe PHWRs

fuel bundles.

Material of construction: SS 304L

Quantity: 5 nos lumpsum

1.1.1.4 Sensing sub-assembly for the bundle on the x-table: (Refer design drawing no. IP1/102A/08058009/DWG/002/R-0)

Pusher-I transfers fuel bundles from trolley onto the x-table. Each fuel bundle is sensed

directly on the x-table by this mechanism. It consists of a bracket, limit switches and a

pneumatic cylinder. A set of five limit switches are used to directly sense the fuel bundles

and additional two limit switches are used to sense the stroke of the cylinder. Five limit

switches are mounted on the bracket and the bracket is fixed to the piston rod. Cylinder is

actuated, when all the bundles are transferred onto the X-table. The bracket with five sensors

senses all the bundles individually on X-table and comes back to its home position, before X-

table starts moving towards chopper (process interlock). The design of this assembly will suit

for handling of 220 & 540 MWe PHWRs fuel bundles.

Material of construction: SS 304L

Quantity: 5 nos. lumpsum

1.1.1.5 X-table sub-assembly: (Refer design drawing no. IP1/102A/08058009/DWG/002/R-0)

X-table receives fuel bundles from trolley at the pool side of tunnel location and carries these

fuel bundles to chopper location. It consists of a table, four guide blocks, two LM rails, one

ball screw and a driving motor. Motor is kept outside the cell. The table is mounted on

four guide blocks. These guide blocks slide over the two LM rails. Rails are fixed to the

structure. Ball screw is used to move the table over the rails. Nut of the ball screw is fixed to

the bottom of the table. Both ends of the screw are supported through bearings. One end of

the screw is coupled with motor shaft. The design of this assembly will suit for handling of 220

& 540 MWe PHWRs fuel bundles.

Material of construction: SS 304L

Quantity: 5 nos lumpsum

1.1.1.6 Five pusher (Pusher-II from X-table to chopper) sub-assembly: (Refer design drawing no. IP1/102A/08058009/DWG/003/R-0) Pusher-II pushes all the bundles one by one into the chopper from X-table. It consists of

pusher, guide blocks, LM rail, ball screw, bevel gears and motor. Motor is kept outside the

cell. The X-table motor at Pusher-II location stops, using its encoder signal. However,

alignment of X-table at Pusher-II location is ensured through actuation of pneumatic cylinder

and a set of limit switch. Once, the X-table position is aligned with chopper cell centre-line,

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Pusher-II is actuated to transfer the fuel bundles one by one. Initial stroke for transfer of first

four fuel bundles is 700 mm, while the last bundle is pushed by about 1.85 m stroke (1.2 m

inside chopper). The X-table moves back to its home position after pushing operation is

over. The design of this assembly will suit for handling of 220 & 540 MWe PHWRs fuel

bundles.

Material of construction: SS 304L

Quantity: 5 nos lumpsum

1.1.2 Control system: (Qty. 5nos)

1.1.2.1 The electrical drive system consists of the control system including the motors, feedback devices, sensors, controller, human-machine-interface (HMI) and the safety interlocks for the direct fuel transfer automation system.

Conventional 3-phase, 415 Volts, 50 Hz induction motors of given rating are used for all the drives. Appropriate feedback devices, located outside the cell, are used to provide the position and force feedback information for the trolley movement, X-table movement and Pusher-I & II movement. ‘Fail-safe’ brake is incorporated to ensure safety. Electromechanical limit switches are used in the cell to sense sequencing and other operations. PLC based controller is used, with touch screen panel and/or SCADA Panel. All the drive motors are fed through VFD’s (variable frequency drives) with soft start/speed, acceleration/deceleration and torque control feature. Indirect continuous and end-limit position information is used for display and generating process interlocks. The control panel displays real time parameters for the operator information. Manual cranking arrangement is provided with all the electrical drives, to bring the respective connected load to its home position, in case of non-availability of that drive. Table-1 gives the summery of various drives and actuators used in this system.

Table-1

Drives and Actuators used

Sr. No.

Sub-System Drive used

1. Trolley 3-phase, 415 V, 50 Hz, 3 HP, 1440 RPM Induction Motor with feedback device Motor fed from VFD

2. Pusher-I 3-phase, 415 V, 50 Hz, 0.75 HP, 1440 RPM Induction Motor with feedback device Motor fed from VFD

3. Pusher-II 3-phase, 415 V, 50 Hz, 0.5 HP, 1440 RPM Induction Motor with feedback device Motor fed from VFD

4. X-Table 3-phase, 415 V, 50 Hz, 0.75 HP, 1440 RPM Induction Motor with feedback device Motor fed from VFD

5. Trolley locking Double acting pneumatic cylinder, stroke 200mm 6. Direct sensing of fuel bundles on

X-table Double acting pneumatic cylinder, stroke 200mm

7. X-Table locking (Both positions) Double acting pneumatic cylinder, stroke 200mm

1.1.2.2 A suitable PLC based control system (5 nos) meeting all the safety requirements e.g. over load relays, safety interlock, push button with lamp indication (P. B / L) etc. shall be provided. All the motions will be pendant operated. Pendant will be detachable type with pendant sockets. Length of detachable flexible control cable will be 15 meters. Suitable limit switch & radio/light operated sensors shall be provided to achieve the required control and interlock mentioned in following para 1.1.2.2.1.

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1.1.2.2.1 Tentative list of Push button (P.B), interlock & trip alarm provided In the Control Panel: This may get changed during the finalization of design.

P. B/L (1) for forward motion of trolley from pool end to cell end P. B/L (2) for return motion of trolley from pool end to cell end P. B/L (3) for locking / front cover opening of the trolley P. B/L (4) for unlocking / front cover closing of the trolley P. B/L (5) for forward stroke of pusher-I for pushing of five bundles from trolley to X-table P. B/L (6) for return stroke of pusher-I from X-table to its home position P. B/L (7) for forward stroke of sensing sub-assembly from its home position of X-table for

sensing the fuel bundle and stroke of the cylinder pusher-I P. B/L (8) for return stroke of sensing sub-assembly from X-table to its home position P. B/L (9) for forward motion of X-table from trolley end to chopper end till 1st fuel bundle

aligns with the c/l of chopper P. B/L (10) for further movement of X-table till 2nd fuel bundle aligns with the c/l of chopper P. B/L (11) for further movement of X-table till 3rd fuel bundle aligns with the c/l of chopper P. B/L (12) for further movement of X-table till 4th fuel bundle aligns with the c/l of chopper P. B/L (13) for further movement of X-table till 5th fuel bundle aligns with the c/l of chopper P. B/L (14) for return motion of X-table from chopper end to trolley end at its home position P.B/L(15) for forward stroke of pusher-II for pushing aligned bundle from X-table to chopper P. B/L (16) for return stroke of pusher-I from X-table to its home position P. B/L (17) for locking of X-table P. B/L (18) for unlocking of X-table Trip and indication of trolley at loading end of fuel bundles towards pool side Trip and indication of trolley at unloading /pushing end of fuel bundles towards cell side Trip and indication of locking / front cover opening of the trolley Trip and indication of unlocking / front cover closing of the trolley Trip and indication at maximum forwarded stroke of pusher-I Trip and indication at home position of pusher-I Trip and indication at maximum forwarded stroke of sensing sub-assembly Trip and indication at home position of sensing sub-assembly Trip and indication of X-table at its home position (unlocked) Trip and indication of X-table at its home position (locked) Trip and indication of X-table for alignment of 1st fuel bundle with the c/l of chopper

(unlocked) Trip and indication of X-table for alignment of 1st fuel bundle with the c/l of chopper

(locked) Trip and indication of X-table for alignment of 2nd fuel bundle with the c/l of chopper

(unlocked) Trip and indication of X-table for alignment of 2nd fuel bundle with the c/l of chopper

(locked) Trip and indication of X-table for alignment of 3rd fuel bundle with the c/l of

chopper(unlocked) Trip and indication of X-table for alignment of 3rd fuel bundle with the c/l of chopper

(locked) Trip and indication of X-table for alignment of 4th fuel bundle with the c/l of chopper

(unlocked) Trip and indication of X-table for alignment of 4th fuel bundle with the c/l of chopper

(locked) Trip and indication of X-table for alignment of 5th fuel bundle with the c/l of chopper.

(unlocked) Trip and indication of X-table for alignment of 5th fuel bundle with the c/l of chopper

(locked) Trip and indication at maximum forwarded stroke of pusher-II Trip and indication at home position of pusher-II Trip and indication for the breaking failure of wire rope Interlock – actuation of locking / front cover opening of the trolley only if trolley aligns with

the home position of X-table Interlock – actuation of pusher-I only if locking / front cover opening of the trolley is done &

X-table is locked at home position and sensing sub-assembly is at home position

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Interlock – actuation of sensing sub-assembly only if X-table is locked at home position and pusher-I is at home position after pushing all the five fuel bundles.

Interlock – actuation of X-table only if pusher-I, sensing sub-assembly and pusher-II is at home position and unlocking of X-table is ensured.

Interlock – actuation of pusher-II only if bundles on X-table are aligned & locked with c/l of chopper and chopper is ready to receive the bundle for chopping.

1.1.2.2.3 Bought Out Components : The bought out components shall be of reputed make and have high reliability. The following are the suggested make of the important bought out components a) Electric motor : NGEF / Siemens / GEC / CGL/ Bharat Bijlee / Kirloskar b) Pushbuttons : Teknic c) Indicating lamps : Teknic d) Proximity / limit switches : Teknic Euchner / Messung e) Switchgear : Siemens f) Fuse : Siemens / EE g) Contactors : Siemens / Telemechanique/ Schreider h) Isolators/Solenoids : Siemens / GE / L & T i) Overload relays : Siemens / L & T / Schreider j) Brake : PETHE / EMM / BCH / Speed O control

k) Encoder : Hengstler l) PLC : Siemens m) HMI : Siemens n) SCADA : Wonderware

1.1.3 Remote handling tools for removal/replacement of above mechanical & electrical system:

The remote handling tools are required to facilitate the remote removal & replacement of

following sub-assembly and the design & fabrication of such tools will also cover in the scope of

supply. It is preferred to have common tool for handling following sub-assembly i.e. single tool

can be used for lifting & handling of all the following sub-assembly otherwise minimization of

number of tools will be done.

a) Trolley and its driving unit sub-assembly (Qty: 5 nos)

b) Trolley locking/ unlocking & front cover opening sub-assembly (Qty: 5 nos)

c) Pusher –I (from trolley to x- table) sub-assembly (Qty: 5 nos)

d) Sensing sub-assembly for the bundle on the x-table (Qty: 5 nos)

e) X-table sub-assembly (Qty: 5 nos)

f) Pusher-II (from X-table to chopper) sub-assembly (Qty: 5 nos)

g) Wire rope assembly (Qty: 5 nos)

h) Replacement module tool to switch over from 220 Mwe to 540 Mwe fuel bundle & vice-

versa (Qty: 5 nos)

Material of construction: SS 304L

1.1.4 Tank, truff along with its supporting structure, top platform along with railing & its supporting

structures as per the design drawing no. IP1/102A/08058009/DWG/006/R-0. Quantity: 1 no.

lumpsum

Material of construction: CS as per IS 2062 Gr B.

All the exposed carbon steel surfaces will be given two coats of epoxy primer of 3 mil each and two coats of 3 mil each epoxy paint of yellow colour.

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a) Tank: A top opening tank having inner dimension of 5000mm L x 5000mm W x 7700mm ht is to be fabricated with 12mm thick CS plate with the stiffener as shown in the design drawing no. IP1/102A/08058009/DWG/006/R-0. Material of construction: CS as per IS 2062 Gr B. Quantity: 1 no. lumpsum

b) Truff: A 12mm thk. assembled CS truff of size 1000mm W x 1200mm ht. x 15000mm L along with its stiffener and the supporting structure is to be fabricated as per the design drawing no. IP1/102A/08058009/DWG/006/R-0. 5 nos of truff having sizes 1000mm W x 1200mm ht. x 3000mm L with 12 mm thk CS plate are required to be fabricated for ease in disassembly and assembled by bolted joint with water leak tight gasket. The provision of perspex glass with water leak tight gasket are also required to be provided in each truff for the viewing of trolley motion inside the truff. The one end of assembled truff will be connected to CS tank and other end will be connected to the top platform structure at an angle of around 25 degree from horizontal as shown in the drawing. Material of construction: CS as per IS 2062 Gr B. Quantity: 1 no. lumpsum

c) Top platform: A platform having 12 mm thk CS plate and its support structure along with railing

is required to be fabricated as shown in the design drg no. IP1/102A/08058009/DWG/006/R-0. Material of construction: CS as per IS 2062 Gr B. Quantity: 1 no. lumpsum

1.2 Operational & maintenance contract for 1 year after successful installation & commissioning of the automated direct fuel transfer system at our site BARC, Tarapur: As the above automation system has been proposed for the first time for nuclear recycle plants,

hence it is proposed to carry out the extensive testing for the above equipment before putting up

in the actual plant. In order to meet the plant throughput capacity, it is required to operate the

above system for minimum 200 cycles per day up to one year. One cycle contains loading of

five fuel bundle on trolley, transfer of trolley from pool side to dissolver cell, opening of front

cover, pushing of five fuel bundle on to X-table by pusher-I, movement of X-table towards

chopper end till the 1st bundle aligns with chopper, thereafter locking of X-table & pushing of

bundle one by one into chopper through indexing of X-table. All tools, tackles & required man

power including engineers, technical supervisors, fitters and helpers & riggers etc. shall be

arranged by supplier for the routine operation & maintenance of the above system. Any break

down part or repair of the component during routine condition of operation shall be replaced by

supplier at his own cost during this period. Following points are required to be noted down.

i) To establish the fuel cycle time of trolley & X-table

ii) To establish the remote removal & replacement procedure of all components inside dissolver

cell like trolley and its driving unit sub-assembly, wire rope sub-assembly, trolley locking/

unlocking & front cover opening sub-assembly, pusher–I (from trolley to x- table) sub-

assembly, X-table sub-assembly, sensing sub-assembly for the bundle on the x-table,

pusher-II (from X-table to chopper) sub-assembly etc.

iii) To establish the routine preventive maintenance procedure/schedule of all components

iv) Noting down of all major & minor operational problems faced during the normal operations of

system and technical suggestions required for the same to be incorporated in the system by

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supplier.

v) Maintaining of log book for normal & emergency operations indicating description of all cycle

operation, date & time of start & stop and technical problems.

2. TECHNICAL SPECIFICATION

2.1 DESIGN FEATURES:

(i) System should be designed to handle fuel bundles of 220/540 MWe PHWRs. The

design of the system will be adaptable for both type of fuel bundle 220 as well as

540 MWe PHWRs after replacing some modules. Following modules shall be required to

replace remotely for switching over from 220 Mwe to 540 Mwe spent fuel bundles and

vice-versa.

• Top tray of the trolley

• Pusher I

• Top tray of X-table

• Direct sensing mechanism of fuel bundles (on X-table)

(ii) Modular construction.

(iii) Electro-mechanical wire rope driven trolley system (friction drive through counter- weight

assembly) to transfer fuel bundles.

(iv) System should be able to transfer five fuel bundles at a time.

(v) Stainless Steel Ball screw drives shall be used for Pusher-I, Pusher-II & X-table.

(vi) Pneumatic actuators shall be used for locking of Trolley and X-Table (at two

positions). Pneumatic actuator is also used for direct sensing mechanism.

(vii) Use of water-resistant stainless steel bearings with end shields both sides. [Custom-built

Rotary Shaft Seals should be used for bearing housing of the Trolley /Guide Pulleys,

to avoid water/foreign particles entering the bearings].

(viii) Provision of remote replacement of all the sub-assemblies.

(ix) Directly actuated switches for sensing of fuel bundles on X-table, which is also used

to generate process interlock.

(x) Use of duplicated wire ropes for high reliability. In order to improve the reliability of wire

rope, two parallel wire ropes should be used.

(xi) Provision to check the healthiness of wire rope during its continuous operation and also

to detect the failure of the wire rope.

(xii) High design safety margin for long life of components.

(xiii) Provision of stopper plate in the trolley tray for restricting axial movement of the fuel

bundles.

(xiv) Provision of manual cranking for Trolley, Pusher-I, Pusher-II and X-table in case of

failure of respective electrical drives.

(xv) Components requiring minimum maintenance.

(xvi) Use of remotised electrical & pneumatic connectors.

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(xvii) Provision of system health monitoring through Motor parameter display (including

in-built protection through VFD), Trolley up/down indication & travel time display and the

Rope counterweight position sensing.

(xviii) Use of duplicated sensors for redundancy.

(xix) A provision shall be made in the automation system to change the cycle timing to optimize the

process resulting in increase in plant throughput.

(xx) Provision of manual charging of fuel bundles, as at present, in case of non

availability of automated system.

(xxi) To establish the remote removal & replacement procedure of mechanical system &

electrical drive system: Trolley and its driving unit sub-assembly, Trolley

locking/unlocking & front cover opening sub-assembly, X-Table sub-assembly Pusher-I

(from trolley to X-table) sub- assembly, Sensing sub-assembly for the bundle on the X-

table, and Pusher-II (from X-table to chopper) sub-assembly and its drive unit.

(xxii) To establish the wire rope replacement procedure.

2.2 POSTULATED DESIGN BASIS ACCIDENT: The system shall be designed to take care of

following scenario.

(i) Failure of electrical actuators: Trolley, Pusher-I, Pusher-II and X-table are operated by

electrical actuators. In case of failure of any electrical actuator, automation system

should be stopped by the watchdog timer interlock. An alarm should be generated.

Operator will operate the system in manual mode. Automation system will be brought to

safe (home) position.

(ii) Failure of pneumatic actuators: Four pneumatic cylinders (two nos. for Trolley locking,

one no. for direct sensing & one no. for X-table locking) are used in the automation

system. In case of failure of any electrical actuator, automation system should be

stopped by the watchdog timer interlock. An alarm should be generated. Operator will

operate the system in manual mode. Automation system will be brought to safe (home)

position.

(iii) Failure of PLC/control system: Manual cranking is provided with all the motor drive

shafts. In case of control system failure, all the electrical actuators, which are kept

outside the cell, will be mechanically disengaged from the automation system. System

will be brought to safe position by operating through manual cranking.

(iv) Failure of one wire-rope: Automation system will be stopped through interlock and

alarm will be generated. Trolley will be brought down to the pool by operating in

manual mode by the operator with the help of one wire-rope. Both the wire-ropes will be

replaced before starting the system again.

(v) Failure of both the wire-ropes: Automation system will be stopped through interlock and

alarm will be generated. Trolley will come down to the pool by its own weight. At its

home position (in the pool) trolley will be stopped through built-in mechanical stopper.

Both the wire-ropes will be replaced before starting the system again.

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(vi) Failure of Ball-screw Drives (X-table/Pusher-I and Pusher-II): Failure/jamming in the

operation of ball-screw drives will be taken care through built-in over- current

protection/torque limiter of the respective drives. This also will be detected by

watchdog timers and system will automatically be stopped. Corrective action will be taken

subsequently using Power Manipulator.

2.3 GENERAL NOTING:

Fabrication/shop drawings, fabrication, inspection & testing shall be carried out as per

this tender specification and required details shall be provided after the purchase order is

placed. All original certificates and inspection reports shall be bound along with built-in

drawing as a QA document and six (6 No) xerox copies of each shall be submitted before

dispatch.

3 DESIGN / FABRICATION DRAWING:

3.1 Applicable design drawing:-

LIST OF DESIGN DRAWING Sr. no. Item

Drg. No.

1 General arrangement of direct fuel transfer system IP1/102A/08058009/DWG/001/R-0

2 G.A. of ‘X’-table assembly IP1/102A/08058009/DWG/002/R-0

3 G.A. of single pusher assembly (pusher-II) IP1/102A/08058009/DWG/003/R-0

4 G.A. of five pusher assembly (pusher-I) IP1/102A/08058009/DWG/004/R-0

5 G.A. of trolley IP1/102A/08058009/DWG/005/R-0

6 G.A. of structural platform detail IP1/102A/08058009/DWG/006/R-0

7 G.A. of rope layout with drive arrangement IP1/102A/08058009/DWG/007/R-0

3.2 Fabrication drawings:-

Supplier shall furnish three sets of ‘fabrication drawings’ along with WPS/PQR/WPQ/QAP for above

equipments after receiving the order and get the approval of Purchaser prior to fabrication. It is the

responsibility of the Supplier to incorporate correctly all the comments conveyed by Purchaser on

Supplier’s drawings.

Drawings prepared by Supplier and approved by Purchaser shall be considered as part of the

specification. However, examination and approval of drawings by Purchaser shall not relieve the

Supplier of his responsibility for proper engineering, design, workmanship and materials under the

contract.

If any time before the completion of work, changes are made necessitating revision of approved

drawings, Supplier shall make such revisions and obtain the approval of the Purchaser. The

fabrication drawings shall be prepared/drawn in ACAD2009 only and a copy of them on CD (R/W)

shall be provided to Purchaser along with the tracings of the same before delivery of the equipment

with built-in dimensions in brackets.

Following fabrication drawings shall be provided before taking up the fabrication:

(a) General arrangement drawing for direct fuel transfer system.

(b) Detailed sub-assembly drawings

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(c) General arrangement drawings for remote removal/replacement of sub-assembly, wire rope

replacement etc, normal maintenance of sub-assembly etc.

4. MATERIALS :-

4.1 Material, processes and workmanship which are not specifically designated here in and which are necessary for the fulfillment of this specification shall be of good quality.

All material shall be new.

All components shall be machined true to a standard acceptable to the purchaser and shall be free from objectionable flaws / imperfection like cracks etc. All structural steel shall be accurately fabricated, true to line and free from wrap or twist. All similar parts shall be made to gauge wherever possible. No patching, plugging, shimming, or other such means of overcoming defects, discrepancies or errors shall be restored to without permission of the purchaser.

4.2 All stainless steel wherever mentioned in the drawing shall be of ASTM-A-240/ AISI 304L unless otherwise specified. Manufacturer's test certificates for chemical analysis and mechanical properties including charpy test & ultrasonic testing and IGC shall be furnished for the materials to be used.

4.3 For small parts / non-load bearing components, the requirement of the test certificates for mechanical properties could be waived, but with suitable hardness test reports with the approval of Purchaser.

4.4 All materials shall be of sound quality and shall confirm to relevant standards as per below :

i) S.S. Plates/sheets/strips : ASTM A-240 Type 304L i) S.S. bars and shapes : ASTM A-479 ii) CS Pipes/Plates/structures : IS 2062 Gr B iii) Bolts, nuts and washers : SA 193 Gr B7 for bolt & SA 194 Gr B8 for nut

iv) Welding materials, welder & weldperformance

: ASME sec-IX

v) Stainless steel wire rope : ASTM-A-492

vI) General requirements for stainlesssteel wire and wire rods

: ASTM-A-555

4.5 Material of construction:

As the components are required under water and subjected to gamma radiation, corrosion resistant

materials having high resistance are selected. Structural components and the manufactured

components are made out of SS 316 and particularly components requiring welded joints are made

out of SS 316L. Similarly SS 316L is used as wire-rope material. All the shafts are made out of 17-

4-PH material heat treated to typically H1100 condition. SS 440C is used as bearing materials

(Inner race, Outer race, Balls). Ball screw drives are forming incell components and they are

manufactured using 17-4-PH. Similarly LM rails & LM guide blocks are manufactured using SS

440C material. Pneumatic cylinders required for Trolley locking, X-table locking and direct sensing

assembly, are also manufactured using SS 304 material. Material testing and qualification should

be governed by applicable respective standards. Bottom rail material for trolley is selected as SS

17-4-PH in H900 condition where as the top guide rail is made out of SS 316L. Trolley wheels are

also made out of 17-4-PH. In order to have difference in hardness, rails are given heat

treatment of H900 and trolley wheels are given heat treatment of H1100. The top rails are acting

only as a supporting element. They are made out of SS 316 L materials. All the guide pulleys (inside

the water pool & also outside) are made of SS 17-4-PH H1050 condition. Details of material of

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construction are given in Table-3.

Table-3

Materials of Construction

SI No.

Items Materials

1. Trolley and its base plate & supports sub-assembly SS 304L 2. Trolley wheels 17-4 PH 3. Wire ropes SS 316L 4. Guide pulleys 17-4 PH 5. Pneumatic cylinders SS 304L 6. Rails 17-4 PH 7. Trolley locking/ unlocking & front cover opening sub-

assembly SS 304L

8. Pusher–I (from trolley to x- table) sub-assembly SS 304L 9. Sensing sub-assembly for the bundle on the x-table SS 304L 10. X-table sub-assembly SS 304L 11. Pusher-II (from X-table to chopper) sub-assembly SS 304L 12 Ball - screw 17-4 PH 13. LM rails / LM Guides SS 440C 14. Fasteners & other hardware items SS 15. Counter Weight (Guided assembly) Lead Bricks & CS 16. M.S tank & its supporting structures CS (IS 2062 Gr B) 17. M.S truff along with its supporting structure CS (IS 2062 Gr B) 18. Top platform along with railing & its supporting structures CS (IS 2062 Gr B)

5. SYSTEM OPERATION

5.1 Trolley operation:

1. Transfer of five spent fuel bundles from storage tray to the trolley, with the help of remotely operated under-water multi-grappler (multi-grappler is not in the scope of supply and will be provided to supplier as FIM for testing purposes).

2. Movement of the trolley (pool to the cell unit), carrying five fuel bundles, through underwater truff.

3. X table is locked at home position in the cell. 4. Locking of the trolley & opening of the front cover of the trolley. 5. Pushing of all bundles from the trolley on to the X- table through Pusher-I. 6. Sensing of all the fuel bundles on the X- table. 7. Pusher-I comes back to its home position. 8. Unlocking of the trolley & closing of the front cover of the trolley. 9. Movement of the trolley back to the home position in the pool.

5.2 X-Table operation:

1. Pusher-II (Pusher at Chopper Station in the hot cell) is at home position. 2. Movement of X-table to the pusher station in front of the chopper in the cell after unlocking. 3. Alignment & locking of the X-table for the pushing of the 1st bundle into the chopperl. 4. Chopper ready for the next batch of charging. 5. Pushing of 1st fuel bundle from the X-table into the chopper (stroke length of 700 mm). 6. Pusher-II comes back to its home position & unlocking of X-table 7. Movement & Alignment and locking of the X-table for the pushing of the 2nd bundle. 8. Pushing of 2nd fuel bundle from the X-table into the chopper (stroke length of 700 mm). 9. Pusher-II comes back to its home position & unlocking of X-table.

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10. Movement & Alignment and locking of the X-table for the pushing of the 3rd bundle. 11. Pushing of 3rd fuel bundle from the X-table into the chopper (stroke length of 700 mm). 12. Pusher-II comes back to its home position & unlocking of X-table. 13. Movement & Alignment and locking of the X-table for pushing 4th bundle. 14. Pushing of 4th fuel bundle from the X-table into the chopper (stroke length of 700 mm). 15. Pusher-II comes back to its home position & unlocking of X-table. 16. Movement & Alignment and locking of the X-table for the pushing of the 5th bundle. 17. Pushing of 5th fuel bundle from the X-table into the chopper (stroke length of 1850 mm). 18. Pusher-II comes back to its home position & unlocking of X-table. 19. Movement of X-table to the home position.

6. DESIGN OF EQUIPMENT, DESIGN CALCULATION AND DESIGN BASIS REPORT:

As the scope of cover includes design of equipment, hence supplier has to carry out the design

detailing, design analysis & design calculation for the above system. The Supplier will prepare the

design basis report consisting of design calculation for components/sub-assembly of direct fuel

transfer system, operation & maintenance procedure, remote removal/replacement procedure of

components/sub-assembly etc.

6.1 Design The major sub-assemblies of this automation system shall be designed with modular construction

namely Trolley sub-assembly, trolley locking/unlocking & front cover opening sub-assembly,

Pusher-I sub-assembly, sensing sub-assembly, X-table sub-assembly, Pusher-II sub-assembly

etc. The design of all sub-assemblies shall be remotely removable/replaceable type and same shall

be established. These shall be manufactured using stainless steel material and hence after

decontamination, these can be taken to the shop for maintenance. Electrical and pneumatic

actuators shall be made using leak tight remotely operable connectors. All the electrical actuators

shall be placed outside the cell, which are easily accessible for maintenance.

Trolley related components also can be taken out of the tank in case of any maintenance

requirement. The support bearings of the underwater rotating shafts (Trolley wheels & Guide

pulleys) are protected against pool water/foreign particles using rotary shaft seals. Due to space

constraints these seals are custom built. In order to further enhance the life of support bearings, SS

440C bearings shall be used. The use of rotary shaft seals for dynamic components shall be

preferred

Wire-rope shall be designed with the desired built-in safety. In order to enhance its service life,

duplicated wire-ropes shall be used. However, in case of wire-rope failure procedure for wire-

rope replacement shall be established.

6.2 Design criterion

Design criterion of this automation system includes:

(i) Simplicity: A simple system shall be designed from ease of manufacture and assembly

considerations.

(ii) Selection: The concept adopted in this automation system shall be based on past

experience of well proven similar systems in operation.

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(iii) System Layout: The system layout shall be designed such that components requiring

maintenance/replacement are placed outside the cell / water pool e.g., drive motors for

trolley, pusher-I&II and X-table are placed outside the cell.

(iv) Minimum Maintenance: Major components of the system shall be selected such that it

requires minimum maintenance.

(v) Built-in Design Safety: System components shall be designed with adequate safety

margin, Duplicated wire rope for driving the trolley, Use of duplicated sensors for

generating various process interlocks for system operation, In-built protection scheme for

all the electrical drives, etc.

(vi) Remote Access & Maintenance: Though the system components shall be designed

with adequate safety margin, provision shall also be made to remotely access the

components and replace the same for the purpose of maintenance, if required.

(vii) Service Life: Critical components of the system shall be designed with sufficient factor of

safety, giving desired service life.

(viii) Material Compatibility: Material selection shall be done to ensure compatibility to work

reliably in the prevailing ambient conditions.

6.3 Design loads: As the automation system is designed to handle radioactive spent fuel under water, selection of

components is done to achieve high reliability and longer service life. The static and rotating

components shall be designed for the loads which include static loads, dynamic loads and

seismic loads. Components shall be designed for desired safety margins as per the applicable

guidelines. As the system components are working at normal ambient temperature, loads due to

temperature difference (thermal load) is not applicable in this case. wire-rope (8x19 IWRC) size

shall be selected considering static load, bending load & acceleration load, which should give safety

factor of minimum six for wire-rope. However, to improve system reliability two wire-ropes may be

used. All the sensors used in the automation system for generating process interlocks shall be

duplicated. The rating of electrical actuators shall be selected to give desired load factor

margin.

The self weight of each fuel bundle is approximate 40 kg. Hence total self load of 5 fuel bundle will

be 5x40 kg i.e. 200kg.

6.4 Design calculation: Following major design calculations for the above equipment are required to carry out by the supplier. i) Size of ball screw, LM guide & rail, pusher rod, motor HP required, etc for pusher-I sub-

assembly ii) Size of ball screw, LM guide & rail, pusher rod, motor HP required, etc for pusher-II sub-

assembly iii) Size of ball screw, LM guide & rail, pusher rod, motor HP required, etc for X-table sub-

assembly iv) Size of trolley wheel & rail, wire rope, motor HP required, etc for trolley sub-assembly v) Capacity of pneumatic actuator for front cover opening sub-assembly vi) Capacity of pneumatic actuator for sensing of fuel bundle sub-assembly

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6.5 Design qualification: Materials are qualified as per the applicable standards. Component level qualification shall

be done for pneumatic cylinders, sensors etc. Wire-rope shall also be subjected to load

testing at shop (minimum three samples). Wire-rope terminals are custom built due to space

constraints. Swaging of end terminals with the wire-rope using hydraulically operated swaggers.

Joint is subjected to breaking load (minimum five samples) testing to ensure 100% joint

efficiency. This is used to qualify the end terminal qualification. Similarly rotary shaft seals used

for sealing the shafts (to avoid pool water coming in contact with the bearings), are also custom

built due to space constraints. Seal design shall be qualified by subjecting one seal to life-cycle

testing using a test rig at suppliers place.

6.6 Seismic Qualification (SSE): As per IAEA-TECDOC-1347 guidelines, this automation system is categorized as Class 1 (High Hazard) for safety classification and as External Event Class 2 as per classification of items in relation to external events and Design Class 2 (ASME Sec. III sub-section NC for Class 2). The supplier will carry out the seismic design analysis including computer simulations and its verification experiment to obtain the seismic qualification (SSE) of the above equipment. The ground response spectra (GRS) at Tarapur site shall be given to supplier as a input for the seismic analysis.

6.7 Applicable design specifications:

i) IS: 807 : Code of practice for design, manufacture erection and testing (structural portion of cranes and hoist).

ii) IS: 3177 : Code of practice for design of over head traveling cranes and gantry cranes

iii) IS: 325 : 3 phase induction motors iv) ASME Sec. VIII Div.I : Radiographic Inspection of Metallic products v) IAEA-TECDOC-1347 : Consideration of external events in the design of nuclear

facilities other than nuclear power plants, with emphasis on earthquakes

vi) ISO 6430 : Pneumatic fluid power- single rod cylinders, 10 bar series,with integral mountings, bores from 32 mm to 250 mm –mounting dimensions

vii) ISO 6431 : Pneumatic fluid power- single rod cylinders, 10 bar series,with detachable mountings, bores from 32 mm to 250 mm –mounting dimensions

viii) ASTM-A-262 : Practices for detecting susceptibility to inter-granular attack in austenitic stainless steels

ix) ASTM A388 : Recommended Practice for Ultrasonic Testing and Inspection of Heavy Forging.

x) ASTM E138 : Specification for Wet Magnetic Particle Testing. xi) ASTM E18 : Standard Methods for Tests for Rockwell Superficial Hardness

of Metallic Materials. xii) ASTM A370 : Standard Methods and Definitions for Testing of Steel Prod

7. FABRICATION :-

7.1 General:

7.1.1 Contractor shall prepare fabrication drawings based on information of the design drawings indicating complete fabrication details, dimension tolerances, weld size, bill of materials etc and submit three copies of these drawings for our approval. The purchaser shall scrutinize these drawings and comments on these shall be marked on one set of the drawings and returned to the contractor for making necessary corrections on the drawings. If major corrections are required the corrected drawings shall be resubmitted for approval.

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7.1.2 Before starting the fabrication contractor shall get all the raw material, consumables, bought out equipments etc inspected / approved by purchaser and shall also submit the following documents for approval.

(i) Fabrication procedure (QAP)

(ii) Inspection procedure

(iii) Cutting plan

(iv) Welding procedure (WPS/PQR/WPQ)

7.1.3 Fabrication shall be done in accordance with approved fabrication procedure and inspection will be carried out at various stages laid down on inspection procedure. Similarly electrodes, which are approved by purchaser, shall only be used.

7.1.4 All work of fabrication shall be done in accordance with ASME section VIII division I. Workmanship and finish shall be in every respect subject to the close inspection / approval by the purchaser.

7.2 Identification and control of materials: Marking of plates and other materials shall be done as per approved cutting plan. Each piece shall be marked for identification. The fabricator shall maintain a detailed record that lists description & marking of each piece material used in fabrication and shall correlate this with material test reports. This record shall be incorporated into the fabrication record.

7.3 Forming of materials: Materials may be formed to the required shape by any process that will not unduly impair the physical properties of the materials, but with the approval of the purchaser.

7.4 Cutting of materials: When oxy-acetylene or an arc process is used for cutting material, all slag and previously molten material shall be removed by mechanical means prior to further fabrication or use. Edges that will be exposed in the finished frame shall be rounded off to a radius of at least 3 mm or chamfered at 45o to 4 mm flat. The fabrication and machining tolerances shall be as per relevant latest IS code unless otherwise specified.

7.4 Repair of defects in materials: Minor defects in material may be repaired after approval by the inspector for the method and the extent of repairs. Defective material that cannot be satisfactorily repaired shall be rejected.

7.5 All the butt welds and the fillet welds in the external surface and internal surface of fuel transfer system shall be ground in flush with the surface.

7.6 All the sharp corners shall be ground to radius of 3mm to avoid the injury to operational persons.

7.7 Cleaning of edges: weld groove edge of the material will be cleaned as per the approved procedure.

7.8 Weld groove geometry, edge preparation, fit up, alignments etc shall be in accordance with ASME Section VIII Division-I.

7.9 Shapes formed and welded shall maintained its geometry, diagonal ovality shall not be expected at any point on its circumference beyond the limits specified in ASME Sec. VIII Div. I.

7.10 Plates to be joined by butt-welding shall be matched carefully so that misalignment, in-complete joints, shall not exceed the limits specified in ASME Sec. VIII Div. I.

7.2 Welding:

7.2.1 Welding processes and filler metals : Only approved procedure and qualified welders as per ASME section IX shall be permitted to carry out the welding.

(i) Stainless steel to Stainless steel: Any inert gas shielded arc-welding process i.e. GTAW may be used with the electrodes approved by the Purchaser's representative. The electrodes to be used are E 308L type.

(ii) Stainless steel to carbon steel: Any inert gas shielded arc- welding process i.e. GTAW may be used with the electrodes approved by the Purchaser's representative shall be used. The electrodes to be used are E 309L type.

(iii) Carbon steel to Carbon steel: Manual arc welding process i.e. SMAW may be used with the electrodes approved by the Purchaser's representative. The electrodes to be used are ER 7018 type.

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7.2.2 Qualification of welding procedures: Each welding procedure to be used in the fabrication shall be qualified by the fabricator in accordance with ASME Section IX. A copy of the welding procedure specification (WPS) & Procedure Qualification Record (PQR) shall be furnished and got approved by the Purchasers' representative and forms part of the fabrication report.

7.2.3 Qualification of welders and welding operators: Performance qualification of welders and welding operators shall conform to ASME section IX. A copy of the Weld Performance Qualification (WPQ) record shall be incorporated into the fabrication record after approval by the inspector.

7.2.4 Fitting and Alignment: Edges to be welded shall be uniform and free of all foreign material. Parts to be welded shall be fitted, aligned and retained in position during the welding operation. Bars, jacks, clamps, tack welds or other appropriate means may be used to hold the edges to be welded in line. Tack welds may be incorporated in the final weld, provided they are free of visible defects. The edges of butt joints shall be held during welding in such a manner that the tolerances stated in the approved fabrication drawing are not exceeded.

7.2.5 Cleaning of surfaces to be welded: Surfaces to be welded shall be clean and free from foreign material such as grease, oil, lubricants and marking paints for a distance of at least 25 mm from the weld preparation area. When weld metal is to be deposited over a previously welded surface, any slag shall be removed.

7.2.6 Joints - Alignment Tolerances: Abutting edges of parts at joints shall not, after being welded, have an offset from each other at any point in excess of one-eighth of the nominal thickness of the part at the joint unless these offsets affect the functional requirements.

7.2.7 Finished joints: Joints shall have complete penetration and shall be free from cracks, undercuts, overlaps, abrupt ridges or valleys. Fillet welds shall have complete fusion at the root of the fillet. To ensure that surface of the weld metals at any point does not fall below the surface of the adjoining part, weld metal that may be built up as a reinforcement shall not exceed the dimensions unless these reinforcements affect the functional requirements.

Thickness of part Max. thickness of reinforcement

(mm) (mm) Upto 12 inclusive 2.5 Over 12 to 25 inclusive 3.0 Over 25 5.0

7.2.8 Miscellaneous welding requirements:

(i) The reverse side of double welded butt joints shall prepared by chipping, grinding so as to secure sound metal at the root of the weldment.

(ii) If the welding is stopped for any reason, extra care should be taken in restarting the process to achieve the required penetration and fusion. In sub-merged welding, chipping out a groove in the crater is recommended.

(iii) Where single-welded joints are used, particular care should be taken in alignment to ensure complete penetration and fusion at the root of the weld over its full length.

(iv) In the case of plug welds, a fillet around bottom of the hole should be deposited first.

(v) All butt welds for load bearing members shall be 100% Radiographed. All butt, T-joints and fillet welds shall be checked by Dye-Penetrant Test for root and subsequent passes of welding as per ASTM-B-165.

Acceptance shall be as per ASME-Sec III NB.

7.2.9 Repair of weld defects: Visible defects such as cracks, pinholes and incomplete fusion, as well as defects that can only be detected by prescribed examinations and tests, shall be removed and the joint re-welded. Weld reinforcement, distortion / warping of the welded structure will not exceed the limits prescribed in the ASME Section VIII Div I.

7.2.10 Postweld heat treatment: Any postweld heat treatment shall be approved by the Purchaser, documented and made a part of the fabrication record.

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8. DESIGN REQUIREMENTS : (Electrical)

8.1 Electrical motors :

8.1.1 Selection of Motor Sizes :– When the duty cycles can be adequately assessed, AC motors shall be selected so that the motor temperature rise in actual service will not exceed the permissible rise taking into account the class of insulation adopted and the ambient temperature at the installation site.

8.1.2 All motors shall conform to latest IS-325 & IS 12615 and shall be suitable for (S4) crane duty with a CDF of 40%. Drives for carriage / bridge crane shall be of totally enclosed, fan cooled (TEFC), high torque squirrel cage type induction motors suitable for operating on a 415V, 3 phase, 50 Hz A.C electrical supply. The motors shall have IP 55 enclosure as per IS 4691. The motors shall be suitable for reversing and frequent acceleration and mechanical brake. All motors shall be of S4 100% rating and have class F insulation suitable for class B temperature rise. Winding overhangs shall be provided with a coat of epoxy gel. The motor shall be energy efficient type. The starting & pull out torque of the motor shall be above 250% of rated torque at rated voltage. The cooling fan of motor shall be made of aluminium. The motors shall be rated for 150 operations per hour. Motor insulation shall be suitable for its operation in hot, humid and tropical climate. Power house treatment shall be given to motor windings Temperature rise of winding, when determined by resistance measuring method, shall not be more than 75o C over an ambient of 45oC. The motors shall be one of Siemens / GEC / NGEF/ CGL / Bharat Bijlee / Kirloskar makes.

8.1.3 Motors should operate satisfactorily for :

a) Voltage variation of + 10%

b) Frequency variation + 5%

c) Any combination of a ) & b)

d) Humidity : 90%

e) Ambient temperature : 450C

8.1.4 Test certificate as per IS-325 (particularly type and routine) shall be provided together with a record of any alterations which have been made since the type tests were carried out. Routine tests shall be carried out in presence of Purchaser’s representative at Manufacturer’s works. The driven equipment shall be tested with the actual motor and starter that will be supplied with the unit. Motors shall be offered for type and routine testing. Tests for noise & vibration measurement shall also be offered.

8.1.5 The motors shall start at 80% voltage. It shall be capable of operating at full load for 15 minutes at 80% voltage. They shall also be capable of withstanding 120% over speed without mechanical damage.

8.1.6 Motor construction shall be suitable for easy dis-assembly and re-assembly, and protected from damage. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repairs. The motors shall be provided with eye bolts or other means to facilitate safe lifting.

8.1.7 The quotation shall include suitable overload relays and single phase protection device for all motors and shall be of Siemens/ L & T / Schreider make.

8.2 Brakes and Clutches :

All the drive shall be provided with solenoid operated electromagnetic brakes. Brake linings shall not be subjected to more than 80% of the rated lining temperatures. They shall be rated for half an hour continuous operation and for 150% rated load. D.C. power operated solenoids shall be provided. The solenoids shall be energised for releasing the brakes. Brake coil rating shall be 150% full load torque (150 operations/hour). Clutches, wherever required, for facilitating emergency motions etc., shall be rated equivalent to that of adjoining brakes. The clutch circuit shall include timer relays for proper functional sequence of the brakes and clutches. The clutches shall be engaged prior to the simultaneous energization of respective brakes and motors. Brakes and clutches shall be of PETHE / EMM / BCH / Speed O control.

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8.3 SOLENOIDS:

8.3.1 For D.C supply, full wave selenium metal rectifiers shall be provided from normal 3 phase A.C. supply of 415V and 50 Hz. (using suitable transformers in the circuit)

8.3.2 They shall be min. 30 minute rated and shall be provided with class F insulation.

8.3.3 MAIN ISOLATER : A suitable local fuse disconnectable switch for 3 phase A.C. supply for trolley / pusher-I / X-table / pusher-II drive unit shall be provided at suitable position at one end of their motions and installed in a dust tight metal enclosure with a dust tight door. The door should be provided with suitable interlocking mechanism to cut off the electrical supply to the units when the door is in open position for any maintenance. The complete switch fuse unit shall be of A.C. 24 duty. Provision for RYB, 25 W lamp indications shall display in control panel, which will indicate the availability of 3 phase A.C. supply. The main isolator shall be one of Siemens / GE / L & T makes.

8.4 Controls and Control System:

8.4.1 The trolley / pusher-I / X-table / pusher-II drive unit shall be operated with connected electrical central console and also with remote control pendent and capable of withstanding rough handling without being damaged and shall be effectively secured.

8.4.2 Stop, start and directional changes shall be accomplished by reversing magnetic contactors, by push buttons operating a control circuit. In all case the push buttons shall be spring loaded and return to off positions when releases and they shall be mechanically interlocked such that the push buttons of two reverse motions can not be simultaneously operated.

8.4.3 All control equipments shall be suitable for operation on 110 V AC, single phase, 50 Hz. Electrical supply to the controls shall be provided from a separate electrical panel. The electrical panels shall be provided with anti-vibration cushions.

8.4.4 Suitable isolator switch shall be provided for the electrical supply to control system.

8.4.5 Suitable ammeters and voltmeters with selector switches shall be provided on the control panel.

8.5 Power system:

8.5.1 Power supply of 415 V, 3 phase, 4 wire, 50 Hz AC shall be provided from separate electrical panels for each motion. All these panels shall be provided with suitable dust tight doors, having suitable interlocking devices for cutting of the electrical supply when the doors are opened. The control panel shall be designed for IP 54 enclosure protection.

9.5.2 Separate isolating switches shall be provided for the main power supply and power supplies to individual motions.

8.6 Contactors:

8.6.1 All the contactors shall be rated to permit 150 switching operations per hour for AC 4 duty. Make of contactor shall be Siemens / Telemechanique/ Schreider.

8.6.2 Each motor shall be provided with HRC fuses and contactors with suitable overload relays. Contactor type motor starter shall be of the full voltage, direct on line, air break, single throw and electromagnetic type. Contactors shall conform to IS-2959.

8.6.3 Reversing contactors shall be provided with electrical & mechanical interlocks between forward and reverse contactors. Contactors shall be provided with at least 2 NO and 2 NC auxiliary contacts.

8.6.4 The contactors shall be provided with a three element, positive acting, ambient temperature compensated, time lagged, hand reset type thermal overload relays with adjustable setting to suit the rated motor current. Resetting of the relay shall be feasible from front door of the panel. The contractor shall be of A.C. 4 duty only.

8.7 Fuses:

All fuses shall be of the HRC cartridge type conforming to IS-2203 mounted on a plug-in type fuse bases. All accessible live connections shall be adequately shrouded and it shall be possible to change the fuses with the current alive, without the danger of contact with live metal. The fuse shall be one of EE/Siemens make.

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8.8 Cables and conduits:

8.8.1 All wiring shall be neat and shall be installed in rigid galvanised steel conduit with threaded type fittings, galvanised outlet and pull boxes. Pull boxes shall be located at frequent intervals to allow cable or conductor to be pulled without abrasion or injury. Conduits shall form a continuous system and shall be properly supported within structural frame works of the unit. The entire conduit system shall be grounded. Conduit for power and control circuits shall not be less than the size recommended by relevant Indian standards for conductors that are to be installed therein. The entire conduit system shall be installed such that any moisture will be drained away from the terminal boxes and electrical devices. Power wiring and control wiring shall be kept in separate conduits. No conduit of size smaller than 25 mm diameter shall be used. Flexible conduits when used shall be of PILCA pipe or galvanised flexible conduit or other type to suit the area conditions. The conduits shall be heavy gauge and ERW type.

8.8.2 The cable and wire shall be of 1.1 KV grade and suitably XLPE insulated and sheathed copper conductors for control circuit.

8.8.3 Wiring adjacent to control panel shall be of stranded 1.1 KV grade, flame, heat and moisture resistant insulation suitable for operation at high temperature.

8.8.4 Wires for motor primary and secondary circuits shall be of HFFR or other sheathed copper conductors and shall have adequate current carrying capacities to carry maximum plugging current of the motors. All insulation and all clearances to the ground shall be designed so that the live points will withstand a high potential test of not less than 2500 V at 50 Hz for one minute.

8.8.5 Conductor cross sections of main power circuit shall be selected taking into consideration of the operating conditions. Suitable opening shall be provided on account of site conditions.

8.8.6 All wiring shall be done in a neat and workman like manner and wherever possible, wires shall be run in the conduits. Internal control panel wiring shall be carried out through wiring troughs.

8.9 Safety earthing:

8.9.1 The trolley / pusher-I / X-table / pusher-II drive unit, motor frames, and metal cases of all electrical equipment including metal conduit and cable guards, shall be effectively connected to earth with tinned copper conductor of not less than 12 SWG for motors up to 5 H.P complying with Indian Electricity Rules (see also IS : 3043-1987).

8.9.2 As the drive unit is connected to the supply by flexible cord or flexible cable, the drive unit shall be connected to earth by means of an earthing conductor enclosed with the current carrying conductors within the flexible cord or flexible cable.

8.10 Limit switches:

8.10.1 Automatic reset type of limit switches of suitable design shall be provided to prevent over travel for the trolley / pusher-I / X-table / pusher-II.

8.10.2 The linear limit switches shall be located in advance of the mechanical stops so that even if they were moving at full speed at the time of limit switch actuation, the same shall be brought to a halt without excessive impact with the mechanical stops.

8.10.3 Make of the limit switches shall be of Siemens/ BCH for lever type and EMM for relay and gravity type.

8.11 Electrical supply leads:

8.11.1 Suitable electrical cable shall be provided for all motions from power supply to motors.

8.11.2 All the conductors shall be so arranged such that they are easily accessible for maintenance.

8.12 Electrical panels :

All panels shall be provided with gaskets for dust and water spray plug protection and shall meet IP-55 rating of latest IS specifications. All panels should have suitable lifting lugs, door handles and key locking arrangements. All 415 V and 250 V fuse holder shall be mounted in separate rows. Separate mounting plates shall be provided for all the electrical components and sufficiently away from back plate. Cable glands shall be provided along with gland plates. Plastic trays for cables shall be provided inside the panels. Steel sheets used for the panels shall be of minimum 14 CRCA gauge, powder coated with acceptable shade. Anti-vibration cushion shall be provided for the

23

2panels. Three phase plug sockets of 415 V A.C. rating and single phase plug socket of 230 V A.C. and 110 V D.C. shall be provided inside the panel. Provision for internal lighting of panel shall also be done. The panel shall be one of Siemens / L & T makes.

9. INSPECTION, TESTING AND FABRICATION RECORD:-

9.1 Inspection:

9.1.1 Access for Inspector: The Inspector shall be permitted free access, at all times while work on the fabrication is being performed, to all areas of the fabricator's shop. The Fabricator shall notify him reasonably in advance of any required tests or inspections.

9.1.2 Inspection of Material : The Inspector shall assure himself that all materials used comply in all

respects with the material requirements. The Fabricator shall make available to the Inspector certified test reports prior to the use of the material. The Inspector shall satisfy himself that the materials comply with the specifications are properly marked and correlated with the test reports. A copy of all approved test records and certificates shall be incorporated into the fabrication record. If there is a question regarding the identity or adequacy of the quality of the material, the Fabricator shall perform chemical analysis and mechanical tests to certify that the material complies with the applicable specification. Reports of such tests shall be by the Inspector and if approved, such records shall be placed in the fabrication records. All materials to be used in fabrication shall be inspected for the purpose of detecting, as for as possible, defects that would affect the adequacy of the fabrication. Particular attention should be given to cut edges and other parts, laminations, shearing cracks and other objectionable defects. The Inspector shall assure himself that the thickness and other dimensions of the material comply with those specified on the design drawings.

9.1.3 Inspection of surfaces during fabrication : As fabrication progresses, the edges of plates, openings

and fittings shall be examined to detect defects and to determine that the work has been properly done.

9.1.4 Dimensional inspection: The Inspector shall satisfy himself that components conform to the

prescribed shape meet thickness requirements after forming. The Inspector shall assure himself of the proper fit up, to curvature of the surfaces and of apparatus to be attached to curved surfaces. During and after fabrication, such dimensional inspections as are necessary shall be performed to ensure that the completed fabrication conforms to the design drawings and mechanical parts be able physically assembled. Any critical feature requiring special inspection, such as the flatness or the surface finish of sliding contact surfaces, specifically those indicated on the design drawings shall be attended to. A report of the dimensional inspection of all such features shall be incorporated into the fabrication record.

9.1.5 Weld inspection: The Inspector shall assure himself that the welding procedures employed in the

fabrication have been qualified under the provisions of this criterion. The Inspector shall assure himself that only welders and welding operators that are qualified under the provisions of these criteria are being used to fabricate the weldment. The Inspector shall have right, at any time, to call for and to witness tests of the welding operator. All welds, including the heat-affected zone shall be inspected with liquid penetranants, using procedure A-2 or B-3 of ASTM E165, or with magnetic particles, using ASTM E109, first on completion of the root pass, after preparing the second side of welds made from two sides (if appropriate) and second, after completing the weld. All butt, T-joints and fillet welds shall be checked by dye-penetrant test for root and subsequent passes of welding. All load bearing butt welds, wherever applicable, shall be 100% radiographed by an authorised person and shall be sent for review and approval to Purchaser’s Engineer. The further work can be proceeded only on clearing of radiographs & welding. Finished welds shall be inspected on both surfaces after heat treatment and/or any machining. Cracks, in-line porosity, or other linear defects should be removed down to sound metal and then repaired. Adequate penetrant inspection will, in most cases, require some grinding of the welds.

9.1.6 NDT of welds: All the NDT test shall be carried out in conformity with ASME Section V by the contractor and he shall keep reasonable qualified persons who shall perform the inspection / non-destructive testing and keep up to date record of joint wise fit ups, dimensional checks and the NDT carried out on the job.

24

The work of welding, inspection and testing shall be subject to the overall supervision and approval of purchaser. The qualification and experience of the inspection / testing personnel of the contractor will be subjected to approval of quality surveillance section of purchaser. Acceptance standard and method of repairs of the defects shall be as per ASME Section VIII division I.

Following NDT on the welding shall be carried out during and after the welding. i) The weld groove surfaces and heat-affected zones shall be 100% tested by D.P. test. ii) Root run, back chipped surfaces and final run on both the sides of butt welds shall be 100%

tested by D.P. test. iii) Root pass and final run on both the sides of fillet welds and butt welds shall be 100% tested by

D.P. test. iv) 100% radiography on the longitudinal butt weld seams. Besides other non-destructive examination, visual examination will be carried out at various stages of inspection for checking the dimensions, tolerances, distortion fit ups, alignment, quality, workmanship etc. Supplier at his own cost shall rectify any defect noticed by purchaser.

9.1.7 Stages of Inspection : (i) Material Identification (ii) Welder's Qualification and Welding Procedure Qualification (iii) Dimensional inspection in Tack weld joints (iv) Radiography and inspection after completion of the welding (v) Final assembly dimension check. (vi) Functional test as per 8.3 (vi) Packing and final dispatch.

9.1.8 Inspection during fabrication: The Inspector shall inspect each component, at such stages of construction, as he seems necessary, to assure himself that fabrication is in accordance with the design drawings. Interior surfaces of enclosed chambers shall be examined as completely as possible before final closure is made.

9.1.9 Supply of testing Instruments : The Supplier shall arrange the required testing and inspection instruments free of cost for use at ex-works and at site.

9.2 Testing :

9.2.1 Component testing: 9.2.1.1 Gasket leak tightness testing :

The flanges of truff and perspex glass bolted with gasket joint shall be hydro tested for its water leak tightness at a pressure of 1.2 Kg/cm2 by water leak test method. Leak tests shall be performed by soap bubble. These tests will be carried out in accordance with the requirements of ASME SEC.VIII Divn 1.

9.2.1.2 Hydro tests for tank and truff :

The weld integrity of the cavity of tank and truff shall be demonstrated by a leak test. Leak tightness of tank and truff will be checked by hydro tested at pressure of 1.2 kg/cm2. At any instance, testing shall be performed while joints are accessible for repair. Leak tests may be performed by soap bubble test. If leakage is indicated, the leaks shall be located, repaired and the test repeated.

9.2.1.3 Load test for speed : All the 5 nos of trolley / pusher -I / X-table / Pusher-II drive unit shall be tested for main speed and

micro speed of all motions with load equivalent to 125% of safe working load at Supplier’s works and variation of speed shall not exceed beyond the permissible limit. No noticeable vibrations / jerks and noise shall be seen / heard during the testing.

9.2.1.4 Performance test with load and without load : All the 5 nos of trolley / pusher -I / X-table / Pusher-II drive unit etc. shall be tested for their smooth

functioning with load and without load at supplier’s works. The performance test includes following :

a) Smooth running of all the drive system. b) Functional testing of clutches and brakes. c) Testing of limit switches.

d) Insulation test. e) Overload test of motor

25

9.2.1.5 Testing of parallelism : Parallelism and vertical offset of the top & bottom rails of trolley / LM guide rail assembly for

pusher-I/X-table/pusher-II shall be tested at supplier’s works. The tests will be carried out seperately for all the 5 nos of trolley / LM guide rail assembly for pusher-I/X-table/pusher-II.

9.2.1.6 Running test of all sub-assembly : All the 5 nos of trolley / front cover opening / pusher -I / sensing of fuel bundle / X-table / Pusher-II sub-assembly etc. shall be checked for its smooth running motion and for intended purposes.

9.2.1.7 Remote removal / replacement of all sub-assembly : The supplier will demonstrate the remote removal of all sub-assembly like trolley, wire rope replacement, front cover opening, pusher-I, X-table, sensing of fuel bundle & pusher-II and remote replacement for the same in case of break down of any sub-assembly.

9.2.1.8 Remote adaptability to switch over from 220 to 540 MWe fuel bundle transfer : The supplier will demonstrate the transfer of 220 MWe fuel bundle as well as 540 MWe fuel bundle by replacing modules remotely as mentioned above. Following modules shall be replaced remotely for switch over from 220 to 540 MWe fuel bundle transfer and it will be demonstrated at supplier’s works.

• Top tray of the trolley • Pusher-I • Top tray of X-table • Direct sensing mechanism of fuel bundles (on X-table)

9.2.1.9 Manual charging of fuel bundle : Manual charging of fuel bundle shall also be demonstrated by the supplier

9.2.2 Assembly testing:

9.2.2.1 Functional testing: The full prototype unit will be tested in full assembled condition. The fuel transfer trolley along with 5 nos. of fuel bundle (220/540 Mwe) will be received at trolley parking position. The trolley will move from pool side to dissolver cell where opening of front cover & locking of trolley shall be made before pushing of all five fuel bundle. After assuring the locking of trolley, all the 5 fuel bundles shall be pushed on to X-table. After ensuring the fuel bundle on x- table by sensing sub-assembly, the X-table shall move towards chopper end & trolley will return back to pool side for transferring the next shipment of 5 fuel bundles on to X-table. The X-table will continue to move forward towards fuel chopper till the c/l of 1st fuel bundle come in line with pusher rod c/l of pusher-II. The X-table drive unit will automatically trip at the c/l matching position. After aligning the fuel bundle, it will be pushed from X-table to chopper by the pusher-II. The pusher-II will be pulled back to its original position after feeding of fuel. The X-table will further continue to move forward for the feeding of 2nd fuel bundle and hence all fuel bundles (5 nos.) will be transferred to chopper in 5 cycle operation for 5 fuel bundles. The X-table will be returned back to its parking end for receiving next batch of five fuel bundle from trolley. Refer sr no 5 (system operation) for the complete operation required for functional testing.

9.2.2.2 Supplier will demonstrate the functional testing of the complete prototype system using actual set up after assembling each component as indicated in the drawing. The supplier will perform at least 1000 trial run (500 trial runs for 220 Mwe fuel bundle & 500 trial runs for 540 Mwe fuel bundle) of the functional testing for each system as mentioned in 9.2.2.1. All the drive units, motors and hand operated wheels, limit switches etc will be kept on actual locations / elevations. The equipment shall be dispatched only after satisfactory performance demonstrated by the supplier at the shop testing. No noticeable noise / vibrations will be accepted during testing. All the speeds will be same as indicated in the technical specifications. The trolley / pusher -I / X-table / Pusher-II sub-assembly etc. will be operated both by motors and hand wheels. Performance of the system will be evaluated based on ruggedness of the system, actual smooth operations, ease in replacement of components in case of break down and ease in regular maintenance etc. Supplier will prepare testing procedure in details and same will be subjected to the purchaser’s approval before starting the trials. All the problems faced during trial run shall be noted. Supplier shall rectify the defects with prior approval of the BARC engineer and again demonstrate the performance to the satisfaction of purchaser before dispatch and rectified with

26

9.2.2.3 After successful testing of the 1st prototype unit the remaining 4 units will be taken up for manufacturing and testing. During testing of 1st prototype unit if any design changes have been made to meet the functional requirement the same design changes will be incorporated in the remaining 4 unit. The supplier will do the such design changes at no extra cost.

9.3 Fabrication record:

9.3.1 A material record shall be kept and shall specify the following:

(a) Product form and heat number, if any.

(b) Correlation of part and test report.

(c) Component name or part number.

9.3.2 Marked drawings or annotated bills of materials may be necessary to satisfy this requirement.

9.3.3 In compliance with the stipulations listed in Sr.No. 4, material test reports for each item of the materials, or other evidence of acceptability, shall be incorporated into the fabrication record after the material has been accepted.

9.3.4 Welding procedure, procedure qualification, welder performance records and lead pouring procedure shall form part of the fabrication record.

9.3.5 Reports of all inspections and tests, including liquid penetrant examinations, dimensional inspections, and pressure and leak tests, shall be prepared in such detail that compliance with this criteria is clearly demonstrated. The radiographic inspection records shall be made a part of the fabrication record.

9.3.6 Reports of any required check analysis, should clearly identify with the material they represent.

9.3.7 Where heat treatment is performed, the procedure followed, together with furnace temperature charts, shall be included in the fabrication record.

9.3.8 Any deviation, for any reason, from this criterion shall be reported in detail in the fabrication record.

9.3.9 If, for any reason, the fabrication process deviates significantly from the design drawings, and those drawings do not present a clear and correct description of the construction of the cask & yokes or do not show proper sizes of materials and location and geometries of welds, the fabricator shall prepare as-built drawings to accomplish this purpose. As-built drawings shall be verified certified by the Inspector. The fabrication record shall be compiled by the fabricator and shall be kept current at all times. The Inspector shall have access to the fabrication record and at regular intervals, shall assure himself that it is complete and correct. Any deficiencies found shall be promptly rectified by the fabricator. On completion of the fabrication, the fabrication record shall be reviewed by the manufacturer and by the Inspector, each of whom shall certify, in writing, that the record is correct and complete and that the fabrication is (with noted exceptions) in complete conformity with the contract. The fabrication record shall then be transmitted to the Purchaser.

9.3.10 The following documents will form part of Quality Assurance Report (QA):

(i) Design of direct fuel transfer system

(ii) Design basis report, design calculation including seismic design analysis & remote

removal/replacement procedure, wire rope replacement procedure, O & M procedure

(iii) Material Testing Certificate for chemical and mechanical properties.

(iv) Q. A. Plan.

(v) Fabrication Procedure.

(vi) Welder's Qualifying Record (WPQ).

(vii) Weld Procedure Qualification Record (WPS & PQR).

(viii) Dimension Inspection Reports in Tack welding.

(ix) Reports on DP Tests and Radiography of joints.

(x) Functional Test Reports of assembly.

(xi) As built drawings, photograph of system with all sub-assembly.

9.3.11 Instruction Manuals :

The Supplier shall furnish six (6) numbers of bound copies of QA reports of all equipments furnished by him. Each manual shall consist of one set of approved as built drawings and catalogues/technical literatures for the bought out components.

27

The instruction manuals shall be corresponding to the equipments supplied and not general in nature. The Supplier shall submit two preliminary instruction manuals to the Purchaser before the submission of actual manuals for approval.

10. PAINTING: All the exposed carbon steel surfaces will be given two coats of epoxy primer of 3 mil each and two coats of 3 mil each epoxy paint of yellow colour. All the surfaces to be painted shall be cleaned by wire brushing and sand blasting as per relevant IS codes or as directed by purchaser’s representative.

11. TIME SCHEDULE:- The Bidder shall submit to the Purchaser the detailed time schedules covering various aspects involved in the manufacture, such as preparation of fabrication drawings, procurement of raw materials and components, fabrication, assembly, inspection, testing & dispatch in the form of individual Bar chart/ PERT chart for items quoted. The time schedules shall be strictly adhered to in consultation with the Purchaser.

12.0 VENDORS: The firm shall ensure that they will be able to carry out the assignment either of their own or through their Affiliate Company/Joint Venture/Consortia (all of them shall be registered in India). Participation of the main firm (lead partner) in more than one joint venture/consortium is not permitted. Organizational set up shall be provided (limitations on joint venture/consortia may be stated). However the responsibility of executing the contract lies with the main firm. Sub-contracting part of the assignment to only those firms who are registered in India are acceptable.

12.1 Vendor Qualification Criteria: The prospective bidder shall be qualified for taking up this work based on following factors.

12.1.1 The firm should have expertise in design, fabrication, precise machined components of remote handling & integration with PLC controls, custom-built equipments and testing of similar type of equipment for nuclear, defence and space industry. The firm shall have in-house facilities for precision machining, fabrication work & tool room facilities. Feedback report from users shall be enclosed along with offer for reference.

12.1.2 In house facilities of large size stainless steel (SS) & CS fabrication & machining consisting of lathe (size 18’ min.), milling, shaper, turning, drilling, grinder, welding & bending machine. Sufficient space & clean environment shall be available in the workshop for carrying out the SS fabrication required for the job.

12.1.3 In house facility for the testing of the equipment

12.1.4 In house sufficient space required to accommodate such a large mock test set up for carrying out the test trial run.

12.1.5 Handling facility up to 15 Te capacity

12.1.6 The firm should have expertise in PLC based control & instrumentation system and their integration with mechanical system.

12.1.7 The firm should have Quality Management System confirming to National/ International standards.

12.1.8 Adequate, qualified & experienced staff as per Annexure-F along with required design codes, software codes & work stations for carrying out design & analysis, 3D modeling and generation of 3D/2D auto-cad drawings/ animation. The firm should have adequate qualified welders, fabricators, machinist as per Annexure-I.

12.1.9 The firm should have satisfactorily completed (based on certification of performance by client)

similar works consisting of the nature of activities as mentioned during last 5 years as follows: Three assignments, each costing not less than Rs 2.7 Crore or Two assignments, each costing not less than Rs 3.6 Crore or One assignment of value not less than Rs 7.2 Crore

12.1.10 The firm should have average annual financial turnover of at least Rs 2.7 Crore for similar job

28

contracts during the last three years ending March 31, 2012. The firm should have bank solvency of Rs 3.6 Crore.

12.1.11 The firm should not have incurred loss in more than two years during the last five years & financial net worth of the firm should not be negative.

12.1.12 The firm should not be under liquidation, court receivership or similar proceedings.

12.1.13 The vendors will be evaluated based on points rating criteria as per following table. The

decision of BARC will be final.

Sl. No. Criteria Maximum Marks Marks

Obtained 1. Financial Criteria:

(a) Average Annual Turnover (16 Marks) (b) Solvency (04 Marks)

20

2. Experience in Similar Jobs Executed 20

3. Performance of Works (Time Overrun) 20 4. Performance of Works (Quality) 15 5. Personnel & Establishment 10 6. Plant & Equipment facilities 15

Note: The minimum qualifying points shall be 70% marks (in total) & 60% marks against individual criteria.

12.2 Pre-Bid Meeting:

A pre-bid meeting shall be arranged to explain the entire system in detail & to address the queries of the qualified bidders. Bidders should nominate technical representative for the meeting.

12.3. Documents Required from the Bidders:

The firm shall submit the following documents as documentary proof for meeting the above requirements:

12.3.1 Annexure-B for proof of technical competency 12.3.2 Annexure-C for vendor evaluation 12.3.3 List of machining/ fabrication facilities, installation/ erection capabilities, quality control/testing

facilities as per Annexure-H. 12.3.4 The profile of the organization with the organization chart & the total technical/non-technical staff

as per Annexure-G. 12.3.5 National / International standard for Quality Management System 12.3.6 Financial turnover statement for the last three years ending March 31, 2012 (refer Annexure-E). 12.3.7 Audited balance sheet for the last five years. 12.3.8 Statement showing the net worth of the firm. 12.3.9 Declaration that the firm is not under liquidation, court receivership or similar proceedings. 12.3.10 List of similar jobs/orders executed for government organizations specially Department of Atomic

Energy as per Annexure-D. 12.3.11 Performance certificates from the users for similar jobs executed. 12.3.12 Agreements/ MoU for consortium’s for similar jobs. Notes: 1. The bidders/suppliers shall indicate the above information (agreements with other firms)

clearly in their quotation. 2. No part bid for part supply will be accepted.

3. BARC reserves the right to split the requirements into two purchase orders to different vendors.

13. SPECIFIC INSTRUCTIONS:-

The quotations shall be furnished as per format annexure-A and shall also accompany annexure-B, annexure-C, annexure-D, annexure-E, annexure-F, annexure-G, annexure-H and annexure-I completely filled in, failing which their quotations shall not be considered. The Bidder shall provide the description and details of company structure, design and drawing

29

office, automation departments, and fabrication units and quality surveillance department as per enclosed format annexure C. Details of any special facilities available with manufacturer for the fabrication of all the equipments covered in the tender shall be furnished. The bidders shall also provide the list, with reference Nos. of orders of the similar jobs of comparable capacities to the government organizations especially to the units of Department of Atomic Energy. This is most important to evaluate the vendors that they give all the details regarding their facilities, manpower, quality control, documentation, fabrication/machining facilities, handling and storage facilities, previous experience in doing the similar jobs.

Quotations shall indicate cost of material and fabrication / machining of CS & SS and also for additional jobbing, if any.

The validity of offers shall be holding good for a minimum period of 120 days.

14. PACKING & TRANSPORTATION:-

After carrying out the tests at manufacturing works as specified in this tender specification and after match marking, the equipment covered in the contract shall be carefully disassembled into major completed subassemblies and then properly packed, suitably crated and protected from damage during transport, transit and storage at site. The packing shall include adequate cushioning, blocking, bracing, antiskidding, hoisting and tie-down provisions with the approval of the Purchaser. All machined parts shall be protected with anti rust grease. Supplier shall be responsible for any damage to the equipments during transport & during transit storage. Any short supply inside the intact package cases shall be supplied by the Supplier without any extra cost.

The equipments shall be supplied to PREFREE stores, BARC Tarapur.

15. INSTALLATION AND COMMISSIONING: The one number of the complete automated direct fuel transfer system (Prototype) with supporting structures for the above equipment shall be installed at our site BARC, Tarapur. The remaining 4 units will cover the scope of supply only at our site BARC, Tarapur.

All manpower, material handling equipment, machines, consumables, tools and tackles required for handling and installation of the system and transportation of all material from supplier works to erection site shall be arranged by supplier at his cost. Only electricity and water consumed during erection shall be provided free of cost.

Installation and commissioning of the complete equipment at the site shall be done as per the agreed time schedule between the Purchaser & Supplier and the availability of site for installation, as there may be some delays due to unforeseen circumstances at the site. The complete responsibility for the transportation of the equipments to the site and their installation and commissioning shall rest with the Supplier. Supplier shall again demonstrate the smooth performance of the direct fuel transfer system after the assembly at our site BARC, Tarapur. All the testing as mentioned in para 9.2 shall be again demonstrated by the supplier (Minimum 500 trial run of fuel transfer) at our site after carrying out the installation of the direct fuel transfer system.

16. GENERAL REQUIREMENTS:-`

16.1 The supplier shall submit the detail list of all components with their material, specification / make and same will be subjected to the purchaser’s approval.

16.2 The supplier shall submit the list of the all bought out components with their make and specification. All components shall be of reputed make, having high reliability.

16.3 The supplier shall submit the fabrication drawings for approval. 16.4 Any material and bought out components to be used will be subjected to the purchaser’s approval

before starting the fabrication/ assembly. 16.5 Suppler shall indicate the salient feature of process of manufacturing of the unit. 16.6 Supplier should maintain high quality of workmanship & precession in design as well as in

manufacturing.

17. SCHEDULE OF DELIVERY:-

Supplier will complete procurement of material, fabrication, testing, supply and delivery at delivery place within a stated delivery period.

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18. GUARANTEE:-

18.1 Supplier shall guarantee that the goods furnished by him shall be in full accordance with the requirements of the tender technical specifications.

18.2 Supplier shall provide the warranty that the goods are new and of high quality and that the goods are free from defects in design, materials or workmanship as applicable and warranty shall cover for a period of eighteen (18) months from the date of satisfactory handing over the equipments to the Purchaser at the site.

18.3 If within the expiry of the above stipulated warranty / guarantee period, the subject goods or an part thereof are found defective because of workmanship or materials, Supplier shall at his own expense repair or furnish and install replacement parts of proper workmanship and material as approved by the Purchaser. The guarantee period for replaced parts or repair works shall be the same as above.

19. DOCUMENT TO BE SUBMITTED: The following documents shall be submitted along with the quotation.

Annexure – A. (Quotation) Annexure – B (Technical evaluation) Annexure – C (Vendor evaluation) Annexure – D (Past Experience of Similar Orders Executed) Annexure – E (Assets & Liabilities of the Firm) Annexure – F (Qualification & Experience of Key Personnel) Annexure – G (Structure & Organization) Annexure – H (List of Typical Plant & Machinery) Annexure – I (List of Engineering & Qualified Welders & Fabricators) Schematic drawing and/or catalogues of complete system. Indicating the overall dimensions

and total dead weight of assembly. List of the bought out component and their make. Fully agree with Technical specification or any deviation. Subcontracting details if any.

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ANNEXURE-A

(To be filled in & submitted along with the offer) Reference Tender Enquiry No. Quotation No. 1. Ex - works cost as per drawing and tender technical specification with all materials:

Sr. No. Item description Qty.

(in nos.) Cost

(in Rs.)

1.1 Design, preparation of design & shop drawings, identification & procurement of all raw material including bought out components, manufacture, shop assembly, testing at supplier’s works, packing, safe transportation, installation & commissioning of the automated direct fuel transfer system along with drive unit & control system at BARC Tarapur site for NRB projects as per enclosed technical specification.

1.1.1 Automated direct fuel transfer system along with drive unit & control system, Qty:- 5 nos

1.1.2 Tank, truff along with supporting structure, top platform along with railing & its supporting structure, Qty:- 1 no.

5 nos

1.2 Spares for 3 year trouble free operation (with list) 5 sets

1.3 Operational & maintenance contract for 1 year after successful installation & commissioning of the automated direct fuel transfer system at our site BARC, Tarapur as per the technical specification

1 no.

2. Packing & transportation charges including Insurance, etc. to PREFREE stores BARC, Tarapur, Mumbai. :

3. Installation and commissioning for the one number of automated direct fuel transfer system (prototype) along with drive unit & control system and its supporting structures (item 1.1) at our site, BARC Tarapur :

4. Total cost (1+2+3) :

5. S.T./ C.S.T./VAT :

6. Excise duty : Exempted for DAE/BARC against excise duty exemption certificate

7. Any other taxes/ duties (specify clearly) :

8. Total cost (1.1 + 1.2 + 1.3 + 2 + 3 + 5 + 6 +7) in Rs. :

9. Delivery period (days) :

10. Validity period (days) :

11. Payment terms : Agree / Disagree (80% of ex-work cost shall be paid after inspection and issue of shipping release. Balance 20% of total amount plus installation and commissioning charges shall be paid after successful commissioning at our site)

Note : The quotation amounts shall be mentioned both in figures and words.Additional cost any for design changes for item 1.1.1 to meet functional requirement per quantity may be mentioned separately in 1.1

32

ANNEXURE - B Note: The Bidders shall indicate in their quotations the required values asked for in Annexure-B clearly and in detail, otherwise the offer may not be considered. Separate sheets may be used for details. 1. GENERAL: 1.1 Whether any deviation including materials from the

drgs. and technical specifications :

1.2 Whether weld performance, weld procedure and weld qualifications shall be carried out as per ASME Sec-IX

:

1.3 Whether all load bearing butt and T-joint shall be 100% radiographed & acceptance as per ASME Sec III, NB

:

1.4 Whether root & final passes of weldments shall be 100% D. P. tested.

:

1.5 Type, make, colour of epoxy primer & paint offered :

1.6 Whether agreeing to carry out all the tests asked for in tender technical specifications

:

1.7 Whether the test certificates of all the bought out materials (chemical composition & mechanical properties) parts & components as indicated in tender technical specification shall be available for Purchaser's review and retention.

:

1.8 Specification of welding electrodes & welding methods (i) CS to CS (ii) CS to SS (iii) SS to SS

:::

2. Automated direct fuel transfer system along with drive unit & control system and its

supporting structures: 2.1 Trolley and its driving unit sub-assembly :-

2.1.1 Material of construction Trolley and its base plate & supports sub-assembly Trolley wheels Wire ropes Guide pulleys Pneumatic cylinders Rails Spring Water & radiation resistant bearing Rails

:

2.1.2 Whether Chemical composition & physical propertiesconfirms to ASTM A-240 Type 304L

:

2.1.3 SS requirement approx (in kg) : 2.1.4 IS Code followed for design & fabrication :

33

2.1.5 Wheels Size No. of wheels Wheel load with impact factor Wheel loading on floor Material Hardness of wheels in BHN

:

2.1.6 Rail Material of rail Hardness of railWhether surface finish & flatness of rail shall be maintained as per Dwg (Give value) Machining method of rails Fixing arrangements of top & bottom rails

:

Bearing used for underwater application (i) Make (FAG/SKF) (ii) Type (iii) Size & Series

:

2.1.7 Material of bolts & nuts : 2.1.8 Details of end stoppers : 2.1.9 Details of greasing system provided : 2.1.10 Relevant Safety Standards : 2.1.11 Whether trolley operation is fully automated : 2.1.12 Whether remote removal/replacement of trolley from

tank side has been considered in design (Attach separate sheet for the remote removal/replacement procedure)

:

2.1.13 Whether remote replacement of wire rope has been considered in design (Attach separate sheet for the remote wire rope replacement procedure)

:

2.1.14 Whether design and fabrication of remote handling tools made of SS 304L required for remote removal/replacement of trolley from tank side has been considered in the offer

:

2.1.15 Whether design and fabrication of remote handling tools made of SS 304L required for remote replacement of wire rope has been considered in the offer

:

2.1.16 Whether design of trolley top is remotely adaptable to fuel handling of 220 MWe & 540 MWe fuel bundle

:

2.1.17 In case of jamming of trolley inside truff, whether design of retrieval system for trolley has been considered in design

:

2.1.18 Whether provision for manual operation of trolley is there

:

2.1.19 Whether agreeing to carry out all the Tests as stated in sr. no. 9.2

:

2.1.20 Whether lifting & handling arrangement provided for the trolley

:

2.1.21 Weight of the trolley in Kgs. (Approx) : 2.2 Trolley locking/ unlocking & front cover opening sub-assembly :- 2.2.1 Material of construction : 2.2.2 Material of spring : 2.2.3 Pneumatic cylinder

Stroke length

Bore :

Inlet / Outlet nipple size

Material

Make :

:

34

Reed Switches Type Rating

2.2.4 Limit switches Type Rating Make

:

2.2.5

Whether agreed for our inspection and testing procedure as mentioned in tender specification.

:

2.2.6 Whether locking operation is fully automated : 2.2.7 Whether remote removal/replacement of pneumatic

cylinder with its supporting frame has been considered in design

:

2.2.8 Whether remote removal/replacement of locking/ unlocking & front cover opening sub-assembly has been considered in design

:

2.2.9 Whether design and fabrication of remote handling tools made of SS 304L required for remote removal/replacement of trolley locking/ unlocking & front cover opening sub-assembly has been considered in the offer

:

2.2.10 Whether remote removal/replacement of locking/ unlocking & front cover opening sub-assembly has been considered in design

:

2.2.11 Description of the system for actuation of locking/ unlocking & front cover opening sub-assembly

: Please attach separate sheets

2.3 Sensing sub-assembly for the bundle on the x-table :- 2.3.1 Material of construction : 2.3.2 Pneumatic cylinder

Stroke length

Bore :

Inlet / Outlet nipple size

Material

Make :

Reed Switches Type Rating

:

2.3.3 Limit switches Type Rating Make

:

2.3.4 Radiation resistant sensors Type Make Durability

:

2.3.5 Whether agreed for our inspection and testing procedure as mentioned in tender specification.

:

2.3.6 Whether remote removal/replacement of sensing sub-assembly has been considered in design

:

2.3.7 Whether remote removal/replacement of pneumatic cylinder with its supporting frame has been considered in design

:

2.3.8 Whether design and fabrication of remote handling tools made of SS 304L required for remote removal/replacement of sensing sub-assembly has been considered in the offer

:

2.3.9 Whether sensing operation is fully automated :

35

2.3.10 Description of the system for the actuation of sensing sub-assembly

: Please attach separate sheets

2.4 Pusher –I (from trolley to x- table) sub-assembly :- 2.4.1 Material of construction

Supporting frame of pusher-I LM Guide block LM rail Ball screw Shaft bearing Shaft gear box & pinion

:

2.4.2 Type of coupling (remotely operated) : 2.4.3 Make of gear box & pinion : 2.4.4 Whether gears are rolled, forged or cast : 2.4.5 Hardness of gears and pinion : 2.4.6 Hardness of ball screw : 2.4.7 shaft bearing

Make Type Size & Series

:

2.4.8 Material of bolts, nuts, washer & screw : 2.4.9 Details of end stopper : 2.4.10 Details of greasing system provided : 2.4.11 Relevant Safety Standards : 2.4.12 Whether pusher-I operation is fully automated : 2.4.13 Whether remote removal/replacement of pusher-I sub-

assembly from cell side has been considered in design (Attach separate sheet for the remote wire rope replacement procedure)

:

2.4.14 Whether design and fabrication of remote handling tools made of SS 304L required for remote removal/replacement of pusher-I sub-assembly from cell side has been considered in the offer

:

2.4.15 Whether design of pusher rod is remotely adaptable to fuel handling of 220 MWe & 540 MWe fuel bundle

:

2.4.16 Whether provision for manual operation of pusher-I is there

:

2.4.17 Whether agreeing to carry out all the Tests as stated in sr. no. 9.2

:

2.4.18 Whether lifting & handling arrangement provided for the pusher-I sub-assembly

:

2.4.19 Weight of the pusher-I sub-assembly in Kgs. (Approx) : 2.5 X-table sub-assembly 2.5.1 Material of construction

Supporting frame of X-table LM Guide block LM rail Ball screw Shaft bearing Shaft gear box & pinion

:

2.5.2 Type of coupling (remotely operated) : 2.5.3 Make of gear box & pinion : 2.5.4 Whether gears are rolled, forged or cast : 2.5.5 Hardness of gears and pinion : 2.5.6 Hardness of ball screw : 2.5.7 shaft bearing

Make Type Size & Series

:

36

2.5.8 Material of bolts, nuts, washer & screw : 2.5.9 Details of end stopper : 2.5.10 Details of greasing system provided : 2.5.11 Relevant Safety Standards : 2.5.12 Whether X-table operation is fully automated : 2.5.13 Whether remote removal/replacement of X-table sub-

assembly from cell side has been considered in design (Attach separate sheet for the remote wire rope replacement procedure)

:

2.5.14 Whether design and fabrication of remote handling tools made of SS 304L required for remote removal/replacement of X-table sub-assembly from cell side has been considered in the offer

:

2.5.15 Whether design of X-table top is remotely adaptable to fuel handling of 220 MWe & 540 MWe fuel bundle

:

2.5.16 Whether provision for manual operation of X-table is there

:

2.5.17 Whether agreeing to carry out all the Tests as stated in sr. no. 9.2

:

2.5.18 Whether lifting & handling arrangement provided for the X-table sub-assembly

:

2.5.19 Weight of the X-table sub-assembly in Kgs. (Approx) : 2.6 Pusher-II (from X-table to chopper) sub-assembly :- 2.6.1 Material of construction

Supporting frame of pusher-II LM Guide block LM rail Ball screw Shaft bearing Shaft gear box & pinion

:

2.6.2 Type of coupling (remotely operated) : 2.6.3 Make of gear box & pinion : 2.6.4 Whether gears are rolled, forged or cast : 2.6.5 Hardness of gears and pinion : 2.6.6 Hardness of ball screw : 2.6.7 shaft bearing

Make Type Size & Series

:

2.6.8 Material of bolts, nuts, washer & screw : 2.6.9 Details of end stopper : 2.6.10 Details of greasing system provided : 2.6.11 Relevant Safety Standards : 2.6.12 Whether pusher-II operation is fully automated : 2.6.13 Whether remote removal/replacement of pusher-II sub-

assembly from cell side has been considered in design (Attach separate sheet for the remote wire rope replacement procedure)

:

2.6.14 Whether design and fabrication of remote handling tools made of SS 304L required for remote removal/replacement of pusher-II sub-assembly from cell side has been considered in the offer

:

2.6.15 Whether design of pusher rod is remotely adaptable to fuel handling of 220 MWe & 540 MWe fuel bundle

:

2.6.16 Whether provision for manual operation of pusher-II is there

:

2.6.17 Whether agreeing to carry out all the Tests as stated in sr. no. 9.2

:

2.6.18 Whether lifting & handling arrangement provided for the :

37

pusher-II sub-assembly 2.6.19 Weight of the pusher-II sub-assembly in Kgs. (Approx) : 2.7 M.S tank, M.S truff along with its support structure, top platform along with railing & its

supporting structures:- 2.7.1 Material of construction

Tank & its supporting structure Truff & its supporting structure Top platform along with railing & its supporting structure

:

2.7.2 Whether Chemical composition & physical propertiesconfirms to IS 2062 Gr. B

:

2.7.3 Wt of tank : 2.7.4 Wt of truff : 2.7.5 Wt of top platform : 2.7.6 Wt of all supporting structure, ladder and railing required

for tank, truff & top platform etc. :

2.7.7 Whether drain valve arrangement in tank for draining of water has been considered

:

2.7.8 Whether Perspex glass with water leak tight gasket provided in truff is considered

:

2.7.9 Whether water leak tight gasket with sealing bolts at the mating flange face of truff has been considered

:

2.7.10 Whether EP’s plate has been considered at the bottom of tank to install the guide pulley & rail of trolley

:

2.7.11 Whether EP’s has been considered in the truff to install top & bottom rail of trolley

:

2.7.12 Whether EP’s has been considered towards cell side at the top of platform to install the Pusher-I, X-table, pusher-II, ETC.

:

2.7.13 Whether two coats of epoxy primer of 3 mil each and 2 coats of 3 mil each epoxy paint of yellow colour has been considered for the all the inner & outer surfaces of CS .

:

2.8 Electrical drive unit along with control systems:- 2.8.1 Description of the drive control system : Please attach separate

sheets 2.8.2 Motor

(i) Make (ii) Rating (iii) Type (iv) Class of insulation (v) Whether confirms to IS 325 (vi) Whether Type test certificates shall be provided (vii) Whether routine tests shall be carried out in the

presence of purchaser’s engineer

:

2.8.3 VVVF drive (i) Make (ii) Description

:

2.8.4 Details of earthing system : 2.8.5 Limit switches

(i) Type (ii) Rating (iii) Make

:

2.8.6 Clutch (i) Type (ii) Rating (iii) Make

:

2.8.7 Brake (i) Type (ii) Rating

:

38

(iii) Make (iv) Holding torque capacity (%) (v) Voltage rating of coil (vi) No. of safe operations/hr

2.8.8 Torque limiter Type Rating Make Max. torque capacity caliberation accuracy

:

2.8.9 Force feed back sensor Type Rating Make Max. force capacity caliberation accuracy

:

2.8.10 Position feedback sensor Type Rating Make Max. range caliberation accuracy

:

2.8.11 Encoder Type Range of precision Make Max. range

:

2.8.12 Pendant control details : 2.8.13 Transformers

(i) Type (ii) Power rating (iii) Voltage & current rating (iv) Make (v) Earthing details

:

2.8.14 Power supply & details of cable support : 2.8.15 Whether electrical panels meet IP-55 rating of latest IS

specification (Attach separate sheet for the logic sequence of control panel)

:

2.9 Whether any design changes if required have been considered for the fabrication of direct fuel transfer system to meet the functional requirement.

:

3 Operational & maintenance contract for 1 year after successful installation & commissioning ofthe automated direct fuel transfer system at our site BARC, Tarapur:-

3.1 Minimum 200 cycles per day up to one year : Agree/disagree

3.2 All tools, tackles & required man power including engineers, technical supervisers, fitters and helpers & riggers etc. shall be arranged by supplier for the routine operation & maintenance of the above system

: Agree/disagree

3.3 Any break down part or repair of the component during

routine condition of operation shall be replaced by

supplier at his own cost during this period

: Agree/disagree

3.4 To establish the fuel cycle time of trolley & X-table : Agree/disagree

3.5 To establish the remote removal & replacement

procedure of all components inside dissolver cell like

trolley and its driving unit sub-assembly, wire rope sub-

: Agree/disagree

39

assembly, trolley locking/ unlocking & front cover

opening sub-assembly, pusher–I (from trolley to x- table)

sub-assembly, X-table sub-assembly, sensing sub-

assembly for the bundle on the x-table, pusher-II (from

X-table to chopper) sub-assembly etc

3.6 To establish the routine maintenance procedure of all

components

: Agree/disagree

3.7 Noting down of all major & minor operational problems

faced during the normal operations of system contract

and technical suggestions required for the same to be

incorporated in the system by supplier.

: Agree/disagree

3.8 Maintaining of log book for normal & emergency

operations indicating description of all cycle operation,

date & time of start & stop and technical problems

: Agree/disagree

4. ANY SPECIAL FEATURES OF THE OFFER

****************************************

40

ANNEXURE - C

VENDOR EVALUATION PROFORMA

(To be filled in & submitted along with the offer) Reference Tender Enquiry No. : Quotation No. : 1. Vendor Details: a) Name : b) Address (office & works) : c) Telephone Nos. : d) Fax Nos. : e) E-mail address : f) Contact Person : g) Details of ownership of premises : (only if not owned by company) 2. Registration details with Registration No. a) Small scale industry : b) Directorate of industries : c) Others : 3. Organization Details: a) Nature (Proprietary, Partnership Pvt Ltd, Public Limited, State/Central Govt. Undertaking) : b) Top management (Name, qualification and position)

: c) Date of incorporation.

(Include all details in case of sister organization, if any) 4. Performance of preceding three years with profit and loss A/C & anticipated for the current year. 1) Year 2) Capital 3) Turnover 4) Profit/loss 5. Give a list of similar jobs executed in the recent past for the Govt.

organization especially that of Department of Atomic Energy : 6. Details of facilities available: a) Floor space b) Key departments c) List of machines, equipments etc. available d) No. and details of welding sets e) No. of qualified welders f) Man power available g) Skilled labours available h) Whether separate quality control section available with 1. Instruments 2. Qualified operators 3. Facilities available from other sources 7. Documentation:

41

a) Reference standards specific to tender enquiry b) Plant standards availability with each

departments duly updated : c) Availability of drawings for Purchaser’s retention. : d) Procurement of material with emphasis on test certificates for

Purchaser’s verification. : e) Availability of Inward Inspection. : f) Availability of Process Inspection. : g) Availability of Final Inspection : Note: Attach separate sheets for details wherever required.

42

ANNEXURE - D

Proforma for Past Experience of Similar Orders Executed

The following information should be provided in the format given below for each reference assignment for which your firm, either individually as a corporate entity or as one of the major companies within an association has been primarily responsible to render the services.

Description of Job:

Schedule Time Period:

Contract Value (Rs):

Name of the Client:

Address of the Client: (with name, telephone & fax no. of contact person)

Start Date (Month/Year) Completion Date: (Month/Year)

Narrative description of the Project with the name of activities carried out by your professional staff under mechanical (machining/fabrication), hydraulics, electrical & control (schematic drawings/diagrams can be attached) List of design codes & standards used:

Any other relevant information:

43

ANNEXURE- E

Assets & Liabilities of the Firm

Assets & Liabilities (In Rs Crores)

2008-2009 2009-2010 2010- 2011

Total Assets

Current Assets

Total Liabilities

Current Liabilities

Profits Before Taxes

Total Annual Turnover

Total annual turnover from ‐ Design ‐ Manufacturing ‐ Welding (including

material content) ‐ Fabrication

(Labour Content)

44

ANNEXURE- F

Qualification & Experience of Key Personnel

Sl. No.

Position & total number on

companies rolls

Experience Qualification Area of Expertise/ Experience

1. Team Leaders - Nos. >20 years

2. Project Coordinator (S) /Project Manager - Nos.

>15 years

3. (a)Sr. Design Engineer(Mech/Hyd./Elec. & Controls) orequivalent - Nos.

(b)QA Managers or equivalent - Nos.

>10 years

4. Production Engineer or equivalent - Nos.

>5 years

5. Planning Engineers/QA Engineers – Nos.

>4 years

6. Specialist in Assembly & Testing - Nos.

>5 years

7. Support Staff – Nos. (Draftsman/Supervisors/Fabricators/Welders etc)

>4 years

8. Any other information

45

ANNEXURE- G

Structure & Organization

Please indicate below or attach the organization chart showing the company structure including communication & responsibilities, structure of engineering group, production group, erection group (project group), finance group, QA group, the positions of Directors & relevant key personnel (by name, educational qualification & experience), specially bring out the line of reporting.

46

ANNEXURE- H

List of Typical Plant & Machinery

A. Machining / Fabrication

Bidder to indicate separate lists of equipment / machinery owned by him and available to him for this project

B. Erection/ installation

Bidder to indicate separate lists of equipment / machinery owned by him and available to him for installation of the machine.

C. Quality Control/ Testing

Bidder to indicate separate lists of equipment / machinery owned by him and available to him.

Note: Bidder to indicate complete list of equipment for Machining/Fabrication / Erection & Testing required for completing the tendered works.

47

ANNEXURE- I

List of Engineering & Qualified Welders & Fabricators

(Employed in service since last three years)

Sl. No.

Name Age Qualification

Experience Nature of

Work Handled

Previous Employment

Project Handled In

Organization

Previous

(1) (2) (3) (4) (5a) (5b) (6) (7) (8)