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TECHNICAL SPECIFICATION

For

Fabrication, Supply, Erection, installation and Commissioning of


Non Regenerative type Demineralisation plant and Online
Polishing plant
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INDEX

S.No Description Page No


1.0 Intent of specification 3
2.0 Scope of work 3
3.0 System Description 8
3.1 Demineralisation Plant 8
3.2 Online polishing plant 9
4.0 General Design Information 9
5.0 Services to be rendered for DM plant and Online Polishing Plant 12
6.0 Evaluation Criteria for Selection of Vendors 13
7.0 Drawings 14
8.0 Welding & Fabrication specification 14
9.0 Pipe Supports 15
10.0 Inspection, Testing, Commissioning 15
11.0 Quality Control and Inspection 21
12.0 Erection Requirements 22
13.0 Transportation & Packing 23
14.0 Special Tools & Tackle 23
15.0 Drawings, data and information required 24
16.0 Commissioning of plants 25
17.0 Guarantee 26
18.0 Area for Contractor’s Plant & Machinery 26
19.0 Sub-Contractors/Sub Vendors 26
20.0 Free issue material 26
21.0 History Docket Requirements for piping work 26
22.0 Taxes 27
ANNEXURE A
ANNEXURE B
ANNEXURE C
ANNEXURE D
ANNEXURE E
ANNEXURE F
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1 INTENT OF SPECIFICATION
1.1 This Specification is intended to cover the design, engineering, procure of
materials, manufacture, assembly/re-assembly, tests at manufacturer’s
works /or site forwarding (duly packed for transportation),
transportation, delivery to the site at BARC, Trombay, unloading,
handling, storage and in plant transportation at site, complete services of
erection, testing at site, successful commissioning, operation and training
to BARC personnel and handing over the DM plant & Online Polishing
plant in a flawless operating condition to Owner.

1.2 The provisions of this technical specification are general in nature and cover
broad aspects. Technical specification outlines the minimum requirements.
However, it would be the absolute responsibility of the bidder to collect,
interpret, analyze all necessary information / data for the successful design and
construction of the plant. Structural safety and successful operation of the plant
shall be the total responsibility of the bidder notwithstanding the approval of
the purchaser.

2 SCOPE OF WORK
2.1 Overall scope of work

The followings are the listing of the minimum overall scopes of the work.

a) Design, fabrication, testing, supply, erection & commissioning of Non


Regenerative type Demineralisation water plant & Online polishing
plant with associated piping as per detailed technical specification and
terms & conditions attached.

b) The material of construction of all the equipments, piping, valves etc for the
two plants is austenitic stainless steel SS 304 L.

c) Both the plants shall be stainless steel skid mounted. All the piping shall be
preferably supported from the skid.

d) Scope of Supply includes following:

DM water plant

I. One (1) Activated Carbon Filter (ACF) Unit with internals, pipe
work and accessories as per technical specification and drawing
submitted.
II. One (1) Cation Exchanger Unit (compact layered bed of strongly
acidic cation resins) with internals, pipe work and accessories as per
technical specification and drawing submitted.
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III. Two (2) Anion Exchanger Units (compact layered bed of strongly
basic anion resins) with internals, pipe work and accessories as per
technical specification and drawing submitted.
IV. One (1) Mixed Bed Exchanger (MB) Units with internals, pipe work
and accessories as per technical specification and drawing submitted.
Online polishing plant

V. One (1) Cartridge type Filter (ACF) Unit (Filter element: Poly
propylene) with internals, pipe work and accessories as per technical
specification and drawing submitted.
VI. One (1) Mixed Bed Exchanger (MB) Units with internals, pipe work
and accessories as per technical specification and drawing submitted.

e) Supply of four numbers (4 nos) of plastic drums of 250 liter capacity (each)
for resin storage.

f) Preparation of spool drawing from the design drawings provided by the


Engineer In Charge.

g) Preparation of drawings for pipe supports and shall furnish to Engineer in


charge for approval. Fabrication and supply of material for pipe support
structures and anchoring of pipe supports as per approved drawings.

h) Supply/arrangement of all welding consumables and machines/equipments


required for the fabrication and testing.

i) Carrying out DPT of the weld joints as per the requirements mentioned in
the following sections.

j) Providing SS nuts, bolts and washers for all spool flange joints.

k) Arrangement for the compressors to supply dry compressed air.

l) Painting and marking of pipe lines as per instruction from engineer-in-


charge.

m) Supply of EPDM/Neoprene gasket for flanged joint.

n) Making arrangements for material handling facilities.

o) Preparation of Reports for all the inspections carried out.

2.2 The detail description of DM plant and Online polishing plant is given in Clause
No. 3.0 System Description of this section.

2.3 The schedule of cost as given ANNEXURE F shall be filled and submitted by
the bidder along with offer.
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2.4 The datasheet as given ANNEXURE C shall be filled and submitted by the
bidder along with the offer.

2.5 On award of contract the bidder has to submit the base template for the
plants which will be used for civil construction of the DM plant and online
polishing plant base.

2.6 The contractor, on award of the contract, shall furnish the detail process
design, mechanical design and drawings to the Engineer in charge for
approval.

2.7 The bidder shall refer to the flow sheet and piping & equipment layout of
proposed DM plant and Online polishing plant enclosed with the specification
attached. The successful bidder shall be provided with the general layout
drawings by BARC, which shows overall dimensions of the pipelines.
2.8 The desired arrangement of the DM plant and Online polishing plant along with
the associated piping from service water storage reservoir to DM water storage
reservoir has been shown in piping & equipment layout as enclosed with this
specification. The bidder shall design the plants as per the flow sheet & piping
& equipment layout. Any changes in the proposed design & layout of plant
shall be considered after approval from Engineer in Charge.

2.9 The piping which are not in scope of the vendor are marked in flow sheet.
The vendor shall carefully study the drawing before quoting.

2.10 The contractor, on award of the contract, shall prepare detailed working drawing
of the said DM plant and Online Polishing plant along with its all equipment
details in consultation with purchaser. The drawings indicate schematically the
size and location of pipes and the associated fittings. The drawing showing
different spools, cross section, longitudinal section, details of fittings, locations
of pressure indication etc, which shall be submitted to engineer in-charge for
approval. No work shall commence prior to approval of drawings. All the welds
shall be numbered for identification. The joint number shall be engraved near the
joint. In case of any doubt, the interpretation/decision as given by the purchaser
shall be final.

2.11 Detailed study of dimensional drawing both in elevation & plan of the piping
layout and verification of the routing of the pipelines as per actual site conditions
before commencement of the work. The volume of the job assessed by the
bidder shall be reported to the Engineer in charge before commencement of
the work.

2.12 The bidder shall aware of that both DM plant and Online polishing plants are
proposed at the ground floor of the building. The piping coming at the
basement of the building is not in the scope of the bidder. The bidder shall
consider all the piping coming at the ground floor after service water header.
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2.13 Supply of complete instrumentation and control for the entire plant as per
ANNEXURE D. Proper calibrations of all the instruments are needed to be
carried out onsite. Date of calibration should not exceed 6 months from the date
of commissioning/testing.

2.14 The job of piping erection shall be carried out as per drawing, actual site
conditions and instructions of Engineer-in-charge.

2.15 Preparation of job schedule & procedure and obtaining the approval of Engineer-
in-charge.

2.16 Preparation and carrying out welding procedure qualification and welder’s
qualification shall be as per Section IX of ASME Boiler and Pressure Vessel
Code. No welding work shall start on prefabrication or installation of piping until
the procedure qualification tests for the particular type of welding have been
accepted by the Quality Surveyor and the agencies concerned.

2.17 Pickling and passivation of pipelines before taking up welding / fabrication, if


required as per ASTM A380.

2.18 Cleaning / flushing of pipelines of all loose material, scales, testing fluids etc.
and pressure testing as per the instruction of Engineer-in-charge. It may be noted
here that these pipelines are for clean demineralised water system and has to be
perfectly clean with no traces of contamination. Even small traces of
contamination can spoil the quality of water.

2.19 Erection of scaffolding as and where required to facilitate working at high


elevation locations specifically for site welding, erection of pipelines and
anchoring of pipe support structures on building roof and side walls. Part of the
pipelines is to be laid at a height along the side walls.

2.20 All necessary lifting tools, tackles, scaffoldings, chain pulley blocks, crane (if
any) ropes etc. shall be arranged by the contractor for lifting and shifting of
material at site and also for installation of supporting structure, vessels,
piping, etc. skilled riggers shall be deployed by the contractor while lifting
and erection of the materials to avoid any accident and damage to the
building structure.

2.21 Liquid Penetrant Testing (LPT) of root and final passes of all the weld joints as
per ASME Sec V and generally conforming to SE-165 “Standard Practice for
Liquid Penetrant Inspection Method”. The halogen in cleaner, developer and
penetrant shall be less than 25 ppm.

2.22 Supply & Installation of various types of flanged and socket-weld end valves as
per the drawings attached: Installation of flanged valve includes fabrication of
gaskets, leveling and alignment of valves to keep bolt holes straddle to the
principal center axis, making of flanges joints with suitable nut-bolts giving
uniform tightening with the help of torque wrench to the predetermined torque
values as instructed by Engineer in Charge. Installation/welding of socket-weld
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end Diaphragm valve includes unbolting/ removal of bonnet with rubber


diaphragm, fillet welding of socket ends and then reassembly of bonnet along
with diaphragm. Supply of gasket material is in the scope of the contractor.

2.23 All piping shall be erected and welded, utilizing materials in accordance with the
drawings approved by the Engineer-in-charge. Unless otherwise specified in the
drawing, tolerance on any linear dimension shall be within + 3mm and tolerance
shall not be cumulative. The bolt holes of flanges in the vertical plane shall
straddle the vertical center line of the pipe in the erected position. The deviation
measuring any direction on flange face alignment shall be within 0.5mm.
Maximum deviation from center lines of bolt hole location shall be +1.5 mm.
2.24 All the pipelines, after installation, shall be flushed before pressure testing.

2.25 All the pipelines, after installation and flushing, shall be hydrostatically tested to
a test pressure of not less than 10 kgf/cm2 for a period of at least 30 min. All
leaks and defects shall be rectified to the satisfaction of Engineer-in-charge.

2.26 Draining and drying of the erected and hydro-tested pipelines completely with
the help of hot & dry compressed air. Contractor shall provide the diesel driven
compressors to supply dry compressed air.

2.27 Painting the identification numbers/markings on the erected pipelines with paint
of approved quality & shade with the help of stencils. Contractor shall arrange
the required stencils for painting the identification numbers/letters. The colour of
the paint used on different erected pipelines and in any other area shall be
decided in consultation with Engineer in charge.

2.28 Erection of pipe supports as directed by Engineer-in-charge including fixing on


concrete wall with the help of cinch anchoring. Stainless steel shims have to be
provided between all MS supports and SS pipelines to avoid direct contact. The
support structure shall be two coat primer and epoxy painted.

2.29 Repair and replacement of parts damaged during erection. Field alteration as
required due to design changes or to correct errors in detailing of fabrication.

2.30 Handling and proper storage of materials procured by the contractor. The
contractor shall be provided with a temporary storage place for the safe storage of
the materials at a place identified by the Engineer-in-charge.

2.31 Quality control, inspection and testing of the work.

2.32 Submission of reports concerning the quality of work, progress of work etc.

2.33 Any other work not specifically mentioned above but is required for efficient
execution of work.

2.34 Contractor should ensure safety of his workmen and should provide personal
protective equipments to his employees and ensure that the same are being used
during the work at site.
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2.35 Transportation of material from the contractor’s works to the site in BARC shall
be arranged by the contractor at their own cost.

2.36 On completion of work, the contractor has to remove and dispose all rubbish and
other unsightly materials caused by his working and thereby leaving the premises
and the cooling tower in good, clean and operational condition.

3 SYSTEM DESCRIPTION

3.1 Demineralisation (DM) Plant


The proposed DM Plant will primarily meet the make up water demand for the
pool evaporation loss. The daily requirement of DM water for pool makeup is 1 m3
(1000 lt).Service water from BMC will be stored in an underground service water
reservoir. From the Service water reservoir, the water will be pumped at a rate of
2.4 m3/hr (40 lpm) directly to DM plant through DM Plant Feed Pumps. The inlet
pressure of water to the DM plant is 5.0 kg/cm2. DM Plant feed pumps will take
suction from service water storage tank, and force the water through Activated
Carbon Filter and Cation Exchanger to the Anion Exchanger and finally through
Mixed Bed Exchanger. Finally DM water will be stored in an underground DM
water storage reservoir. The DM water will be pumped to the pool for makeup.
The DM plant is proposed to operate once in a week for 4 hrs in a day, to produce
9600 litre of DM water per week. However, in case of urgency of DM water the
plant may operate continuously for 8 hrs in every day of a week.

All the ion exchangers should be of Non regenerative type i.e, no regeneration
of ion exchanger beds as well as acid /alkali handling are desired. The resin
shall be removed after minimum production of 270 m3 of DM water in 6 months.

The operation of demineralisation plant will be manual. The backwashing of


activated carbon filters and rinsing of all ion exchangers will be done
manually. Once a filter/ exchanger has been backwashed, operator will have to
manually put back the vessel into service. On exhaustion of any vessel, the
particular filter/ exchangers will be completely isolated from the system. The
resin/ activated carbon replacement and fresh resin/activated carbon charging shall
be done manually.

As described above the DM plant shall consist of following major items:

Activated Carbon Filter (1 No)-Cation Exchanger (1 No) (compact layered


bed of strongly acidic cation resins)-Anion Exchangers (compact layered bed
of strongly basic anion resins) 2 Nos (One operating/one standby)-Mixed Bed
Exchanger (1 No) –Under ground DM Water Storage reservoir.

No pumps shall be in the scope of the vendor. Under ground storage reservoir
is already available the site.
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The desired arrangement of the DM plant has been shown in piping & equipment
layout as enclosed with this specification.
The design raw water analysis and details of the DM Plant is given in
ANNEXURE-A.
3.2 Online polishing plant (OLP)

The water in Underground DM water storage reservoir will be polished whenever


the quality of DM water deteriorates. The polishing will be carried out by
recirculating the DM water through a filter (Polypropylene Cartridge type) and a
non-regenerative mixed bed (MB) ion exchanger. The inlet pressure of water to the
online polishing plant is 5.5 kg/cm2. The polishing flow of 15m3/hr (250 lpm) is
passed through the cartridge filter first and only 1.2 m3/hr of flow (20 lpm) is
passed through the mixed bed ion exchanger. The rest of the flow from filter outlet
is bypassed to the mixed bed outlet. The water from mixed bed outlet will returned
to the underground DM water storage reservoir. The entire operation of the plant
will be manual.

As described above the Online Polishing plant shall consist of following major
items:

Polypropylene Cartridge type Filter -1No, Non regenerative type Mixed Bed
Ion exchanger- 1 No.

No pumps shall be in the scope of the vendor. Under ground storage reservoir
is already available the site.

The desired arrangement of the Online polishing plant has been shown in piping &
equipment layout as enclosed with this specification.

The design polish water analysis and details of the Online polishing Plant is given
in ANNEXURE –B.

4 GENERAL DESIGN INFORMATION

4.1 The water analysis to be adopted for the design of DM Plant and Online Polishing
plant has been furnished in ANNEXURE-A & ANNEXURE-B enclosed along
with this specification. The design of both the plants shall guarantee the
parameters related to outlet water quality as specified in the annexure.

4.2 The bidder shall remember that the basis of the Sizing of vessels shall be such that
the DM plant will normally operate for 4 hrs in a week with a flow of 2.4 m3/hr to
get the water quality mentioned in ANNEXURE A and the resin shall be removed
after minimum production of 270 m3 of DM water in 6 months duration. No
resin shall be replaced before six months under normal operating condition.
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4.3 The bidder shall remember that the basis of the Sizing of Mixed bed shall be such
that the Online polishing plant will normally operate with a flow of 1.2 m3/hr to get
the water quality mentioned in ANNEXURE B and the resin shall be removed in 6
months duration. No resin shall be replaced before six months under normal
operating condition.

4.4 Water temperature varies seasonally. The temperatures and other weather data
have been given elsewhere under this specification. However, ion-exchange units
shall be designed at 45C temperature of filtered water inlet to ion exchangers.

4.5 The type of valves used in DM plant and Online Polishing plant are indicated in
the Flow sheet as well as in piping & equipment layout. The materials of all valves
are austenitic stainless steel SS 304L. Fabrication, testing, supply, erection and
commissioning of all valves shall be done in accordance with the requirements of
for Standard 150 Class Category valves of ASME B-16.34. The end to end and
face to face dimensions of valves shall be as specified in ANSI B -16.10.
Installation of valves shall not be initiated till QAP and fabrication drawing
are approved by the purchaser.
4.6 End connections shall be integral with the main body of the valve. End
connections joined to the main body by welding is not permitted.

4.7 All check valves shall be of swing type. The design shall ensure perfect seating of
disc with seat for zero differential pressure condition across the valve.

4.8 All valves shall be easily accessible and located at a convenient height from the
operating floor. Drain valve at lowest point and vent valve at top most point shall
be provided.
4.9 At the time welding with pipe, the diaphragm valve along with the bonnet shall be
removed in order to prevent the damage of diaphragm.

4.10 For DM plant & Online polishing plant the pipe material shall be as per the
requirements of ASTM A 312/A 312M – 06 “Standard Specification for
Seamless, Welded and Heavily Cold Worked Austenitic Stainless Steel Pipes” and
Grade shall be TP 304 L”. The pipes shall have wall thickness corresponds to
Schedule 40. The physical and chemical test shall be carried out on test sample of
pipe.

4.11 For DM plant & Online polishing plant the material shall be as per the requirement
of current edition of ASTM-A – 403/A- 403M – 06, WP-S 304 L (Standard
Specification for Wrought Austenitic Stainless Steel Piping Fittings) for the butt
welded pipe fittings of nominal size more than 15 mm. The material shall be as
per the requirement of current edition of ASTM-A-182/A – 182M – 05a, WP-S
304 L (Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe
Flanges, Forged Fittings, and Valves and Parts for High Temperature Service) for
the pipe fittings of nominal size 15 mm. The material for
weldolets/elbolets/thredolets/latrolets shall be as per the requirement of ASTM-A-
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182, Gr. F304L. All the fittings shall have wall thickness corresponds to schedule
40.
4.12 The bidder shall aware of that the operation of DM plant is not continuous. The
DM plant is proposed to operate once in a week for 4 hrs in a day. However, in
case of urgency of DM water the plant may operate continuously for 8 hrs in every
day of a week.
4.13 The approximate volume of the resin and the activated carbon contained in
respective vessels and other design details are mentioned in ANNEXURE A&B.
However, the bidder shall calculate the bed volumes on their own which can
guarantee the required outlet water quality. The bidder shall consider
atleast a free volume height of 1/3 rd of bed height over the beds and shall
design the vessels accordingly. The nozzles shall be located above the free
volume.

4.14 The design of vessel for DM plant and Online Polishing plant shall be
carried in accordance with ASME SECTION VIII Division 1 for the
pressure vessels. The material of construction of all the vessels shall be SS
304L. Manufacturing process shall not be initiated till QAP and fabrication
drawing are approved by the purchaser.

4.15 The design pressure and temperature of all the components of the plant shall
be 8 kg/cm2 and 600C.

4.16 Proper free board (considering overloading of the plant by a maximum of 15%)
shall be provided for all vessels of the complete plant covered under this
specification.

4.17 The L/D ratio for the cylindrical region (excluding two dish head ends) for each
vessel shall not be less than 2.5.

4.18 The minimum shell thickness shall not be less than 6 mm.

4.19 The material of stainless steel threaded fasteners shall conform to the following
specification

Bolts & Studs ASTM A 193 Grade B8 MA


Buts ASTM A 194 Grade B8 MA

4.20 The bidder shall design the vessels such that it can be easily accommodate in
the given foundation for the plants. (Refer: Piping & Equipment Layout of
DM plant and Online Polishing plant)

4.21 The material for support angle, base plate and anchor plates shall be IS 2062 grade
B and lifting lugs shall be SS 304 L, conforming ASTM A 240

4.22 The resins and activated carbon shall meet the requirements of technical
specification given in ANNEXURE E
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4.23 As both the plants are small in capacity no separate resin removal system with
separate resin transfer line, resin transfer vessel etc are considered. The charging
and discharging of the resin shall be carried out manually. The design of vessels
shall facilitate the easiness for the replacement of resin.

4.24 The activated carbon or resin bed shall be supported on a plate containing cap
strainer inside the vessel. The cap strainers shall be of good material of
construction so that it can withstand the load of the resin/carbon.

4.25 To prevent any media loss into piping system stainless steel Resin traps of
appropriate size shall be provided at the filter and ion exchanger outlet pipe as
indicated in flow sheet as well as in piping & equipment layout. The micron rating
of the resin traps shall be decided in consultation with purchaser.

4.26 The instrumentation required for the DM plant and Online polishing plant are
indicated in flow sheet and piping & equipment layout. Supply, erection and
commissioning of all the instruments are under the scope of the vendor. The
vendor shall refer to ANNEXURE D for detailed specifications and other
conditions for instruments.

4.27 Any changes in the design information given above shall be consulted with the
Engineer in charge before commencement of work.

5 SERVICES TO BE RENDERED FOR DM PLANT AND ONLINE


POLISHING PLANT
The following services are to be rendered by the Bidder:
5.1 Design & detail engineering of entire plant (as per the detail technical
specification.
5.2 Preparation of detail layout/isometric drawing of the plant in consultation with
purchaser.
5.3 Arrange for access to Owner’s representative for the all the equipments and
components at different specified stage inspection testing at manufacturer’s
works.
5.4 Arrange for despatch of all the material by rail / road to sites.
5.5 Arrange for transportation of all the items upto site.
5.6 Receiving and unloading of all equipment, plant and materials at site, checking
with consignment note and reporting for missing damaged items.
5.7 Proper stacking, storing under contractor’s custody and security, providing
proper maintenance of stored items and keeping proper records of materials at
store for convenience & proper scheduling of erection work and for quick
identification and when required. Stores as required shall have to be constructed
by the bidder in the open space provided.
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5.8 Preparation of job schedule & procedure and obtaining the approval of Engineer-
in-charge.

5.9 Preassembly at site after proper checking/ overhauling, as required.


5.10 Services for fabrication, erection and subsequent cleaning/ flushing as required at
site.
5.11 Carry out prestart check of the installation to ensure correctness of the erection.
5.12 The performance and guarantee test shall be performed at site to get the required
quality of water.
5.13 Startup, testing, commissioning and handing over of the complete plant /
equipment / system / sub-systems in a flawless operating condition.
5.14 Supply of all mandatory, erection/ commissioning and recommended spares,
tools & tackle including required after-sales services during and after the
warranty period.
5.15 Supply of performance test instrument on returnable basis for carrying out
performance and guarantee test at site.
5.16 Furnishing of all document, drawings, design basis reports, optimization, study
reports, instruction manuals, test certificates etc. as called for in the specification.
5.17 Provide all skilled, semi-skilled/unskilled workmen labour supervisory staff,
inspectors, erection and commissioning engineer, electrical staff watch and ward
staff, store keeper, driver etc. as required for all services including O & M
training till handing over of the plant.
5.18 Equipment shop painting and final painting including supply of paints.
5.19 Supply of a phased time schedule for various stages of completion of plant,
which shall be the essence of the contract and guaranteed.
5.20 Any other service, although not specifically called for but required for such a
vital contract of the size and nature indicated in this specification.
6 EVALUATION CRITERIA FOR SELECTION OF VENDORS

Following is the criteria for the evaluation of the offers:

a) The bidder/contractor shall be reputed manufacturer of DM water plant


or water treatment plants. Only reputed manufacturer of DM water
plants are eligible to quote.
b) No Sub-contractor is allowed to supply the DM Water plant and Online
polishing plant.

c) For Piping fabrication, supply & installation, the job can be sub
contracted to the outside agencies with the approval from BARC and
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same shall be clarified in the offer. However, the overall responsibility of


the material in any respect lies with the bidder.

7 DRAWINGS
Bidders may see the following drawings for reference, which are with EIC,
before submitting their offers. Final layout drawings will be provided to the
successful bidder after placement of order.
i) Flow sheet of DM plant and Online polishing plant (Tender Drawing No:
DWG NO.1).
ii) Schematic of DM plant building (Tender Drawing No: DWG NO 2).
iii) Piping & Equipment layout of DM plant & Online polishing plant (Tender
Drawing No: DWG NO 3).
8 WELDING & FABRICATION SPECIFICATION
The welding for SS piping shall be performed as per following overall
specification sheet.

1 Code of Construction : ASME Section VIII Div. 1


2 Fluid handled : DM water
3 Working pressure & Temp : Less than 8 kgf/cm2& 400C
4 MOC : Conforms to ASTM A 312/A
312M–06 “Standard
Specification for Seamless,
Welded and Heavily Cold
Worked Austenitic Stainless
Steel Pipes” and Grade shall
be TP 304 L.
5 Type of joints : Butt & Fillet
6 Welding process : Gas Tungsten Arc Welding
7 Welding Filler Wire(Advani- : AWS-ER-308 L for SS
Oerlikon/Essab makeonly) piping, AWSE7016 (low
hydrogen potassium) for CS
piping.
8 Welding Special Features : Delta Ferrite of weld 4-9 FN
(Test certificate for weld
filler wires)
9 Welding Insert : EB/Y 308 L (only if
required)
10 Pipe Surface Cleaning : Pickling & passivation
11 Inspection : By BARC
12 Dye Penetrant Testing (Total : Root and final pass of all the
Halogen & Sulphur below 25 weld joints as per ASME Sec
ppm) V Article 6
12.1 Acceptance standard : ASME Sec. VIII Div I
13 Testing : Hydro at 12 Kg/sq. cm
13.1 Test acceptance standard : No pressure drop
13.2 Acceptance standard : ASME Sec. VIII Div I
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No production welding shall be undertaken until the purchaser has


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

9 PIPE SUPPORTS
For piping, the Contractor shall formulate the piping support GA drawings
based on the site conditions and install pipe supports in accordance with the
details finalized in consultation of the Engineer-In-Charge. The raw material
for forming of the structural members shall be procured by the contractor.
During erection, piping shall be provided with adequate temporary supports
until the final supports are installed. Temporary supports shall rest on paving or
through indirect contact with concrete or structural beams. Platform grating or
scaffolding shall not be used for temporary supports. The Contractor shall
supply the necessary materials for the temporary supports as a part of his scope
of work and remove the same after completion of site work. Anchor bolts
proposed to be used shall be of “HILTI” make in Stainless Steel material
suitable for RCC application. Contractor shall got approved the proposed
model of the HILTI anchor bolt from Engineer-In-Charge. Drilling or holes
and installation of the anchor bolts shall be in scope of the contractor.

10 INSPECTION, TESTING & COMMISSIONING


10.1 The Contractor shall be responsible for and shall provide and perform all the
inspection and testing required as per this specification.
10.2 The fabricator shall submit a detailed Quality Assurance Plan (QAP)
covering all the items and stages of inspection for purchaser’s approval.
There shall be separate QAP for procurement of each material form. The
QAP shall include all sequences and procedures to be followed for achieving
the quality required to meet the stipulations of codes and specifications.
Clearly identifying witness point, hold point, review point etc.
10.3 BARC QA or his authorized representative shall have complete access to the
work areas of the fabricator and shall have the right to intervene wherever
incorrect practices are detected.
10.4 Weld joints, not meeting the minimum requirements of the applicable
specification or code, shall be repaired or replaced at fabricator’s expense.
10.5 The bidder shall submit all the material test certificates for each and every
component of the plant.
10.6 The bidder shall offer the PMI test of each size of the valves and the piping
from NABL approved laboratory.
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10.7 The following tests/inspection shall be carried out for the relevant
components:
10.8 Inspection of welds for all components
a) The Contractor shall provide all the testing & inspection services,
facilities, manpower, except where otherwise specified, for the inspection
and testing requirements covered under the scope of this specification.
b) Contractor shall submit all the inspection & testing procedures, Weld
Inspection Report (WIR) as per format given in Appendix III, RIR etc and
got the same approved through Engineer-In-Charge.
c) All piping joints inside the vaults shall be of “butt” design and structural
welds shall be of “fillet/Groove & Fillet” design. Any other the other weld
construction proposed by the contractor shall be got approved through
Engineer-in-Charge.
d) All welds shall be LP examined after root and final pass as per ASTM E
165. The LPE material shall be of quality suitable for stainless steel
material.
g) Prior to start of welding, inspection procedures shall be established in
accordance with the applicable code and this technical specification.
Written procedures for each inspection method and technique (including
acceptance criteria) shall be submitted to BARC for approval.
Table 1 NDT requirements for welded joints

S. No Welds Visual LPE


100 % 100 %
1 Butt welds Yes Yes
2 Nozzle welds Yes Yes
3 Corner weld Yes Yes
4 Fillet weld Yes Yes

10.9 Visual inspection of weld joints


Visual inspection shall be carried out for following:
a) Materials and components to ensure that these are as per the
specification and are free from defects.
b) Joint preparation and cleanliness.
c) Fit-up, joint clearance and internal alignment prior to joining.
d) All welds shall be visually inspected by BARC QA after
completion.
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10.10 Dye penetrant examination/Liquid Penetrant Examination (DPE/LPE)


Dye penetrant examination method shall conform to ASME Sec. V and
acceptance standards shall conform to ASME Sec. VIII Div 1 together with
requirements specified in succeeding paragraphs. Only visible dye-penetrant
solvent (removable type) method shall be employed for all welds, and other
metallic surfaces. When used on austenitic stainless steel surfaces, the
penetrant materials (penetrant, developer and cleaner), sulphur and total
Halogens content shall be less than 1% and 25 ppm respectively when tested
in accordance to ASTM D129 (Sulphur) and ASTM D808 (Halogen).
Any indication which is believed to be non relevant, shall be regarded as a
defect and shall be re-examined to verify whether or not actual defects are
present. Surface conditioning may precede the re-examination. Non relevant
indications and broad areas of pigmentation, which would mask indication of
defects, are un acceptable. Only indications with major dimensions greater than
1/16 in.(1.6 mm) shall be considered relevant.
For the valves the extent of liquid penetrant examination shall be of the
maximum feasible surfaces for the valve body, valve bonnet, closing disc,
stem, root and final welds, threaded fasteners and counter flanges of all the
valves of various sizes.
10.11 Passivation & Cleaning
All surfaces of the stainless steel parts, all the welds and heat affected zones
shall be passivated by the oxidising solution/mixture containing 25 % by
volume HNO3, 5 % by weight Na2Cr2O7,2H2O at about 500 C for 15 minutes.
Then it shall be washed thoroughly to remove the solution completely. Finally,
water shall be used to rinse the passivated surface to eliminate the
contamination of acids.
10.12 Hydro-Testing of Piping
The hydro-testing of the erected pipeline and valves shall be carried out as
per approved procedures issued by the Engineer-in-charge and considering
following points.

a) All system shall be tested for test loops as approved by BARC.

b) Hydrotest of all the assembled valves shall be carried out separately before
installation. When valve in fully open condition the water at test pressure of 1.5
times the maximum permissible working pressure as given in ASME B-16.34
for which the valve is designed (12 kg/cm2), there shall be no leakage from
any part of the valve. With valve in fully closed condition, when water at above
stated test pressure of 1.1 times the maximum permissible working pressure as
given in ASMEB-16.34 for which the valve is designed is applied at one end of
the valve, there shall be no leak past the seat. When water at 1.1 times the
maximum permissible working pressure as given in ASME B-16.34 for which
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the valve is designed is applied at the gland packing, there shall be no leakage
from the gland packing. Any leakage observed shall be the cause of rejection.
This tests shall be performed on all valves of various sizes.

c) In the event of the valves or any part thereof fails to meet the examination or
test requirements specified herein, the vendor shall notify the purchaser. The
vendor shall obtain written permission from purchaser before repair and
subsequent use of such valve or part. If the repairs, including redesign, are
likely to affect the results of examination and tests of work previously
completed, appropriate re-examination, re-inspection and re-testing shall be
conducted.

d) If any of the test/inspection results is not in conformance to the requirements of


this specification the valve will be rejected.

e) The installed piping systems shall be subject to hydro-tests to ensure integrity


of the erected system.

f) Pressure testing shall be carried out only after the completion of non-
destructive testing of welds.

g) All piping and valves, after installation, will be tested hydraulically at a


pressure, one and half times of the maximum attainable pressure in the system,
to check against leak tightness.

h) All valves shall be operated throughout 100% of the travel and these should
function without any trouble whatsoever.

i) Visual checks on all structural components, welding, painting etc. and if doubt
arises then these will be tested again.

j) All testing and calibrating instruments and equipment shall be furnished by the
Contractor free of cost to the satisfaction of the Purchaser.

k) Preliminary flushing of the pipeline shall be carried out prior to hydro-test.


After successful completion of the test, the lines are to be drained and dried
using compressed air and then sealed with dry nitrogen gas if required.
Nitrogen gas cylinders will be supplied by BARC.

l) Hydro-testing for all pipelines/spool segments shall be done by the Contractor


as per the test scheme and procedures approved by the Engineer-In-Charge.
Hydro-testing shall be discussed after erection of the piping and considering all
the constraints.

m) The test medium shall be DM water.

n) The hydrostatic test at a pressure 1.5 times of the design pressure (8 kg/cm2)
shall be conducted on the vessel during the test. The hydrostatic pressure
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shall be maintained for a minimum of 10 minutes prior to conducting the


examination for leakage and no drop in pressure and no leak and deformation

o) Contractor shall provide all isolations, temporary blanking, additional supports


testing equipment, calibrated pressure gauges as needed for the job. For
convenience of testing a system may be subdivided into various circuits and
loops. Wherever required, spools fabricated at shop shall be tested at shop.

p) In case of any leak observed during testing from the pipes or pipe-fittings, the
same shall be rectified as per procedure. All manpower and tools required for
this shall be supplied by the contractor at no extra cost.

q) After satisfactory completion of the leak test, the system shall be gradually de-
pressurized.

10.13 Tests at Manufacturer's Works


Shop tests shall include all tests to be carried out at Contractor's works, works
of his sub-contractor and at works where raw materials supplied for
manufacture of equipment is manufactured. The tests to be carried out shall
include but not be limited to the tests described under each specification and
the following:

a) Filter media
Determination of the following parameters of activated carbon filter as
per IS: 877.
i) Sieve Analysis, Uniformity coefficient, and effective
size.
ii) Ash Content, Surface area, Silica Content, Iodine
number, Bulk Density, Wet Particle Density, Moisture
Content, Carbon Content.
b) The resins shall be tested in resin manufacturer's plant for
determination of following parameters, strictly as per IS: 7330-1988.
i) Wet screen analysis for determining effective size and
uniformity co-efficient.
ii) Backwashed and settled Density, Wet and Dry Absolute
Density.
iii) Moisture Content.
iv) Total Exchange capacity.
v) Operating Exchange capacity.
vi) Strong Base Capacity in case of anion exchange resin.
vii) Resistance to osmostic shock.
viii) Pore dia, Pore volume for macro-porous resins.
ix) Composition of all materials, castings, forgings etc.
x) Hydraulic test for pressure vessels, pipes, valves etc.
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xi) Tests for all electrical items/accessories shall be as per


relevant Electrical specifications.
xii) System panels are to be checked for dimensions, wiring
continuity, insulation, tubing leakage, etc. as detailed in
relevant sub-section for instrumentation.

10.14 Performance Guarantee Tests

a) Any special instruments, calibration instrument/equipment, equipment,


tools & tackle necessary for performance and guarantee tests shall be
arranged by the Contractor free of cost.
b) The guaranteed performance figures of the equipment shall be provided
by the Contractor during these tests. If the results of these tests show
any deficiency from the guaranteed values the Contractor, shall modify
the equipment as required to enable it to meet the guarantees. In such a
case, performance and guarantee tests shall be repeated within one
month from the date, the equipment is ready for re-tests and all costs
for modifications including labour, materials and the costs of additional
testing to prove that the equipment meets the guarantees, shall be borne
by the Contractor.

c) Performance

i) The units shall be run for 8 hours continuously under steady


state conditions.
ii) After starting plant, samples of water will be drawn every hour
from the outlet of activated carbon filter, cation exchanger,
anion exchangers and mixed bed exchangers, and tested in the
laboratory. The results shall be compared against the required
parameters stipulated elsewhere under this specification.
Similarly for online polishing plant, samples of water from the
inlet and outlet of the plant will be tested in laboratory.
iii) End of run shall be indicated by predetermined water
quantity/sodium leakage at cation outlet, predetermined water
quantity/high conductivity reading at anion outlet,
predetermined water quantity/pH/high conductivity/high silica
level at the effluent water from mixed bed, whichever occurs
first for DM plant and for online polishing plant. The resin of
corresponding exchanger shall then be transferred to Resin
transfer vessel and finally removed.
iv) Inlet water analysis is determined by making arithmetic
average of all hourly readings of filtered water taken during the
test.
v) Based on this inlet water analysis, resin volume provided and
characteristic curves of the resins employed, the capacity of the
stream in terms of total volume of treated water (cu.m)
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between two (2) successive removals of resin shall be


calculated. The calculation shall be approved by the Owner.
vi) Quantity of treated water as determined by test as in (iv) shall
be checked against calculated quantity of treated water during
regeneration as in (vi) and must be equal to or more than the
calculated amount.
vii) The performance test of the Demineralisation Plant and online
polishing plant shall be deemed, as a failure in case
performance as determined in item (ii) and (vii) does not meet
the requirement. In case of failure retesting will have to be
arranged after necessary addition/alteration/modification made
in the system.

a) Guarantee
i) Activated Carbon Filter
a) Each filter will have a design (net) normal capacity not less
than 1.2 m3/ hour and 3m3 / hour maximum (net) under
over-loading condition for 4 hrs in a day (once in a week).
The backwash interval shall be decided by the contractor
and same shall be approved by the Owner.
b) Free chlorine content in effluent water shall be nil.
c) Suspended iron content in the effluent water shall be nil.
d) Turbidity in the effluent water shall be nil.
iii) Ion Exchange Units
a) DM plant ion exchange unit shall be guaranteed for a
design net flow of 2.4 m3/hour (with maximum net flow of
3 m3/hour) for 4 hrs in a day (once in a week). Net output
from each cation and anions unit between two successive
removals shall be not less than 270 m3 for the design water
analysis as exhibited in ANNEXURE-A. In case water
analysis is different from the design values, guaranteed
quantity shall be calculated as indicated in this
specification and guarantee shall be applicable on this
calculated quantity.

11 QUALITY CONTROL AND INSPECTION


a) The contractor shall prepare and submit the following documents.
i) Detailed Fabrication and Erection Plan/Methodology (All
welding should be classified as either to be performed at shop
floor or in-situ as per plan)
ii) Fabrication and completion Schedule.
iii) Quality Control Plan.
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iv) Quality Control Record.


v) Welding Procedure Record.
vi) Welding Inspection Record, as per proforma given in
Appendix III.
vii) Testing procedures for D.P. testing of weld passes and hydro
test for piping.
b) The contractor shall be responsible for and shall provide for and
perform all the inspection and testing required by the Engineer-in-
charge's Specifications.
c) Contractor shall submit for approval a Quality control plan together
with the qualifications of the inspection and test personnel.
d) A Quality Surveyor shall be designated by the Engineer-in-charge. The
Quality Surveyor and his designated staff will be responsible for checking the
quality of work to the extent necessary to assess compliance with the
provisions of the specifications. His surveillance shall not be limited to
examination of the end product, and he shall have complete access to the
work and the right to intervene where bad (non-standard) practices are
detected. He shall also have the right to conduct or ask the contractor to
perform, any additional inspection or testing he feels necessary. If any
unacceptable defects are noted by such tests, the contractor shall repair the
defects free of charge.
e) The surveillance provided by the Engineer-in-charge or the approval by the
Quality Surveyor of finished work shall not relieve the contractor of any of
his responsibilities under this specification.
f) The Contractor shall maintain quality control records, which shall record fully
all the quality control operations that were performed. The Quality Surveyor
shall have the right to witness any or all such operations.
12 ERECTION REQUIREMENTS
a) During the various stages of plant construction, all the stainless steel material
equipments shall be handled and processed with the due care and attention
normal for critical nuclear applications.
b) Direct contact between the stainless steel material with ropes, soft padding
shall be used to protect the material from abrasive damage. Only nylon rope
shall be used for lifting purposes.
c) Loading and unloading of materials and equipment shall be by hoisting or
skidding so as to avoid shock or damage. Under no circumstances materials
shall be dropped. Plates shall not be drilled for the purpose of handling. All
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pipes and plates and prefabricated assemblies shall be adequately supported


during handling and storage.
d) At no stage of handling, the process equipment or any other material of plant
construction from the stores yard to its final location and till testing and
acceptance, shall contact with any other chloride or sulphur bearing material,
as encountered usually in identification marking coding, cleaning, flushing or
testing, etc. for this purpose the contractor shall do test for checking the
presence of chloride as per the specification.
e) Equipment shall not be used for temporary attachments. The areas from
which temporary attachments have been removed shall be dressed smooth
and shall be examined by DP method. Defects, if any, shall be removed and
the material shall be re-inspected to ensure a defect free workmanship.
f) Weld repair, when permitted, shall be made using qualified welding
procedures and qualified welders. The repair weld shall be followed by
complete cycle of inspection and acceptance at no extra cost.
g) The CONTRACTOR shall provide adequate provisions to take care of
tolerances in erection of structures, equipment etc. Final adjustments shall be
made so as to achieve the desired connection locations after installation, but
before final welding. This fact shall be considered while carrying out pre-
fabrication.
h) Effective precautions shall be taken to protect exposed surfaces and other
items in the custody of the CONTRACTOR to prevent mechanical damage
and ingress of foreign matter.
13 TRANSPORTATION & PACKING
13.1 All the equipment shall be suitably protected, coated, covered or boxed and
crated to prevent damage or deterioration during transportation, handling and
storage at site at the time of erection, considering tropical humid climate.
Contractor shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing.
13.2 For transportation if totally enclosed boxes are not used, the equipment shall
be mounted on skids and enclosed in open wooden crates.
14 SPECIAL TOOLS & TACKLE
14.1 The bidder shall quote separately for a complete and unused set of all special
tools and tackle, including required number of the tool boxes, as required for
erection, maintenance, overhaul/or complete replacement of the equipment
and components required for the plants. The bidder shall enclose with his
proposal the list of tools and then item wise price.
14.2 The tools shall be supplied in separate containers clearly marked with the
name of the equipment for which they are intended.
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14.3 The tools & tackle shall include all necessary equipment for calibration of
instruments shall be included.
15 DRAWINGS, DATA AND INFORMATION REQUIRED
15.1 The Bidder's formal proposal must be accompanied by the following but
not limited to the drawings/information and documents as required for all the
basic components of the Demineralization and online polishing plant as a
whole.
i) Schematic flow and instrumentation diagram indicating scope of
supply.
ii) Detail layout drawing with sectional views of the plant showing
equipment, pipe work etc.
iii) Description and illustrative literature/drawings with materials of
construction for equipment and instruments offered.
iv) Schedule of valves
v) Schedule of piping
vi) Schedule of instruments with Specification.
vii) General cross-sectional drawings of all basic components, equipment
and machineries.
viii) Experience list, showing the locations where Bidder has supplied and
commissioned similar plant as under this specification, for similar
application under similar duty conditions, with complete details.
ix) List of potential sub-contractors.
x) Preliminary foundation requirements, including shipping and
operating weights.
xi) Literature with Catalogues (for particular model numbers) of the
different instruments/control offered.
xii) A comprehensive write-up or Brochure indicating the details of the
testing facilities including different tests that can be performed in the
shop of the manufacturer.
xiii) Descriptive literature of the resins supplied with various
characteristics like:
a) Capacity reduction of anion exchanger due to silica at different
temperatures.
b) Pressure drop and bed expansion V/s. flow rate.
c) Leakage characteristics.
d) Curve showing deterioration in efficiency of the different exchange
materials with passage of time and its effect on effluent electrolyte
& silica content.
e) Calculations justifying resin volume selected.
xiv) General arrangement drawing showing plan and section of DM Plant
building.

15.2 Technical Information, Drawings, Data to be submitted for approval


after award of contract
Owner's requirement of information, drawing and data from the successful
bidder after finalization of contract in respect of equipment covered under the
specification are indicated in this section.
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The actual schedule of these data/drawings shall be discussed and mutually


agreed to, between the Owner and the successful Bidder before the issue of
notice of award of Contract.

Following Drawings shall be furnished:


i) Piping & instrumentation diagram of Demineralization plant and online
polishing plant.
ii) Piping layout with suitable sectional views of Demineralization plants,
pump Houses, online polishing plant etc.
iii) Detailed cross-sectional drawings of all equipment and bill of materials.
iv) Detailed dimensional drawings of electric drive motor frame, bearing
cable boxes, cable termination arrangements etc.
v) Complete specification of Instruments and other drawings/ documents.
vi) Design calculation in respect of process and mechanical design,
engineering to the extent found necessary by the Owner.
vii) Detailed procedures of testing shall be submitted to the Owner for
approval before performance tests.
viii) Following test certificates/test curves/data shall be furnished:
a) Material test certificate
b) Performance test results & characteristics curves blower and
electric drive motors.
c) Test results of filter fill.
d) Test results of ion-exchanger Resins
e) Hydraulic test results of pressure vessels, pipes, valves, fittings
etc.
f) Test results of anti-corrosive coatings
g) Non-destructive test results as applicable.

ix) Following lists/tables shall be furnished, complete with tag nos :

a) Instrument bill

b) Valve bill
c) Pipe bill
x) All other drawings, data manuals and test certificates as specified in
the relevant sections of electrical equipment/works specification.

16 COMMISSIONING OF PLANTS
The commissioning of the DM Plant & Online polishing plant shall be carried out as
per commissioning procedure issued by the Engineer-in-charge. In case of any leak
observed during commissioning from the pipes and pipe-fittings, the same shall be
rectified as per procedure. All manpower, tools and consumables required for this
shall be supplied by the contractor at no extra cost.
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17 GUARANTEE

The contractor shall guarantee satisfactory performance of the entire work executed
by him including the materials, equipments supplied by him against defects and
improper/ bad workmanship for a period of 12 months from the date of
commissioning or 18 months from the date of completion of all works, whichever is
earlier.

18 AREA FOR CONTRACTOR'S PLANT & MACHINERY

Suitable area near the site of work will be provided to the contractor free of cost for
carrying out the work. The contractor shall be solely responsible for proper storage
and safe custody of his materials/equipments and materials issued to him.

19 SUB-CONTRACTORS/SUB VENDORS

No Sub-contractor is allowed to supply the DM Water plant and Online polishing


plant. For Piping fabrication, supply & installation, the job can be sub contracted to
the outside agencies with the approval from BARC and same shall be clarified in the
offer. However, the overall responsibility of the material in any respect lies with the
bidder.

20 FREE ISSUE MATERIAL


No free issue material (FIM) will be provided from the department for the subject
job.

21 HISTORY DOCKET REQUIREMENTS FOR PIPING WORK


Five (5) bounded copies of history dockets shall be provided by the contractor for
piping job, apart from the history dockets of valves (to be provided separately). This
docket (5 copies) shall consist of the following documents:

a) Work Order Technical Specification


b) Approved QAP
c) As built drawings of all the components
d) Certified material test reports of all the components
e) Valve catalogue
f) Heat treatment records of all the components
g) Approved inspection/test procedure
h) Approved WPS & PQR
i) Welder/welding qualification test reports
j) Certified material test reports
k) DPT test report
l) Hydrostatic and Air Leak test reports
m) All NDT documents
n) As built isometric drawings with weld joint details
o) Any other document required for completion of work
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22 TAXES
The rates quoted, including for supply items, by the tenderer in the “schedule B‟
shall be inclusive of all the taxes & duties whatever applicable like Excise Duty,
Sales Tax, VAT, Works
Contract Tax, Education Cess, Service Tax and /or other duties levied by the
government or other public bodies.

Only Octroi Duty & Excise duty exemption certificates will be provided by the
department to the contractor and obtaining Octroi & Excise exemption will be the
responsibility of the contractor.

Income Tax, Surcharge on Income Tax, Education Cess and Works Contract Tax
will be deducted from the running bills at the prevailing rates.
TENDER DRAWING
DWG NO.1
'D'

'E' 'A'

'B'
'D'
'E'

SECTION `D-D' SECTION `E-E' SECTION `F-F' SECTION `G-G'

'G' 'G'

'F' 'F'
'A'

SECTION `A-A'

2 2A 3
GROUND FLOOR DM PLANT & ONLINE POLISHING PLANT PLAN

SECTION `B-B'
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ANNEXURE A

Properties of Service Water (supplied by BMC)

Chemical parameters Results


Appearance Clear
Smell Odourless
pH 7.5-8.0
Specific conductance at 250C, micro-siemens/cm 110-120
Turbidity expressed in SiO2, in ppm 2.0
Total residue, dried at 1100C, in ppm 66.0
Filterable residue, dried at 1100C, in ppm 64.0
Alkalinity to methyl orange, as CaCO3, in ppm 31.6
Alkalinity to phenolpthalien, as CaCO3, in ppm Nil
Total hardness, expressed as CaCO3, in ppm 44.0
Calcium hardness, expressed as CaCO3, in ppm 24.6
Magnesium hardness, expressed as CaCO3, in ppm 19.4
Silica in solution, expressed as SiO2, in ppm 17.2
Nitrate + Nitrite in solution, as NO3-, in ppm 1.0
Sodium in solution, expressed as Na+, in ppm 4.4
Potassium in solution, expressed as K+, in ppm 0.3
Total iron in solution, in ppm <0.1
Chloride in solution, expressed as Cl-, in ppm 9.6
Sulphate in solution, expressed as SO42-, in ppm 4.8

CATION – ANION BALANCE


expressed as CaCO3 in ppm.

Cations – Anions –
Calcium : 24.6 Carbonate : 0.0
Magnesium : 19.4 Bicarbonate : 31.6
Sodium : 9.6 Sulphate : 5.0
Potassium : 0.4 Chloride : 13.5
Total Cations = 54.0 Nitrite + Nitrate : 0.8
Total Cations = 50.9

Quality of water after treatment:

pH 5.5-7.0
Specific conductance < 1.0 micro-siemens/cm
Silica as SiO2 0.5 ppm
Turbidity <2.0 ppm
Chloride Nil
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DETAILS OF DM PLANT

Design parameters
Capacity (m3/hr) 2.4
Operating time 4hrs, once in a week
Per day requirement 1 m3
Inlet service water Pressure 4.0-5.0 kg/cm2
Line size 25 NB
MOC SS 304L
ACTIVATED CARBON FILTER
No. of activated filter 1
Carbon volume 500 litres **
Depth of the bed 1000 mm **
Material of housing Austenitic stainless steel (SS 304L)
CATION BED
No.of Cation bed 1
Resin volume 250 litres **
Cation resin Indion 525H+
Material of housing Austenitic stainless steel (SS 304L)
ANION BED
No.of Anion bed 2
Resin volume 250 litres (each) **
Anion resin Indion GS 300 OH-
MIXED BED
No.of Anion bed 1
Cation Resin volume 50 litres **
Anion Resin volume 50 litres **
Material of housing Austenitic stainless steel (SS 304L)
Cation Resin Indion 525H+
Anion Resin Indion GS 300 OH-

** The bidder shall check the values and design the beds on their own which can guarantee
the required outlet water quality. The bidder shall not consider volume of the resin/carbon
less than the volume indicated above for designing of beds.
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ANNEXURE B
Properties of polish water
Parameter Specification
pH 5.5-7.0
Specific conductivity Less than 1.0 µs/cm
turbidity Less than 2 ppm
Alkanity to methyl orange Less than 2 ppm
Total hardness Nil
Sodium as Na Nil
Nitrate +nitrite Nil
Silica in SiO2- Less than 0.5 ppm
Chloride Nil
Total iron Nil
sulphate Nil
COD Nil
DETAILS OF ONLINE POLISHING PLANT

Line size of the plant 50 NB


CARTRIDGE FILTER
No. of cartridge filter 1
Capacity (m3/hr) 15
Filter cartridge element Polypropylene
Material housing Austenitic stainless steel (SS 304L)
Filter rating 25 micron
Operating temperature (Max) 0C 40
Design temperature 0C 60
Allowable pressure drop 5 mwc
MIXED BED
No. of Anion bed 1
Capacity (m3/hr) 1.2
Cation Resin volume 50 litres **
Anion Resin volume 50 litres **
Cation resin Indion 525H+
Anion resin Indion GS 300 OH-
Operating temperature (Max) 0C 40
Design temperature 0C 60
Material of housing Austenitic stainless steel (SS 304L)

** The bidder shall check the values and design the beds on their own which can
guarantee the required outlet water quality. The bidder shall not consider volume of the
resin/carbon less than the volume indicated above for designing of beds.
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ANNEXURE C

BIDDER TO FURNISH ALL THE PARTICULARS GIVEN BELOW FOR EACH TYPE OF
VESSEL

1.0 General
1.1 Vessel number/name
1.2 Fluid handled
1.3 Capacity (m3)
1.4 Overall dimensions of vessel
1.5 Height of the bed mm
1.6 Height of free volume over the bed mm
1.7 Shell OD mm
1.8 Shell thickness mm
2.0 Design conditions
2.1 Design pressure kg/cm2 (g)
2.2 Design temperature 0C
2.3 Joint efficiency
2.4 Empty vessel weight
2.5 Weight of Vessel filled with water
2.6 Stress relief Yes/No
3.0 Codes & standards
3.1 Material , fabrication examination & testing
3.2 Level of weld examination as per the requirements of Yes/No
specification
4.0 Thickness of various parts/ components shall be same as specified Yes/No
in fabrication drawing
5.0 Material Specification and testing
5.1 Shell and head
 Chemical test Yes/No
 Mechanical test Yes/No
5.2 Nozzle
 Chemical test Yes/No
 Mechanical test Yes/No
5.3 Nozzle flanges and counter flanges
 Chemical test Yes/No
 Mechanical test Yes/No
5.4 Body flange and cover
 Chemical test Yes/No
 Mechanical test Yes/No
5.5 Support & structural attachments
 Chemical test Yes/No
 Mechanical test Yes/No
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5.6 Threaded Fasteners


 Chemical test Yes/No
 Mechanical test Yes/No
6.0 Examination & Testing
6.1 Liquid penetrant test on all welded joints as per specification Yes/No
6.2 Hydrostatic test
 Test pressure
 Duration
7.0 Confirm all accessories such as nozzle flanges, counter flanges, Yes/No
gaskets and threaded fasteners as per this specification shall be
provided
8.0 Confirm that the passivation will be done as per this specification Yes/No
9.0 whether the vessels are guaranteed as per this specification Yes/No
10.0 Confirm all documents to be submitted after the award of contract Yes/No
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TECHNICAL SPECIFCATION July,2016

ANNEXURE-D

INSTRUMENTATION

Scope: The scope of the vendor is supply, erection & commissioning of instrumentation in DM
Plant and Online Polishing Plant.

S.No. Item Quantity


1 Pressure gauges 13
2 Orifice plate & orifice flange assembly 1
3 Flow transmitter (DP transmitter) with 3 valve manifold 1
4 Conductivity sensor with transmitter 1
5 Metal tube rotameters with transmitters ( 0 -100 lpm) 2
6 Stainless steel tubings As necessary
7 Stainless steel fittings As necessary

Table 1: Scope of supply - Instruments in DM Plant and Online Polishing Plant

S.No. Item Quantity


1 Spares for pressure gauges mentioned in Table 1 above 30 % in each range
2 Pressure gauges of range - 1 to 1.5 kg/cm2 (g) 3
3 Pressure gauges of range - 0 to 6 kg/cm2 (g) 2
4 Pressure gauges of range - 0 to 10 kg/cm2 (g) 6
5 Stainless steel tubings 30%
6 Stainless steel fittings 30% in each type

Table 2: Scope of supply – Spare Instruments

SPECIFICATIONS:

1. Orifice plate and flange assembly shall be as per ISO 5167 & ISA RP 3.2
2. All transmitters shall be SMART, 4-20 mA and HART protocol type.
3. Conductivity meter shall be online and the sensor shall be retractable type.
4. If the individual Pressure gauges provided at inlet and outlet of a process equipment ( like
filters, strainers) are not suitable to measure the differential pressure (because of accuracy
limitations of the gauges), the vendor shall provide a differential pressure gauge.
5. All instruments including transmitters shall be pipe mounted. In case of necessity of DP
gauges, DP gauges shall be panel mounted. This panel shall be part of the skid mounted DM
& OLP plant and not outside/separate from it.
6. Scope of vendor also includes supply of cables for all transmitters. Cabling shall be done up
to the nearest junction box/local panel.
7. Erection, installation & commissioning of each instrument shall be carried out only after the
approval of the purchaser.
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TECHNICAL SPECIFCATION July,2016

8. Catalogues and data sheets with complete specifications shall be submitted along with the
offer for approval.
9. Detailed dimensional drawings and user manual for all instruments shall be submitted after
award of contract.

10. Before pre-dispatch inspection, certificates for following shall be submitted.


 Raw material chemical and physical testing in government recognized standard
laboratory for all instruments.
 Calibration certificates for all instruments.
 Certificates of tests as per approved QA plan.

11. Following tests will be carried out during pre-dispatch inspection:


 Hydrostatic test (1.5 times the maximum working pressure ) shall be carried out for
pressure gauges, 3 valve manifolds, tubings, fittings and metal tube rotameters with
flanges, for 10 minutes.
 5 point calibration and accuracy checks for all instruments.
 Dimensional checks.
 Functional checks, IR tests, output load variation tests, reverse supply voltage
protection tests for all transmitters as per IEC 60770.
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ANNEXURE E

Specifications for Nuclear Grade Cation Exchange Resin in H+ Form

1] Form to be supplied H+ (Hydrogen) form


2) Matrix Structure Cross linked polystyrene divinyl
benzene
3] Appearance Uniform, strong, spherical beads free
from surface cracks, supplied in moist
completely swollen condition.
4] Chemical nature Strongly acidic with sulphonic acid as
functional group.
5] Exchange capacity 1.8 meq/ml of wet resin (minimum)
99.5% of its exchange sites in H+
form (minimum)
6] Particle size 0.3 to 1.2 mm
7) Bead strength Not less than 500 gm/bead (avg.)
8] Effective size 0.45 to 0.65 mm
9] Uniformity coefficient 1.8 (maximum)
10] Fines content passing through 0.5% v/v (maximum)
300 micron sieve (No. 52BSS/
30 IS)
11] Moisture content 50 – 55% w/w
12] Impurities (mg/ltr of wet resin)
[maximum]:
a) Iron 20
b) Copper 10
c) Heavy metals (as Pb) 10
13] Water soluble organics 0.1 mg KMn04/ml of wet resin
(maximum)

Specifications for Nuclear Grade Anion Exchange Resin in OH- form

1] Form to be supplied OH- (Hydroxide) form


2) Matrix Structure Cross linked polystyrene divinyl
benzene
3] Appearance Uniform, strong, spherical beads free
from surface cracks, supplied in moist
completely swollen condition.
4] Chemical nature Strongly basic with quaternary
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ammonium as functional group.


5] Total exchange capacity 1.0 meq/ml of wet resin (minimum)
(1) Hydroxide : 94% (more than)
(2) Chloride : 1% max
(3) Carbonate : 5% max
6] Particle size 0.3 to 1.2 mm
7) Bead strength Not less than 250 gm/bead (avg.)
8] Effective size 0.40 – 0.50 mm
9] Uniformity coefficient 1.8 (maximum)
10] Fines content passing through 0.5% v/v (maximum)
300 micron sieve (No 52 BSS/
30 IS)
11] Moisture content 60% w/w (maximum)
12] Impurities (mg/ltr of wet resin)
[maximum]:
a) Iron 20
b) Copper 10
c) Heavy Metals as Pb 10
13] Water soluble organics 0.1 mg KMn04/ml of wet resin
(maximum)

Specifications of Activated Carbon

Physical form as supplied Granular


Appearance Porous form of Carbon manufactured from Coconut
shell, wood or coal
Mesh size (US) 8 × 30 OR 12 × 40
Apparent Density 0.5 gm / ml (min.)
Iodine Number 800 mg / gm (min.)
Moisture content 10 wt.% (max.)
Uniformity Coefficient 2.0 (max.)
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ANNEXURE F

COST SCHEDULE FOR DM & ONLINE POLISHING PLANT SHALL BE


FIILED & SUBMITTED BY THE BIDDER

Sr.No Name of the Item Quantity Unit cost Total cost


1 DM plant 1
2 Online polishing plant 1
Spare
3 Spare 2” diaphragm valve 5
4 Spare 1” diaphragm valve 10
5 Spare 2” diaphragm 30 % of total valve
6 Spare 1” diaphragm 30 % of total valve
Spare Instruments
7 Pressure gauges for each range for DM & 30% of the total
OLP gauges
8 Pressure gauges range: - 1 to 1.5 kg/cm2 3
9 Pressure gauges range: 0 to 6 kg/cm2 2
10 Pressure gauges range: 0 to 10 kg/cm2 6
11 Stainless steel tubings & fittings for 30% of each type
instruments
Others
12 Plastic drums of 250 liter capacity 4
13 Testing, Installation & commissioning
charges
14 Packing & forwarding if any
15 Freight charges if any
16 Excise duty
17 SALE/VAT
18 Total Cost