Annexure

Detailed Technical Specification of SS304L Dissolution tanks with Agitator

Specification for dissolution tank (Reference: Drawing No. C-DWS-ZOP-1293)

1. Scope: Manufacture, Testing & Supply of 2 nos. of dissolution tanks with agitator.

2. Delivery Schedule: The equipment shall be delivered to NFC within 12 months of receipt of P.O.
including all the items as mentioned in PO.

3. Quantity: 2 nos. Dissolution tanks of 10 kL capacity with agitator.

4. Type: Cylindrical shell with conical bottom & flat bolted lid of split type (two halves) having a
provision for installation of agitator. The tanks would be used for holding DP slurry under agitation.

5. Liquid to be handled: Crude zirconium hydroxide (DP) dissolved in 60 % nitric acid (12 N) at
700C.

6. Specific gravity of the slurry: 1.4-1.6

7. Operating pressure: Atmospheric

8. Operating temperature: 900C

9. Diameter: 2000 mm ID

10. Shell height: 3000 mm

11. Thickness: Shell & cone – 8 mm, Flat top – 4 mm

12. Cone angle: 900

13. Baffles: 4 nos. of baffles of width 175 mm each, positioned at every 90 0 in the vessel.

14. Flushing: Provision for flushing the tank from bottom with steam, compressed air and service
water. Separate nozzles are to be provided for steam, compressed air and service water (as per
above referred drawing.)

15. Painting: 1 coat of red oxide primer followed by two coats of synthetic enamel paint on outside of
tank.

16. Material of Construction: SS304 L

17. Pre - Fabrication requirements:

a. Raw Material:

SS 304L Plates:
 1. Plates shall be in hot rolled, annealed and pickled condition and shall conform to SA
240 & SA 480 of ASME Sec II.

2. The plates shall be free from surface defects like pits, cracks, laminations and
inclusions. If any grinding is done to remove these defects, it shall be ensured that
there is a smooth merger of the ground surface with the remaining surface and
thickness is within the tolerance limits of ASME SA 480.

3. Inspection and testing of plates shall include:

a. 100% visual Examination
b. 100% dimensional inspection
c. Chemical analysis to be carried out as per SA-751.Carbon content shall be
checked by LECO combustion method.
d. Mechanical tests to be carried out as per SA 370
e. IGC Practice A/E test as per ASTM SA 262 requirements

4. Valid test certificate of the material from NABL accredited lab as per PO specifications
shall be submitted by the vendor with proper identity.

5. In case of proper co-relation between test certificate & plate heat/lot number, one
sample per heat/lot and thickness will be subjected to chemical analysis and
mechanical testing at NABL accredited lab. Product chemical composition and mech.
properties will be in accordance with ASME SA 240 within the tolerance limits of ASME
SA 480. Arrangements for test will be made by vendor and test will be witnessed by
TPI agency. If all the tests are meeting P.O requirements material will be cleared.

6. In case there is no correlation between heat/ lot number on the plate and certificates,
one sample from each plate will be subjected to chemical and mechanical tests at
NABL accredited lab. Arrangements for test will be made by vendor and test will be
witnessed by TPI agency. If all the tests are meeting P.O requirements material will be
cleared.

7. One sample per heat/lot of SS plate shall be subjected to IGC Practice A/E test as per
ASTM SA 262 requirements. The test shall be witnessed by NFC/TPI agency.

8. If the material is offered at the original manufacturers works , testing as specified at Sl

no.3 above can be carried out in their laboratory.

SS 304L Pipes:
1. Pipes for nozzles shall conform to SA 312 of ASME Sec II. They shall be of seamless
nature.

2. Ultrasonic testing of pipes meant for steam coils fabrication only needs to be carried
out as per ASME Sec V, SE 213 standard. UT procedure for pipes to be approved by
NFC. UT test report to be submitted by supplier.

3. Inspection and testing of materials shall include:

a. 100% visual Examination
b. 100% dimensional inspection
 c. Chemical analysis
d. Mechanical tests
e. IGC Practice A/E test as per ASTM SA 262 requirements

4. Valid test certificate of the material from NABL accredited lab as per PO specifications
shall be submitted by the vendor with proper identity.

5. In case of proper co-relation between test certificate & pipe heat/lot number, one
sample per heat /lot and size will be subjected to chemical analysis and mechanical
test as per ASME Sec II SA 312 requirements at NABL accredited lab. Test will be
witnessed by TPI agency.

6. In case there is no correlation between heat number/lot number on pipe, one sample
from each pipe will be subjected to chemical test and mechanical tests at NABL
accredited lab. Arrangements for test will be made by vendor and test will be witnessed
by TPI agency.

7. One sample per heat/batch and size of pipe shall be subjected to etch test to confirm
seamless nature. If there is no batch or heat number, one sample from each pipe shall
be subjected to etch test to confirm seamless nature. Arrangements for test will be
made by vendor and test will be witnessed by TPI Agency.

8. One sample per heat/lot of SS pipe shall be subjected to IGC Practice A/E test as per
ASTM SA 262 requirements. The test shall be witnessed by NFC/TPI agency.

9. If the material is offered at the original manufacturers works , testing as specified at Sl

no.3 above can be carried out in their laboratory.

Flanges & Fittings:

1. Flanges & Fittings shall be as per ASME SA182 requirements.

2. In case of proper co-relation between test certificate & heat number One, sample per
heat/lot and size will be subjected to chemical analysis at NABL accredited lab.
Arrangements for test will be made by vendor and test will be witnessed by TPI
Agency.

3. In case there is no correlation between heat/lot number on flange/fittings, one sample

from each flange/fittings will be subjected to chemical analysis at NABL accredited lab.
Arrangements for test will be made by vendor and test will be witnessed by TPI
Agency.

Angles, Channels & beams:

1. Angles, channels & beams shall confirm to ASME Sec II, SA276 requirements.

2. In case of proper co-relation between test certificate & heat number One, sample per
heat/lot and size of component will be subjected to chemical analysis at NABL
accredited lab. Arrangements for test will be made by vendor and test will be witnessed
by TPI Agency.
 3. In case there is no correlation between heat/lot number on the components, one
sample from each component will be subjected to chemical analysis at NABL
accredited lab. Arrangements for test will be made by vendor and test will be witnessed
by TPI Agency.

b. Welding:

1. Welding of tanks to be performed using SMAW welding technique.

2. Welding electrode shall confirm to ASME Sec-II Part-C requirements. E308L

electrodes shall be used for welding 304L to 304L. E309 electrode shall be used for
welding SS304L to MS. The welding electrode shall be of one of the following makes
only: Esab, Advani Oerlikon, Philips, D&H.

3. Inspection and testing of weld consumables shall include:

a. 100% visual Examination
b. Chemical analysis as per SFA 5.4 of ASME Sec II requirement

4. Valid test certificate of the material from NABL accredited lab as per PO specifications
shall be submitted by the vendor with proper identity.

5. One weld pad sample is to be made from each size, batch/lot number of electrodes
and shall be subjected to chemical analysis as per SFA 5.4 of ASME Sec II
requirement. Only if chemical analysis is meeting the P.O requirements , material shall
be cleared for fabrication.

6. All the welds shall be of a quality acceptable in DP test. Acceptance criteria for DP test
are as per ASME Sec VIII Div I.

7. Welder & welding procedure qualification shall be as per ASME Sec IX requirement.

8. If the vendor is already having a qualified welder with approved WPS, documents will
be verified by NFC. Permission for welding will be given only after verification of
documents.
.
c. Others:

1. Vendor shall submit the fabrication drawing to the customer within 15 days of receipt of
P.O. and get it approved by the customer before starting the fabrication of tank.

2. The vendor shall submit a detailed manufacturing procedure, any additional working
drawings, QA plan and stage wise check lists and documentation formats along with
time schedules to the purchaser for approval before fabrication. These documents
shall be submitted within 3 weeks from the placement of order and before offering the
raw material and other consumables for inspection.

3. Manufacturing plan shall include the detailed procedure of manufacture, the equipment
used and the tolerances that are maintained at various stages of manufacture to
achieve the final required specifications.
 4. QA plan shall detail the procedures for carrying out inspection and testing at various
stages.

18. Fabrication

1. Fabrication & Inspection shall be as per ASME Sec. VIII.

2. The items to be fabricated shall be numbered as per the identification number given by
the purchaser. The number shall be legibly marked on the items at a prominent
location.

3. The edges / surfaces to be welded shall be cleaned thoroughly using Acetone / TCE
and checked by DP for any defects, including cracks, before welding. If defects are
found, the same shall be removed by grinding followed by DP test until the defects
disappear.

4. All the welds shall be DP tested. Acceptance criteria for DP test are as per ASME Sec
VIII Div I.

5. All the butt welds of shell & cone & steam coil shall be subjected to spot radiography
testing (10%) as per ASME, Sec VIII, Div. I requirements. Radiography shall be with
X ray source only.

6. The items after fabrication shall be free from injurious defects such as dents, pits,
handling marks, remains of fixtures etc.

7. If the number of repairs on any weld during entire fabrication is more than three, the
welder will be disqualified and the welding procedure and welder needs to be re-
qualified.

8. The vendor shall not carry out any weld repairs without the prior approval of the repair
procedure from the purchaser.

19. Inspection and Testing:

1. Vendor shall arrange for PMI of all parts of tanks including welds, during final
inspection.

2. Inspection documentation by the vendor shall include the following checks before, during and
after fabrication:
1) Inspection of materials of construction including test certificates from NABL accredited
lab and check analysis reports at NFC.
2) Accuracy of Templates/markings/ cut-outs
3) Dimensional checks/ Alignment / Ovality before and after fabrication.
 4) The straightness of the cylindrical shell and flatness of bottom plate shall be ensured.
There shall be no bend/curvature in them.
5) Inspection of edge preparation, root pass and final welds.
6) DP test.
7) Water fill test

Visual and Dimensional inspection:

1. The components after fabrication should be free from any handling and welding marks
etc .Handling marks if any shall be removed by grinding without reducing the wall
thickness and affecting surface finish.

2. Dimensions of the component should be within the tolerance limits as per IS 2102.
Tolerances wherever not specified are general tolerance as per IS 2102 medium for
machined parts and extra coarse other parts.

3. Calibrated equipment to be used for dimensional inspection.

Dye penetrant testing:

1. DP test shall be carried out by color contrast penetrant technique using solvent
removable penetrant systems.

2. 100 % DP test shall be carried out on all the welds after root and final weld pass.

3. Any defect found shall be corrected by grinding and re-welding followed by DP test to
ensure defect free weld.

4. The dye, developer and cleaner used for DP test shall be of reputed brands and spray
type only and shall conform to the specification given in ASME Sec V.

5. Acceptance criteria shall be as per ASME Sec. VIII, Div. I

Water-fill test at vendor's works:

1. Water-fill test is to be carried out at vendor's works.

2. Water is stored in the vessel till 100 % of the volume for a duration of 24 hours at
atmospheric conditions.

3. Leaks, if any, need to be rectified.

Pickling & passivation:

1. To be carried out as per ASTM SA380 requirements. Should be carried out before
water fill test. Procedure for pickling & passivation to be submitted to NFC for approval
before test.
 Hold points for inspection:

Following shall be the hold points during stage wise inspection by the purchaser:

i. Pre-fabrication:
a) Fabrication drawing clearance
b) Raw material clearance
c) Layout drawing clearances
d) Welding Consumables clearance
e) Approval of QA plans
f) Approval of all inspection and testing procedures
g) Welder & welding procedure qualification.

ii. In process clearances:

a) Fit-up of C-seams, nozzles to shall/top cone and bottom plate to shell & top cone to
shell.
b) Final inspection of all welds including DP.
c) Review of radiographs of spot radiography of all the butt welds.
d) Final inspection of tank, PMI and water fill test.

Note:
1. Fit ups of C seams to be taken up only after the clearance of L seam welds in
radiography.
2. All radiography films shall be submitted to NFC for evaluation. After clearance
from NFC repair in welds to be taken up.

20. Specifications of agitator for dissolution tank (Reference drawing no.: C-DWS-ZOP-1295)

a) Scope:
Fabrication, testing, supply of agitator and associated mounting structure for dissolution tanks

b) Quantity: 2 nos.

c) Type: Top entry type

d) Application: The agitator will be used in a baffled tank for dissolution of Zirconium washed &
dried frit (WDF) in 12 N nitric acid.

e) Qty. of Acid: 5600 litres

f) Quantity of powder: 1000 kg

g) Specific gravity of slurry: 1.4-1.6

h) Percentage of undissolved solids: 20 % approx.

i) Duty: Intermittent operation

j) Temperature of operation: 900C maximum

k) Material of Construction: All wetted parts shall be of SS304L, ASME SA240

l) Motor: Flameproof motor of 12.5 HP, 3 phase, 415 V, 50 Hz & 1400-1500 rpm

m) Scale of mixing: 6

n) Agitator speed: 150 rpm

o) Shaft: Diameter – 95 mm, Length – 3500 mm

p) Impeller: Two stage four blade (adjustable blades) turbine type impellers of 650 mm diameter,
Thickness of blade = 5 mm, Blade angle = 450

q) Mounting: Standard lantern support type

r) No. of bearing in steel: 2

s) Connection between gear box & stirring shaft: Jaw Flexible coupling. Makes: Fenner,
Lovejoy, Rotex

t) Connection between motor & gear: Tyre type flexible coupling. Makes: Fenner, Lovejoy,
Unique

u) Sealing arrangement: Stuffing box with gland packing

v) Important Notes for agitator:

a. Vendor shall submit fabrication drawing of agitator & mounting details of agitator in the tank
to the customer and get it approved by the customer before starting fabrication of agitator.

b. Motors shall be of standard makes such as Kirloskar/CG/Siemens/Bharat

Bijlee/IEC/Marathon/Havells

c. Bearings shall be of standard makes such as SKF/NTN/FAG/TIMKEN/RHP(NSK)

d. Mounting details of agitator on separate civil structure shall be mentioned in the offer. Civil
works shall be in the scope of NFC (customer) as per the design & drawing given by
vendor.

e. Material samples for analysis at NFC laboratory will be collected before fabrication.

f. Pre-dispatch inspection test shall consist of the following and will be carried out at the
vendor’s works by NFC:
 i. Dimensional check.
ii. Dry run amperage.
iii. Shaft speed measurement
iv. Material test certificates
v. Agitator shaft ultrasonic test certificate
vi. Impeller dynamic balancing certificates.

21. Vendor Qualification Criteria for Dissolution Tanks:

a. Financial Capability: A minimum average turnover of Rs. 28.3 lakhs during last three financial
years. Documentary evidence attested by Chartered Accountant to be furnished.

b. Past Experience: Recorded documentary evidence (like successfully executed POs) of atleast
three fabrication jobs involving austenitic stainless steel within last 7 years.

c. The party should have a welder qualified for welding austenitic stainless steel with qualification
as per ASME Sec IX requirements and with valid documentary evidence. WPS, PQR and WPQ
documents should be qualified by TPI agency like Lloyds, BV, DNV, SGS and TUV or QA
department of any DAE unit.

d. Detailed technical specifications of the agitators to be supplied with makes (refer to technical
specifications of agitators at end) along with pamphlets, drawings etc. The agitators shall
conform to relevant standards (such as EEUA Handbook no. 9) to ensure stability as well as
satisfactory performance. Design shall incorporate good engineering practices.

e. Copy of the annexure duly signed by the bidders accepting all the requirements of technical
specifications, Pre fabrication documents and inspection criteria shall be submitted along with
the quotation.

f. Offers with incomplete information will be liable for rejection.

FIRMS NOT ADHERING TO THE ABOVE QUALIFICATION CRITERIA WILL NOT BE

QUALIFIED.

22. GENERAL

a. Bidders are requested to go through all the specifications, pre-fabrication documents,

inspection and testing procedures to be followed and submit their quotation accordingly.

b. Price quoted shall be for safe delivery at NFC inclusive of all expenditure involved in arranging
inspection and testing as per the details indicated in the technical specifications.

c. Bidders shall note that the inspection shall be carried out as per the approved Quality
Assurance plan.
 d. Inspection shall be carried out by Third Party Inspection Agency(TPI) like TUV India, TUV Sud,
DNV, lloyds & BV only. No other TPI agency apart from the above listed TPI agency will be
acceptable.

e. Responsibility of hiring the services of any one of the above mentioned TPI agency and
the cost incurred toward carrying out the inspection shall be borne by the fabricator. It
shall be noted that after hiring the TPI agency, the credentials of the surveyor of the TPI
agency designated for the inspection shall be sent to NFC for review.

f. Inspection shall be carried out at each stage as indicated in the QA plan . Step wise
authorization for proceeding further will be communicated by NFC to the fabricator only after
receiving he signed stamped ( both from fabricator and TPI agency) copy of the inspection
reports from the fabricator against each stage.

g. NFC reserves the right to carry out inspection at any stage of fabrication. NFC shall
witness the final inspection including water fill test and PMI.

h. Fabricator has to submit the entire inspection report in the form of a booklet as well as the soft
copy (through email) after final inspection for review and for giving the dispatch clearance.
Same will be retained at NFC for records.

i. All the materials of construction shall be procured from the manufacturers / authorized agents
of manufacturers. Local traders shall be avoided. The materials shall be neatly stacked by the
vendor with proper identification marks to avoid mix-up and to ensure correct usage.

j. The vendor shall give details of the sub contractor in case of any sub-contract and the sub-
contractor shall be approved by the purchaser before sub-contracting.

k. The vendor shall strictly comply with the approved drawings, specifications & codes and shall
maintain and submit complete documentation of fabrication, inspection and testing at every
stage up to the final product.

l. Vendor shall inform the purchaser well in advance for carrying out stage inspection as per
approved QA plan. All the arrangements required for carrying out inspection and testing shall
be provided by the vendor.

23. Technical Specifications convention for X-ray radiography

a. Parameters used for carrying out X-ray radiography

i. X-Ray film to be used: AGFA D4 or equivalent
ii. Film to focus distance: 30” (750 mm) approx.
iii. Lead intensifying screens: Front 0.002” (0.05 mm), Back 0.006”(0.15 mm)
iv. Penetrameter: ASTM strip type as per ASME Sec V (source side)- Essential
hole to be seen 2T.
v. Each shot length shall be adjusted to achieve the desired optical density
requirements (1.8 to 3)
vi. Technique: SWSI for all butt welds of shell, dish/cone
 DWDI for butt welds of pipes

b. Lead markers shall identify

Tank no.
Date of testing
Section details (a,b,c & so on) before starting the job.

c. Spots for radiography shall be selected by NFC. Radiographs of one longitudinal and one
circumferential weld shall be certified by the approved QA agency before proceeding with the
remaining job.

d. All the radiographs shall be submitted to NFC along with evaluation reports and shall remain as
property of the purchaser.

e. The developed films which do not conform to acceptable quality standards shall be discarded
and the welds re-exposed to achieve proper quality.

f. Radiography procedure shall be submitted by the vendor and this shall be approved by NFC.

24. Technical Specifications convention for lead marking

The following convention shall be followed while carrying out radiography on all tanks.
a. The lead marker shall indicate the items (tank number), weld (circumferential/longitudinal).
Section details (AB, BC etc.) & date of testing.
b. Circumferential Welds of tank:
The circumferential welds shall be numbered from the top end (open end) of the tank i.e. CS1,
CS2, ___etc. The lead marking shall be

TK____Tank No.______ CSi______ AB etc.

Date:
Where i = 1,2,3,4 & so on.

“A” shall start from tank number marking on the bolted flange for tank and shall proceed in anti-
clockwise direction when viewed from flange side.

Eg: TK1-CS1-AB
Where TK1 = Tank number
CS1 = Circumferential weld 1
AB = Section AB
Date of testing = dd/mm/yyyy

c. Longitudinal weld:
 The numbering of longitudinal welds shall start from bolted flange of the tank and are
numbered as LS1, LS2 & so on. In order to number the welds within a shell, a reference i.e
tank number on bolted flange is taken. The first longitudinal weld shall be the one which will
come first in anti-clockwise direction from the tank number when viewed from the open side.

The lead marking shall be

TK1___LSi___AB etc.

Date: dd/mm/yyyy

Where i=1, 2, 3, 4 & so on

“A” shall start from the flange side of the tank

Eg: TK1-LS1-AB

Where TK1 = Tank no.

LS1 = Longitudinal weld 1
AB = Section AB
Date of testing: dd/mm/yyyy
d. Circumferential Welds of pipe:
The circumferential welds shall be numbered from the open end of the steam coil of the tank
i.e. Coil CS1, coil CS2, ___etc. The lead marking shall be

TK____Tank No.______ Coil CSi______ AB etc.

Date:
Where i = 1,2,3,4 & so on.
AB - segment name

Eg: TK1-CS1-AB
Where TK1 = Tank number
Coil CS1 = Coil Circumferential weld 1
AB = Section AB
Date of testing = dd/mm/yyyy