NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A Government of India Enterprise)

PROCUREMENT OF RAW MATERIAL, MACHINING, HEAT TREATMENT,

MANUFACTURE, INSPECTION, TESTING, PACKING, SAFE DELIVERY AND
GUARANTEE

OF

SEAMLESS CARBON STEEL PIPES

FOR

KGS-2 En -Masse FEEDER REPLACEMENT PROJECT

SECTION – C: TECHNICAL SPECIFICATIONS

SECTION – C

TECHNICAL SPECIFICATIONS OF STORES

 Section – C

CONTENTS

Sr. No. CONTENTS

1 Sub Section – C1
1.1 Special Instruction to Tenderers
1.2 Annexure – 1-List of Components for KGS-2 For EMFR
1.3 Annexure – 2-Format for NCR
2 Sub Section – C2
2.1 Technical Specifications
2.1.1 PP-M-697 R-2 along with QAP
2.2 NPCIL Procedures
GUIDELINES FOR ULTRASONIC THICKNESS MEASUREMENTS OF PIPING
2.2.1
,COMPONENTS, SUCH AS PIPES AND ELBOWS
QAD/NDT-PROC/MT-01,REV- 3 - PROCEDURE FOR MAGNETIC PARTICLE
2.2.2
TESTING WITH PROD TECHNIQUE
QAD/NDT-PROC/MT-02,REV- 3 - PROCEDURE FOR MAGNETIC PARTICLE
2.2.3
TESTING WITH YOKE TECHNIQUE
QAD/NDT-PROC/MT-05,REV- 3 - PROCEDURE FOR MAGNETIC PARTICLE
2.2.4 TESTING WITH WET HORIZONTAL / STATIONARY MAGNETIC PARTICLE
TESTING MACHINE
QAD-NDT-PROC-PT-04 REV. NO. 2- PROCEDURE FOR LIQUID
2.2.5 PENETRANT EXAMINATION (GENERAL REQUIREMENT)
QAD-NDT-PROC-RT-01 REV. NO. 3-PROCEDURE FOR RADIOGRAPHY
2.2.6
EXAMINATION OF WELDS
QAD-NDT-PROC-UT-03 REV. NO. 3 - PROCEDURE FOR ULTRASONIC
2.2.7
EXAMINATION OF PIPES AND TUBES
QAD/NDT-PROC/UT-06 REV. 3- PROCEDURE FOR ULTRASONIC
2.2.8
EXAMINATION OF STEEL FORGINGS FOR GENERAL PURPOSE
QAD/NDT-PROC/UT-011 Rev. 3- PROCEDURE FOR GENERAL
2.2.9
REQUIREMENTS OF ULTRASONIC EXAMINATION
QAD-NDT-PROC-UT-10 Rev.3-
2.2.10 PROCEDURE FOR PRE-SERVICE AND IN-SERVICE ULTRASONIC THICKNESS
GAUGING OF PIPING COMPONENTS FOR SURVEY OF EROSION OR CORROSION
SECTION-‘C’: TECHNICAL SPECIFICATIONS OF STORES AND DRAWINGS.

Sub-section – C-1: Special Instructions to the Tenderer

Annexure-1 – List of Components under the scope for KGS-2.

Annexure-2 – Format for NCR.

Sub-section - C-2: Technical Specifications, Procedures and QAP

1. Following applicable NPCIL Technical specifications are attached.

Sr. Technical Specification

Technical specification Description
No. No.
PP-M-697-R2 along with
1 Feeder Pipe
QAP

2. Following applicable NPCIL Procedures are attached.

Sr.
NPCIL Procedure No. Technical specification Description
No.
1. GUIDELINES FOR ULTRASONIC GUIDELINES FOR ULTRASONIC
THICKNESS MEASUREMENT THICKNESS MEASUREMENTS OF
PIPING ,COMPONENTS, SUCH AS PIPES
AND ELBOWS
2. QAD/NDT-PROC/MT-01,REV- 3 PROCEDURE FOR MAGNETIC
PARTICLE TESTING WITH PROD
TECHNIQUE
3. QAD/NDT-PROC/MT-02,REV- 3 PROCEDURE FOR MAGNETIC PARTICLE
TESTING WITH YOKE TECHNIQUE
4. QAD/NDT-PROC/MT-05,REV- 3 PROCEDURE FOR MAGNETIC PARTICLE
TESTING WITH WET HORIZONTAL /
STATIONARY MAGNETIC PARTICLE TESTING
MACHINE
5. QAD-NDT-PROC-PT-04 REV. NO. 2 PROCEDURE FOR LIQUID PENETRANT
EXAMINATION (GENERAL REQUIREMENT)
6. QAD-NDT-PROC-RT-01 REV. NO. 3 PROCEDURE FOR RADIOGRAPHY
EXAMINATION OF WELDS
7. QAD-NDT-PROC-UT-03 REV. NO. 3 PROCEDURE FOR ULTRASONIC
EXAMINATION OF PIPES AND TUBES
 8. QAD/NDT-PROC/UT-06 REV. 3 PROCEDURE FOR ULTRASONIC
EXAMINATION OF STEEL FORGINGS
FOR GENERAL PURPOSE
9. QAD/NDT-PROC/UT-011 Rev. 3 PROCEDURE FOR PRE-SERVICE AND IN-
SERVICE ULTRASONIC THICKNESS
GAUGING OF PIPING COMPONENTS
FOR SURVEY OF EROSION OR
CORROSION
10. QAD/NDT-PROC/UT-11 Rev.3 PROCEDURE FOR GENERAL REQUIREMENTS
OF ULTRASONIC EXAMINATION

Sub-Section-C1

SPECIAL INSTRUCTIONS TO THE TENDERER

1. SCOPE :

The scope of this tender document is procurement of raw materials, heat treatment, manufacture,
inspection, testing, protective coating, packing, safe delivery & guarantee of feeder pipe for
KGS-2 as per Technical Specifications as annexure to this tender document.

The scope of this tender includes the following:

 Preparation of manufacturing documents viz. specification for material procurement,

Process plans, Quality Assurance Plans, NDE procedures, Examination procedures,
Testing Procedures, packing procedures etc.
 Procurement/ manufacture of all raw materials.
 Packing & delivery of Feeder Pipe from manufacturer’s shop to KGS-2 site meeting the
requirement of Technical Specifications.
 Supply of History dockets in soft form

1.1 The bidder is deemed to have examined all the parts of the tender document and fully informed
himself as to the nature & scope of work and conditions related to performance. For any further
clarification, deviation from the specification/ drawing etc. the bidder is requested to send his
pre-bid queries in writing to NPCIL in the prescribed format i.e. Appendix-Y attached with
section A of this tender only. The clarifications will be furnished by NPCIL during pre-bid
meeting with the suppliers.

1.2 Supplier shall assign single coordinator as project manager to interact, coordinate, monitor,
submitting report of progress etc and will be responsible to interact with various agencies till
completion of work.

2. SUB-CONTRACT

2.1 If any item covered in this tender is proposed to be sub-contracted for forging, machining, heat
treatment, stress relieving, testing, examination/ inspection or packing, the same shall be
indicated right at the time of submitting the offer (Technical Part-I). Approval of such sub-
vendors by purchaser is mandatory. The supplier shall indicate the name of the sub-contractor
likely to be engaged, at the time of submission of their Part-I offer.
2.2 The scope of works that are proposed to be sub-contracted (indicated by bidder in Part-I) only
will be allowed for sub-contract after due approval of the sub-contractor by the purchaser after
placement of purchase order. All other works shall be carried out In-house by the supplier as
mentioned during technical evaluation. Any change in the scope of sub-contract or change of
sub-vendor shall be considered in specific cases, only on submission of detailed proposal with
proper reasons and this change will be subjected to approval of the purchaser.

2.3 If the sub-contractor is not in the suggested list of NPCIL, the same needs to be evaluated first
by the bidder and the report should be submitted along with the offer. Subsequently, NPCIL
will evaluate and approve the proposed sub-contractor prior to finalization of contract against
the tender. Later on, the Contractor will not be permitted to change the sub vendor except in
unavoidable circumstances, that too, with the consent of NPCIL. In view of this, the bidder is
advised to get approval of multiple sub-vendors prior to finalization of order against the tender.

2.4 The technical specification and draft sub-PO shall be submitted to NPCIL for approval prior to
placement. In case of sub-contract, the supplier shall be responsible to the purchaser for all the
work of the sub-contractor. The supplier shall forward to NPCIL the un-priced copies of all
sub purchase orders placed on sub-contractor within two weeks of placement of purchase
orders.

2.5 All Technical approvals, permissions, reporting etc. shall be in writing. In lieu of signed
permission or reporting, electronic communication from authentic source shall also be
acceptable.

3 MATERIAL PROCUREMENT/PROCESSING

All the materials shall be procured/processed and tested in accordance with enclosed NPCIL
specifications & drawings attached. The Mill Test Certificates shall be submitted to NPCIL.
The source of raw materials procurement/processing as well as shape, size & heat treatment
condition may also be indicated. In the absence of original mill test certificates from reputed
source, material shall be tested to specification/ drawing requirements as per approved QAP.

4 MANUFACTURING DOCUMENTS & PROGRESS REPORTS

4.1 The contractor shall record all duly approved deviations, concessions, changes etc. which
occurred throughout the manufacturing, examination/inspection and testing stages.

4.2 Being Class-1 and critical component, any deviation from the drawing/ specifications
requirement will not be preferred. However, in case it occurs during the course of manufacture,
the same shall be reported immediately to the purchaser. A detailed report along with root cause
analysis, steps taken to avoid re-occurrence and action proposed on deviation shall also be
submitted for acceptance of the purchaser. The supplier shall proceed further on the job only
after getting confirmation of acceptance of the deviation from the purchaser. The contractor
shall raise design concession request (DCR) for the deviation occurred in the format attached
as Annexure-2 for the approval of the purchaser.

4.3 The Contractor shall prepare detailed monthly progress reports on the works carried out and
shall submit each month’s progress report to the purchaser before 7th day of the succeeding
month on MS project or any other project management package by e-mail.

4.4 The soft copies of all the manufacturing drawings, as built drawings, procedures, QAP,
inspection check lists, reports etc shall be maintained and submitted on DVD/CD/PEN DRIVE
to NPCIL on completion of each components.
4.5 Contractor shall prepare History dockets, for all the Feeder Pipe covered under this tender
(documents not available in soft form may be scanned and compiled in PDF format) and submit
4 copies of properly bound volumes & 2 set on DVD/CD/PEN DRIVE. The History docket
should contain minimum of the following documents.

I. Copies of NPCIL Purchase Order and Supplier’s sub-orders

II. Manufacturer’s Test certificates and compliance certificate.
III. NPCIL Shipping Releases
IV. Quality Assurance Plans
V. Examination/Inspection reports & Test Certificates of all the raw materials
VI. Material clearance records
VII. Manufacturing process plans
VIII. NDE procedures
IX. Heat Treatment Procedures
X. Hydro test Procedure
XI. Packing procedures and all other approved procedures.
XII. Dimensional Inspection Reports
XIII. NDE reports
XIV. Hydro test Report
XV. Technical Specifications

4.6 The Contractor shall ensure that his commitments for other contracts in no way hamper delivery
schedule. The loading and availability of resources along with man power identified for
execution shall be indicated in technical bid.

5 INSPECTION AND TESTING :

5.1 The supplier shall examine all the feeder pipes for full compliance with the specifications for
dimensional accuracy, complete workmanship & testing as per specifications.

5.2 The supplier shall provide all the inspection and testing facilities at all stages during the period
of manufacture of the Feeder Pipe. The examination/inspection and testing shall be done in a
manner acceptable to NPCIL. If deemed necessary, NPCIL will have right to specify additional
inspection/testing other than specified in the specifications & drawing and cost of such tests/
inspection will be borne by purchaser. The supplier shall maintain the records of all the
inspection and tests and the same will be submitted to NPCIL.

5.3 The supplier shall have qualified inspectors to carry out the above examination/inspection.
They will report directly to the management and not to the production group. Quality
Surveillance by the Purchaser or his authorized representative shall not relieve the Contractor
from the responsibility of meeting the specification or the examination/inspection/testing
requirements.

5.4 The examination/inspection shall meet the suggested QAP enclosed with the tender. However,
depending on the manufacturing procedure, quality assurance system of the Company and
manufacturing & Inspection facilities available with the Supplier, some additional checks may
also be necessary over & above suggested QAP. Such checks shall be incorporated &
implemented by the Contractor without any extra financial implication to NPCIL. However
supplier shall submit a QAP likely to be followed depending upon the sequence planned by the
supplier for the manufacture of Feeder Pipe for approval of NPCIL before implementation of
the same for the work.
5.5 In the event of any failure of the component to meet dimensional, examination/inspection or
test requirements specified, the manufacturer shall notify the purchaser or his authorized
representative. The manufacturer shall obtain permission from the purchaser before any repair
is undertaken. The repair procedure shall be got approved from NPCIL before implementation
of the same.

6 CLEANLINESS &WORKMANSHIP:

6.1 The machines and processes used for manufacture of feeder pipes shall ensure the consistent
surface finish and dimensional tolerances specified in specification/ drawings.

6.2 Feeder pipe shall be thoroughly cleaned to remove all traces of dirt, oil, grease and other foreign
matters. Oil or grease contamination shall be cleaned with suitable cleaning agent.

6.2 Clean conditions shall be maintained at all stages of machining, manufacturing,

examination/inspection, storing, handling, and packing.

6.3 Cleaning procedure shall be submitted to NPCIL for approval.

6.4 Furnace for heat treatment (Annealing, Hardening, tempering and stress relieving) shall be
subjected to clearance by the purchaser or his authorized representative, with regard to
uniformity of temperature on working zone, correctness of recorded indication etc., wherever
need arises.

7 HANDLING, PACKING & DELIVERY :

7.1 The bidder shall have sufficient shop floor space & handling facilities available at the place of
manufacture and testing of Feeder Pipe covered under the scope of this tender.

7.2 The supplier shall ensure that all the Feeder Pipes are protected against any corrosion or
damage during all stages of manufacture, examination/inspection, testing, handling, transit and
storage. The packing shall be suitable and rigid enough to ensure safety and shall be protected
from ingress of rain water in to the component packed during all stages of shipment by road to
site, loading, stacking and storage at plant site.

7.3 The packing procedure shall be in accordance with specifications and shall be submitted to
NPCIL for approval. Adequate number of silica gel packets along with a copy of shipping
release shall be kept inside each crate/packing. The crate/packing shall be clearly marked with
numbers and the quantities. Feeder pipe shall not be dispatched unless shipping release from
NPCIL is obtained.

7.4 All openings shall be protected with plastic covers/caps to prevent entrance of dirt and ingress
of moisture during shipment to plant site, storage at site and erection.

7.5 Each package shall be stenciled in bold characters with indelible paint, protected with shellac
to indicate shipping mark, package numbers, dimensions and gross weight, the purchase order
number, consignee address and any other necessary data to identify the component and relate
it to the contract.

7.6 Packing list shall clearly show package numbers, kind of packages, contents, dimensions and
net, legal and gross weight of each package. If different items are in a package, the net weight
of each item shall be specified.
7.7 Transshipment in transit will not be allowed and Contractor shall arrange specially hired
transport arrangement for direct delivery to respective site.

7.8 Unloading of Tendered item(s) at Purchaser’s site shall be in the scope of Purchaser.

8. INFORMATION TO BE GIVEN AGAINST PART-I (TECHNICAL PART) AS PER

THE FORMAT GIVEN IN SECTION ‘D’ OF THIS TENDER DOCUMENT:

8.1 The tender shall contain complete technical details and information sought in the tender. Along
with the technical part, the bidder shall submit all the details mentioned in the tables of Section-
D

8.2 The bidder shall submit sequence wise schedule for raw material procurement, testing,
manufacture, inspection, completion and delivery of all the items. The shortest delivery period
of completion shall be indicated separately including the rate of supply of items per month. The
bidder shall submit schedule for achieving the important mile stone stages as defined in
Section-D of this tender document.

8.3 The bidder shall submit schedule on MS-project or any other project management package for
total scope of this tender with the break up schedule of major activities considered for arriving
at completion schedule with critical path based on their experience on similar activities.

8.4 In addition to the above, the bidder can also give any other additional information (if necessary)
relevant to this tender.

All information/data as called for in this tender document must be submitted along with the
offer. The Purchaser reserves the right to seek additional information/data from the Bidder
during evaluation of the bid.

9 EVALUATION OF OFFER:

9.1 The tenderer shall ensure that all information / data as called for in this tender document are
submitted with the offer. The offer submitted will be evaluated by tenderer w.r.t. qualifying
criteria and other data/information asked in section-D of the tender.

10. GUARANTEE PERIOD:

The material shall be guaranteed in accordance GeM GTC.

11. DISCREPANCY CLAUSE:

In case any of the condition, testing, examination etc. Specified here with contradicts with
same w. r. t. technical specification or other specification, then technical specification will
govern the requirement.

12. PROPRIETARY CONDITION:

In case the bidder is not considered for this tender, the drawing and specification forming part
of this tender document downloaded by bidders being proprietary information, is prohibited for
use other than this tender purpose.

13. PRESERVATION AND PACKING FOR SHIPMENT:

 The bidder shall be responsible for preparing, preserving and packing of the pipes to prevent
corrosion and damage of any kind during shipment to destination and also during storage at
site.

14. DELIVERY PLACE:

All the items covered in this tender pertaining shall be delivered to

Manager (Materials),
Kaiga Generating Station -2
Karnataka
 Kaiga Generating Station -2
Annexure-1

List of Components for both the Unit of KGS-2 EMFR Program

[Link]. Item Qty (KGS-2) Applicable

(MTR.) Spec No
1.1 Feeder Pipe 32 NB 1447 PP-M-697 ( R-2)
1.2 Feeder Pipe 40 NB 2040 PP-M-697 ( R-2)
1.3 Feeder Pipe 50 NB 2705 PP-M-697 ( R-2)
1.4 Feeder Pipe 65 NB 1429 PP-M-697 ( R-2)

Note :
1. Purchaser reserves the right to obtain Price Break up to facilitate dispatch of items in
number of lots.
 Annexure-2
Format for submission of NCR

NUCLEAR POWER CORPORATIONOF INDIALTD

(AGovernment of India Enterprise)
NUCLEARPOWERCORPORATIONOFINDIALTD
(AGovernmentofIndiaEnterprise)DE
DESIGN CONCESSION REQUEST
SIGNCONCESSIONREQUEST
ConcessionRequestNo(USINo./SRNo)…….
APPLICATION FOR DESIGN CONCESSION
APPLICATIONFORDESIGNCONCESSION [Link]./[Link].----------------Date……….
Manufacturer/Contractor________________Component/System/StructureManf/Co
Purchase OrderNo. Date of PO
ntractor'sRefNo________________Spec/DrgNo___________________Equipment/
Sub. [Link].(Ifapplicable) Date
TagNo______________________Detail/ItemNo________________
( For package contract include allrelevant order details)
…………………………………………………………………………………………………………………DET
ConcessionRequest No (Proj./USINo./Sr No)
AILSOFPROPOSED
Manufacturer/Contractor
CONCESSION:(Thisshouldincludereasonsfordeviationsandcorrectiveactiontpreventrepetition–
enclosesketch,attachadditionalsheetifnecessary-SeeNote-1oftheback.
Component / System / Structure/Item
Manf/Contractor's RefNo Spec&DrgNo
Thisrequestdoes/doesnotinvolveachangeincontractprice________________________Estimat
Equipment/TagNo_
eCost________________
[Link] No
(Name,Signature&Date)Requestedby____________________
…………………………………………………………………………………………………………………
…………………………………………………………………………………………………
QUALITYSURVEYOR'SCOMMENTS (SeeNote-2ontheback)
a) Details of deviations and proposed concessions:

Name_________________________Original Signed_______________Date_____________
………………………………………………………………………………………………………………..
APPROVALOFINDENTER/FE/ED/CONSULTANT
b) Correlation with the relevant drawings / specifications (Attach relevant portions of
APPROVEDASNOTED REJECT
drawings(SeeNote-3ontheback)
or sketches and relevant portion of the specification wherever applicable)
NOTES:

Name,Signature&Date IndentingEngineer/FE
c) Reasons for occurrence ImmediateSuperior
of Non-conformance and root cause analysisACE/CE/HeadFE
…………………………………………………………………………………………………………………CLO
SINGOFDCRINCASEOF“APPROVEDASNOTED”:VERIFICATIONBYQUALITYSURVEYOROFMANUF
ACTUTRER/CONTRACTOR/QANPCIL.

Allstipulationsinconditionalapprovalmet?
d) Corrective action proposed to avoid Yes/No
recurrence
IfNo,defectiveitemrepaired/rejected. Ifrepaired,newDCRNo……………

e) Cost implication :This requestManufacturer/Contractor

(Name,Signature&Date) does/ does not involve a change inQANPCIL
contract price
………………………………………………………………………………………………………………
Distribution
f) Cost reduction proposed from Purchase Order value Rs.
CONSTRUCTION
IndentingGroup/DesignEngineer
RequestBy:
ConcernedConstruction___________QualitySurveyor___________
CE(QA) _____________Manufacturer
___________ ACE(FE).____________
Designation

(Name,Signature,Date&Seal)
………………………………………………………………………………………………
QUALITYSURVEYOR'SCOMMENTS
1. All relevant inspection reports/test reports attached Yes / No
2. All the deviations are identified and included Yes / No
Page1 of3
3. Analysis / Technical comments of QS engineer on proposed DCR

(Name,Designation,Signature&Date)
……………………………………………………………………………………………...
Tickasapplicable:

There is no financial implication to NPCIL by acceptance of this deviation

(Refer para8.0 of the Procedure) .

Cost implication/reduction as worked out by the manufacturer is justified.

Justification appended.

NCR Forwarded with comments/Technical justifications to Design Group for

concurrence

NCR Checkedby

Indentor/Project Engineer/Field Engineer

(Name,DesignationSignature&Date)

---------------------------------------------------------------------------------------------------------------------------------

Designers concurrence: Acceptance of the DCR will affect/ not affect the design
intent. Technical justification is appended.

NCR Concurred/ Not Concurred

(Name,Designation,Signature&Date)

To
Indentor/ProjectEngineer/FieldEngineerforfurtherprocessing
Page2of3
 APPROVAL/REJECTIONOFDCR:

Tick as applicable:

Design intent is not affected. Justification for acceptance appended with the DCR.
Financial implication as brought out in page 2 of3 of this format is approved.

Deviations are accepted after detailed calculations, analysis. Justification for

acceptance of the deviation is attached with this DCR. Financial implication as
brought out in page 2 of 3 of this format is approved.

No other System/Assembly/component(of other USIs) is affected by this

deviation

List of system/components/assemblies(of other USIs) affected by this deviation

and the concurrence from the concerned design group is appended.

APPROVED APPROVEDASNOTED REJECTED

NOTES:

Reviewedby Approvedby

(Name,Designation,Signature&Date) (Name,Designation,Signature&Date)

Note: All the signatories shall have valid Technical Authorization (referED-Proc.-60)
------------------------------------------------------------------------------------------------------------
---------------------CLOSING OF DCR INCASE OF“APPROVED AS NOTED
(TECHNICAL REASONS)/REJECTED ”DCRs : VERIFICATION BY QUALITY
SURVEYOR OF MANUFACTURER / CONTRACTOR / QA NPCIL.
All stipulations in conditional approval met ? Yes/ No
If No, defective item rejected………………………. If repaired, new DCRNo……………

(Name,Signature&Date) (Name,Signature&Date)
QA of Manufacturer/contractor QA NPCIL
………………………………………………………………………………………………………
…………
Page3of3
…………..
Distribution
[Link] Group
2. DesignGroup
3. Consultant_
4. QualitySurveyor
5. Contractor/Manufacturer
6. Hist. Doc
Supply – 1 Section – C Page 16 of 16