GOVERNMENT OF INDIA
DEPARTMENT OF ATOMIC ENERGY
DIRECTORATE OF PURCHASE & STORES
Separate item wise sealed tenders are invited from the reputed
manufacturers/dealers/also from firms registered with DPS/DGS&D/NSIC or
any other Central Government Department, BY THE REGIONAL DIRECTOR, MADRAS
REGIONAL PURCHASE UNIT, DIRECTORATE OF PURCHASE AND STORES, DEPARTMENT OF
ATOMIC ENERGY, VI FLOOR, SHASTRI BHAVAN, 4 HADDOWS ROAD, CHENNAI- 600 006,
for the supply at Central Stores, HWP, Tuticorin/Indira Gandhi Centre for
Atomic Research, Kalpakkam- 603102, as detailed below.
TENDER COST LAST LAST DATE EMD SPECIFICATION AND
NO OF DATE DATE OF (INR) QUANTITY
TEN FOR FOR OPENI
DER SALE RECEI NG OF
(INC OF PT OF TEN
LUSI TENDER TENDER DER
VE SET (1300 (1100
OF HRS) HRS)
DPS/ 735 24/10/ 17/11/ PART-I 320000 Linear Auto Sampler
MRPU/ 11 11 18/11/ Systems – 4 Nos.
FAB/ (Detailed specification
1309/ PART-II and quantity are given
TPT- 30/12/ in the tender document
1014 which can be purchased
Unit, Department of
Atomic Energy, VI
Floor, Shastri Bhavan,
4 Haddows Road, Chennai
600 006 by paying the
cost of the tender)
The Documents priced as above can be obtained in person from the above
address between 10.00 a.m. And 1.00 p.m. on all working days on
submission of a written request in the firm’s letter head along with an
account payee DEMAND DRAFT or Banker’s cheque drawn in favour of Deputy
Controller of Accounts, Madras Regional Accounts Unit (no MO, cash or
postal order acceptable), payable at Chennai. Wherever the tender
documents are required to be sent by Post at Vendor’s risk, a written
request for the same along with an Account Payee Demand Draft towards the
tender fee, shall be sent to the Deputy Controller of Accounts, Madras
Regional Accounts Unit at the above address indicating the details of the
tender No., Name and address of the firm on whose favor the tender
documents are to be issued. It must be ensured that such request should
be sent in advance to reach this Directorate at least 10 days prior to the
last date for sale of tender.
Page 1 of 79
The envelope should be super scribed with the wordings “Request for issue
of tender document against Tender No._________________”.
Alternatively prospective bidders can download the set of Technical
Specifications along with the, instructions, terms and conditions, from
the web link mentioned below and submit the completed format along with
applicable tender fee, EMD and all applicable documents much before the
due date of tender opening. However in the case of two part tenders,
bidders can submit their Part-I and Part-II offers in separate covers
(size: S-8) in different colors, in sealed envelopes/wrappers, by clearly
and legibly super-scribing the appropriate Part Number of their offers in
bold letters and the covers have to be kept in a single cover which
is also to be super-scribed with TENDER REF No. & DUE DATE, and submitted
Link for downloading Standard Tender Annexure:
For all indigenous contracts FORM DPS-P 11 and for all Imported contracts
FORM DPS-P.12 may be downloaded as the case may be from
The tenderer shall submit along with the tender, Earnest Money Deposit
(EMD) as mentioned above in the form of Demand Draft or Banker’s Cheque
from any Nationalized / Scheduled Banks drawn in favor of Deputy
Controller of Accounts, Madras Regional Accounts Unit, Chennai. Any offer
not accompanied with the EMD shall be rejected summarily as non-
responsive. The EMD of the unsuccessful bidders shall be returned within
30 days of the end of the bid validity period. The same shall be forfeited
if the tenderers withdraw their offer after the tender opening during the
bid validity period. The Government shall not be liable for payment of any
interest on EMD or any depreciation thereof.
However, those who have valid registration with DGS&D, NSIC or DPS as on
the date of submission of bids are exempted from payment of EMD.
Brief information about our public tender is also available at
For terms and conditions, instructions please visit
REGIONAL DIRECTOR, MADRAS REGIONAL PURCHASE UNIT HAS THE RIGHT TO REJECT
ANY OFFER IN PART OR IN FULL WITHOUT ASSIGNING ANY REASON.
Page 2 of 79
ANNEXURE TO TENDER NO. DPS/MRPU/NRPP/FAB/1309/TPT-1014
Description of Item: Detailed design, preparation of fabrication drawings, collection of free
issue materials, procurement of all materials other than FIM, fabrication,
machining, assembly, testing, safe delivery, installation at site, final
testing and commissioning of Linear Auto Sampler Systems. Qty – 4 Nos.
Note: Bidders desired to respond for this tender are requested to intimate
their contact details well in advance to our email id: firstname.lastname@example.org,
email@example.com, firstname.lastname@example.org, email@example.com
for prebid meeting before opening of Part I.
This specification covers the requirements for takeoff of free issue material as per
procedures, procurement of non–FIM, inspection, testing, certification, fabrication,
machining, assembly & testing of Linear Auto Sampler systems. The Linear Auto Sampler
system consists of the M.S. shielded enclosure housing the Linear Auto Sampling unit along
with supporting structure, motors with drive units & PLC programmed to perform sampling
Four nos. of Linear Auto Sampler system shall be supplied, installed, tested and
commissioned at Project P3-A, Kalpakkam. Fabrication, assembly, testing, installation and
commissioning shall conform to the approved drawings and specifications laid down by the
purchaser. Four Auto sampler units along with shielded enclosure with M.S. enclosure of 150
mm thickness called as MA enclosure along with control units (PLC).
2. GENERAL DESCRIPTION:
Process solution sampling is an essential requirement for tracking the process parameters.
Stainless steel tanks which hold process solutions are housed in concrete shielded cells.
Process solutions from these tanks are sampled with vacuum assisted air lift operated
sampling system. Two lines which are known as uptake line and return line (1/4” Sch 40 SS
304L pipes) one for drawing liquid sample from the process tank to the sample bottle and the
other for returning the liquid to the process tank (recirculation), are laid from the process
tanks to the sampling gallery through the heavily shielded concrete cell walls. The sampling
uptake and return lines emanate from cell wall through a rectangular cut out in cell wall. The
sampling galleries are situated in floor-2 & floor-3 of P3-A process building. Two units each
shall be installed in each gallery. The uptake and return lines enter the M.S. shielded
enclosure and are connected to an angle plate mounted on the rear plate of the enclosure.
Sampling blocks also called needle blocks are fixed on this angle plate. Each sampling
enclosure has 10 nos. sampling blocks. The sampling block has two needles fixed to the
block. Each sampling block is dedicated to a particular tank. The M.S. shielded enclosure
shall be installed abetting the cell wall. The shielded enclosure houses the Linear Auto
2.01 DESCRIPTION OF LAS SYSTEM:
The Linear Auto Sampler system has mainly three components viz. a shielded enclosure,
Linear Auto Sampler Unit & Control Unit. The shielded enclosure which houses the sampling
unit shall be manufactured from M.S. plates. The enclosure shall have carbon steel walls
lined internally with 3 thick SS 304L plate. One enclosure called the MA enclosure shall have
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all walls, except the rear-side wall, made of 150 mm MS plate. The rear wall shall be made of
20mm thick MS plate. Two enclosures called the LA enclosures shall have all walls, except
rear wall, made of 50 mm thick MS plates. The rear wall shall be made of 20 mm thick MS
plate. The rear plate shall have a cut out for accommodating ¼” N.B. Sch. 40 SS 304L pipes
(20 Nos.). These pipes shall be given as FIM. The Needle blocks which are supplied as FIM
shall be fixed on the rear wall on Needle clip support plate. Supply manufacture and
installation of the needle clip support plate shall be in the scope of the vendor. Twenty nos.
¼” NB Sch. 40 pipes shall be welded to the needle block support plate as shown in drawing.
The needle block support plate shall support 10 nos. needle blocks. Needle block placement
i.e. locations of the needles shall be correct within 0.1 mm. Each block shall have two ¼” NB
Sch. 40 pipes (welded to the support plate as indicated above), one called the uptake line
and the other called return line. All the sample uptake and return lines shall enter the cut out
from the rear wall and extend through the cell wall behind the enclosure into the cell at 15
deg. angle. These pipes shall be introduced inside the cell through cell wall nitch. Shielding
door is provided on the front face of the enclosure to house radiation shielding window. RSW
will be given as FIM to the vendor for fixing on the door at site. Supply and fixing of all
fasteners (S.S.) for this purpose shall be in the scope of the vendor. Stepped openings with
M.S. shielded plugs for introducing lighting fixtures are provided, one each on either side of
radiation shielding window on the top block. Internal faces of the enclosure, M.S. shielded
plugs, inside face of the front door and the front face of the enclosure which is in contact with
the door shall be lined with 3 mm thick SS 304L plate. The enclosure shall be supported on
the concrete platform with proper supporting. The enclosure shall have a drain tray with
proper slope at the bottom to collect and to drain the spilled liquid. The drain nozzle of tray
which protrudes out of the bottom block shall be of 1” NB size shall be extended upto 2 meter
length and shall be introduced into the cell through the hole provided in the cell wall at a
specified angle. The vendor shall review the site conditions and plan the installation work,
welding of pipes as required for installation. The bottom block shall have 40 NB sample
delivery pipe extended upto 300mm length. The top block of the enclosure is provided with
stepped shielded plugs just above the needle blocks. The shielded plugs are meant for
manual intervention in the case of maintenance on sampling blocks. The top block shall have
40 N.B. pipe for feeding the sample bottles to the auto sampler unit. The linear auto sampler
box shall be inserted from the side blocks of the enclosure and shall slide and get supported
on 25 mm thick square block rails of 725 mm length fixed on the front and back face internal
walls. The auto sampler unit shall be locked in position after sliding in. The locking
arrangement shall be easy to operate preferably from outside the enclosure. Provision for
mounting of motors for operation of Linear Auto Sampler on the sidewalls at specified
location shall be made. Adequate compensating shielding shall be provided at places where
E.Ps. are penetrating the enclosure wall.
2.1 ENCLOSURE DETAILED DESCRIPTION:
The Enclosure shall have six walls viz. Back wall, Front face, Bottom block, Top Block, L& R
Side blocks. All the six walls shall be dowel pins at suitable locations for assembling the
enclosure. Dowel pins shall also be provided for parts having relative motion for fixing to the
ground i.e. respective plates.
2.1.1 Back Wall: The back wall of the enclosure shall be 20mm SS 304L plate. The back wall shall
hold needle clip support plate & supporting square block rails for Linear Auto Sampler unit.
This back wall shall have a rectangular slit of 605mm x 100mm. The enclosure shall be
installed abetting the cell wall. The cell wall shall have 5 nos. of 75 mm dia holes with SS
pipe sleeve inserted into the holes. The slit in the back plate shall match with these holes. A
pad plate 3 mm thick having matching 75 mm holes shall cover the rectangular slit in the
back wall and the sleeve pipes shall be inserted in these holes and seal welded to this pad
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plate during installation. The pad plate in turn shall be seal welded with the back plate. The
supplier shall however counter check the actual dimensions and EP positions at site.
2.1.2 Front Face: The front face of the enclosure shall have stepped opening as shown in the
drawings to house a hinged door. This hinged door shall have locking arrangement. A
radiation shielding window is housed in the hinged door. RSWs will be given as FIM for
installation at site. The internals of front face & of the door shall be lined with 3 mm thick SS
304L plate. The Front face internal wall shall have SS 304L 25 thick Sq. supporting flat of
725 mm length welded at appropriate location for supporting Linear Auto Sampler unit. This
rail shall be aligned and leveled with the rail mounted on the back wall.
2.1.3 Bottom Block: The enclosure bottom shall have a drain tray preferably formed from 3mm
thick SS 304L plate and shall have a skirting of 35 mm height on all sides. A 1” N.B. bottom
drain nozzle shall be provided with pad plate to the bottom tray at the specified location.
Drain nozzle shall be fabricated from SS 304L forged bar as per the drawing attached. The
bottom nozzle length shall be extended suitably by welding an extra pipe. This weld on tray
shall be D.P. tested and a defect free weld shall be obtained. Any welds on the tray shall be
DP tested / radiographed / vacuum box tested, as the case may be. The drain shall have a
sieve plate cover press fitted over it by tack welding inside the drain nozzle. The bottom
shielding thickness shall be suitably added on to the tray to compensate for loss of shielding
at the drain point & drain line. Enclosure side face linings shall be welded to the tray. The
vertical joints of internal lining shall be D.P. tested. The bottom block shall also have 1 ½”
N.B. S.S. 304L pipe of 300 mm length protruding out of the enclosure for bottle delivery. The
bottom block shall have rectangular raised portion at delivery pipe location as indicated in the
drawing. The Bottle delivery pipe in the linear auto sampler shall not protrude below the
linear auto sampler unit bottom. The delivery pipe further to the liner auto sampler unit shall
be separate and with a provision of pressing from bottom of the enclosure for sealing against
leakages as indicated in the drawing.
2.1.4 Top Block: The top block of the enclosure shall have one No. 1 ½” N.B. Sch. 40 SS 304L
E.P. for feeding sample bottles at the specified location. This bottle feeding chute shall have
locking mechanism with an input to PLC and proximity switch to sense the bottle feed. The
top block shall have lining of SS 304 L plate of 3mm thickness on the inner face. A
rectangular cut out shall be made to accommodate stepped shielding blocks for manual
maintenance. Stepped shielding blocks of different configurations to curtail radiation
streaming shall be located on the top block as given in the drawing. The internal faces of
these shielding blocks are also lined with 3 mm thick SS 304L plate. Cut out for housing
these stepped shielding blocks shall also be lined with 3 mm thick SS 304L plate. These
stepped shielding blocks shall be machined after SS lining for achieving snug fit into the
groove provided on the top block. Circular stepped openings on either side of the
rectangular cut out shall be provided for fixing illuminating fixtures. Supply, installation of
illuminating fixture and bulb shall be in the scope of the vendor.
The top outer face of the enclosure shall have 5 thick box type M.S. cover and this cover
shall have channel section at the resting place. This channel section shall have 6mm thick
rectangular groove to accommodate neoprene gasket for sealing. The box cover shall have
fixing arrangement. Wing nut fasteners shall be used for fixing the cover. The cover shall be
fixed on the stepped shielding blocks. This cover shall also have 3 thick neoprene gasket for
2.1.5 Side Blocks: The Left and Right sidewalls shall have stepped cut outs for insertion of Linear
Auto Sampler unit. The cut outs shall be covered by stepped shielding blocks having suitable
holes with bushes to accommodate the shafts of the LAS. These stepped shielding blocks
shall be fastened to the side blocks. This stepped shielding block shall have rectangular
groove with neoprene gasket for sealing. The left hand side-shielding block shall have
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support frame for the drive motors & sensors. The external face of sidewall shall also have
box type covers (doors openable) for the motors on RH side and for sensors on LH side.
2.1.6 Lining: The enclosures shall be lined with 3 mm thick S.S. 304L sheet on internal faces.
Adequately sized SS plates shall be welded at support locations for taking the concerned
load. The lining shall be seal welded to these support plates on all sides to maintain integrity
of the lining. The inner surface of the enclosure door and the front external surface of the
enclosure shall also be lined with SS 304L plate. SS lining of 3 mm thickness, on all walls
except drain tray. The drain tray shall be made from 5 mm thick SS 304L plate and shall be
welded to make a leak tight SS box. The integrity of the complete lining of the box shall be
ensured by D.P. testing. It should be ensured that no air pockets are left during lining;
adequate plug welding may be resorted to.
2.1.7 The Linear Sampling Unit: The Linear Auto Sampling (LAS) unit shall be of all S.S.
construction. The unit shall be slid into the enclosure through the side wall opening and
mounted and locked in place on S.S. rails fixed to the front and back walls of the enclosure.
The unit consists of a linear movement mechanism (S.S. Ball screw & carrier nut) driven by
drive motor. The carrier nut of the ball screw is fixed to the bottle holder. The ball screw when
driven by drive motor moves a bottle holder cup to the desired location. The carrier nut
connected to the bottle holder shall have anti rotation guide for achieving linear movement of
the bottle holder on ball screw. The ball screw shall be fixed with stainless steel bearings on
either side at support locations in LAS unit. The cup is normally parked at the bottle loading
station also referred to as home position under the loading chute. There are 12 positions of
the cup. The first position of the cup is the loading station, followed by ten sampling point
positions and the last being the bottle delivery port position. All the above positions are 52
mm apart. A bottle-loading chute is aligned with the bottle loading station and protrudes out
of the enclosure for ease of bottle loading. The bottle delivery chute is aligned with bottle
delivery location and protrudes out of the bottom block of the enclosure. The deliver chute
shall have closing cover inside the LAS unit. This closing lid shall be operable by carrier nut
movement. The lid shall start opening when the bottle holder reaches 9th sampling position
and shall get completely opened after reaching 10th sample position. The lid shall start
closing once the bottle holder reaches 9th sample position and get completely closed on
reaching 8th position. The lid shall be spring loaded for this purpose. The needle blocks are
mounted on an angle plate fixed on the back wall such that the needle blocks are aligned
with sample positions 1 to 10. The LAS unit also consists of a lifting mechanism shaft driven
by a drive motor. The lifting mechanism consisting of cams mounted on this shaft, which
pushes the bottle holder cup, aligned above it for piercing the bottle with the needles
attached to the needle blocks. There shall be 4 cams mounted on the lifting mechanism
shaft. One each on either end i.e. below 1st sample block position and 10th sample block
position, the remaining two shall be equidistantly placed fro the centre. The LHS side of
these shafts shall have a provision for engaging handles for manual operation. Fabrication,
testing and supply of these handles with every unit shall also be in the scope of the supplier.
2.1.8 The Drive units: The drive units for the LAS unit consist of drive motors of suitable torque
rating one for linear movement and the other for lifting mechanism. An encoder is mounted
on the linear movement shaft for providing feedback on the physical position of the cup. This
also gives a positive feed back for home position. An additional positional sensor to sense
the proximity of a pin pushed by the cup when it reaches the home position is provided as a
home position indication. A positional sensor is provided to sense the position of the lifting
mechanism. All the drive unit components, sensors and electrical connection shall be
installed out side the shielded enclosure.
2.1.9 Door covers for LH & RH externals: Box type open able covers shall be provided for
RH side block of sampling blister for covering Drive units & LH side for covering sensors.
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This door shall have wing nut type locking arrangement to the sampling enclosure. The LH
side box type cover shall have arrangement for holding handle for manual over ride operation
of the drive shafts in case a need arises.
2.1.10 The programmable Logic Controller: Two Reliable PLCs with suitable number of I/Os shall
be programmed to perform all the functions of sampling of two units each. The PLC shall be
programmed to generate error signals like Not in HOME position, Misalignment, Power
Failure, and Lifting Mechanism UP & NO Bottle. The PLC shall also have suitable Relay
cards for driving the system. The steps, feed backs, trips & error conditions to be generated
by the Programme shall be communicated by the purchaser. The PLC shall be amenable to
modification and augmentation. The vendor shall train the purchaser for programming the
PLC & also for incorporating changes in the Programme.
The unit shall have adequate number of feedbacks & trips for safety of the system. It shall
have a zero finder facility for alignment & reliable operation. There shall be a dump cycle
provision. This is necessary in any error operation condition of the unit. During dump cycle
the bottle holder shall move initially to home position check for alignment then move to
delivery station, deliver the bottle, return back to home position and show cycle complete
indication. The unit shall have safety locks on the bottle-loading chute for tamper proof
operation. It shall have facility to introduce only one bottle per operation. Detailed description
of PLC is given in the attached APPENDIX-P.
2.1.11 Operating panel: The vendor shall provide a sleek, elegant & sturdy operating panel with all
controls and LED indications. Indication for various steps in operation shall be available on
the panel. The panel shall be lockable. All error signals shall be indicated on the panel. The
panel shall be wall mounted / self supporting type. There shall be two panels, one panel each
shall be installed in both galleries. An attachable pendent shall also be supplied for
maintenance of the unit. This pendent shall over ride the normal operations. This shall have
provision for selecting required operation i.e. dump cycle, movement of bottle holder to
desired location, operation of lifting mechanism etc.
Machining, fabrication, and assembly of heavy M.S. shielded enclosures, manufacture of
Linear Auto Sampling unit, support structures, take off of free issue material as per
procedures, procurement of non–FIM including drive motors, Drive units, PLC, Programming
of PLC as per purchaser’s requirement, encoders, positional sensors & panels, inspection,
testing, packaging, supply, installation at site & commissioning of the LAS Units shall be in
the scope of the vendor. The Sampling circuit piping in-side the cell shall not be in the
vendor’s scope. Weld connections of the up-take, return lines & the drain line emanating
from the shielded enclosure upto introducing these lines into the cell shall be in the scope of
the vendor. This amounts to twenty nos. ¼” Sch 40 pipe welds and one no. 1” N.B. sch. 40
pipe weld. The sampling uptake and return lines shall be fillet welded to the needle clip
support plate. These welds shall be fillet welds. In case it is not possible to directly extend
the pipes from needle clip support to in-side cubicle in one length of pipe any butt welds thus
arise in between shall be radiographed all these welds are field welds this point shall be
noted by the vendor. The radiography of these welds shall be in the scope of the vendor.
Fixing of RSWs in the shielded enclosure windows, installation of wall plate & support
structure as required as per site conditions shall be in the scope of the vendor.
The wiring of the unit in “ready to plug in” condition along with detachable maintenance
pendent & the certification of non-FIM material shall also be in the scope of the supplier.
Fabrication, assembly, testing, installation and commissioning shall conform to the approved
drawings and specifications laid down by the purchaser. Supply & installation of appropriate
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illuminating fixtures along with 24 watts CFL bulbs two nos. for each shielded enclosure for
ready to plug in & use shall be in the scope of the vendor.
FIM shall be as per the list attached. Take off of the FIM shall be governed by the DPS
4.0 REFERENCE DRAWINGS:
The purchaser shall furnish basic design drawings/ sketches. The vendor shall prepare
detailed fabrication drawings. The drawings shall be complete with all details of fabrication
and welding. The list of reference drawings for this purpose is given below:
Sr. TITLE Drg. No.
1. SHIELDING BLOCK ASSEMBLY FOR MEDIUM A2/NK.04.01.02.62.
ACTIVE ENCL. (150 THK.) GA/R0
2. DETAILS OF MEDIUM ACTIVE ENCLOSURE A1/NK.04.01.02.63/DD/R0
INTERNALS SH EET 1 OF 2
3. DETAILS OF MEDIUM ACTIVE ENCLOSURE A1/NK.04.01.02.63/DD/R0
INTERNALS SHEET 2 OF 2
4. LINEAR AUTO SAMPLER UNIT ASSY. A1/NK.04.01.02.64 GA/R0
5. LINEAR AUTO SAMPLER UNIT (DETAILS). A1/NK.04.01.02.65/DD/R0
6. DRAIN LINE FOR TRAY A4/NK.04.01.02.66/DD/R0
4.1 The supplier shall get the fabrication drawings approved from the purchaser before
commencement of the job. The supplier shall incorporate changes or modifications as
deemed advisable without affecting the functional requirements. Such changes shall be
intimated to the purchaser and written approval shall be taken before commencement of the
4.2 The dimensions of the Shielding block assembly and linear auto sampler unit may vary as
per manufacturing requirements. The vendor shall take this into consideration while quoting.
4.3 The supplier shall be responsible and bear the cost of any alteration of works due to any
errors or omissions in the drawings or other particulars supplied by him, whether such
drawings or particulars have been approved by the purchaser or not. The vendor shall supply
all design details, fabrication & machining drawings, as built drawings, all technical details of
Non-FIM, in three hard copies, All manufacturing drawings will complete dimensional details
and final approved drawings shall be submitted in A Cad format.
5.0 FABRICATION PROCEDURE & QA PLAN:
5.1 Single thick or composite plates shall be used for fabrication of all machined shielded
enclosure. In case of composite plates being used the welding shall be staggered, at least
2/3rd of the thickness shall be available at all places for shielding. The blocks shall be
accurately step machined to achieve fit up without gaps. This fit up shall be approved and
witnessed by the purchaser before welding.
5.2 A stepped hole for insertion of the LAS unit shall be made on both the side walls of the
enclosure these holes shall be exactly in line to accommodate the shafts of the LAS. Hence it
is required to machine both the sidewalls and the cut outs in a single operation. These
blocks shall be fixed to the sidewalls with adequately sizes counter sunk grub screws. The
motor supports shall be mounted to achieve accurate alignment between the LAS shafts and
the drive motor shafts. The motors shall be coupled to LAS shafts with splined couplings.
The supply and installation of couplings shall also be in the scope of the vendor. A Cut out
for accommodating stepped shielding blocks on the top block shall be accurately machined.
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5.3 The Front wall shall have a smoothly opening hinged door, which shall house a radiation-
shielding window. A dummy of the RSW shall be made for testing the cut out made in the
5.4 The encoder & sensors shall be rigidly mounted on the LAS. The encoders and sensors shall
be of reputed make. These shall be sturdy and reliable in operation.
5.5 A panel of suitable size shall be made to accommodate the PLC, Relay cards, drive units,
terminal blocks etc. Various indications and error signals shall be displayed with LEDs on the
door of the panel.
5.6 Manufacture of enclosures shall be done in strict accordance with the procedures and QA
plans. Installation of the enclosures at the suppliers works with wiring; accessories and
supports shall be done as per instructions from the purchaser. Each enclosure with
installation of internals shall be inspected, checked for smooth functioning and cleared
individually before shipment. All the internals shall be dismantled, labeled and packed for
5.7 The vendor shall fabricate, assemble, test, inspect and deliver all items safely to the stores at
the site as per the final approved design & specifications.
6.0 FABRICATION OF SHIELDING BLOCKS:
6.1 Shielding blocks shall be all machined and fabricated preferably from single thick plates. In
case use of single thick plate is not possible then optimum number of laminations and weld
joints shall be made to meet the shielding requirement considering weld joints as radiation
leakage path. Plug welding shall be done for shielding block fabrication. The joints on the
laminations shall be staggered so as to avoid leakage of radiation. After fabrication at least
two third of the block thickness shall be available for shielding at any given point. Fabrication
scheme showing laminations and weld details shall be submitted for approval before
fabrication. The inside faces of the enclosure shall be lined with 3 mm thick SS 304L sheet
as shown in the drawings. The blocks shall have a suitable stepped design to facilitate
interchangeability and to avoid radiation streaming. Plano miller shall be employed for
manufacture of the shielding blocks.
6.2 Dimensions marked in the drawings are finished dimensions. Sufficient machining allowance
shall be provided during fabrication. All sharp edges shall be rounded to a minimum radius of
6.3 Cutting of SS plate shall be done by mechanical shearing or plasma arc cutting. In case of
plasma arc the heat affected zone i.e. 15 mm from the cutting face shall be removed by
mechanical means before utilizing the plate for production purpose.
7.0 FABRICATION, MACHINING AND ASSEMBLY:
7.1 Shielded Enclosure:
7.1.1 Vendor shall ensure that unit plate shall only be used in the assembly. The machining
allowances for final machining shall be clearly indicated. The vendor shall indicate the
design, size and grid for plugs welded for sandwiching of the plates.
7.1.2 Procedures and practices for on-line inspection and documentation of the dimensional
tolerances shall conform to high standards.
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7.1.3 Components of hinges and brackets of the doors shall be machine manufactured to ensure
smooth functioning of the heavy doors. Bearings shall be provided for the hinges to achieve
smooth operation of the front door. The complete fabrication procedure shall ensure smooth
and easy opening and closing of doors after enclosure assembly. All mating surfaces shall
be dowelled together.
7.1.4 The fabrication of the enclosures will involve handling and machining of thick M.S. plates.
The vendor shall ensure machining thick plates to make square faces & square/ rectangular /
round openings. The vendor shall have facility for lining M.S. with S.S. The vendor shall have
a facility and skilled manpower for welding of thick MS plates and executing the SS lining
7.1.5 Stepped openings for accommodating viewing windows on the front door shall be tested for
dimensional accuracy. Viewing windows shall not be supplied to the vendor’s site, as they
are fragile. The vendor shall make dummy pieces for window for testing the correctness of
the openings in the shielded structure. The dimensions and other details of the dummies to
be fabricated by the vendor shall be provided by the purchaser.
7.2 Linear Auto Sampler Unit:
7.2.1 Linear auto sampler unit is a box structure manufactured in all Stainless steel construction of
approximately 150mm width x 725 mm length x 175 mm height.
7.2.2 Front panel plate shall be of 10 thick SS 304 plate of 165 mm width x 715 mm length. This
plate shall have a groove of 15 mm width x 650 mm length x 3 mm depth. A trapezoidal bar
as shown in the drawing shall be screwed at suitable intervals for anti rotational lock of
carrier nut in this groove. This trapezoidal block shall have ground finish. Six nos. SS 25mm
cubic blocks on top and bottom with suitable tapings shall be welded to this front panel plate
for fixing the top and bottom panel plates & side panel plates. There shall be 10 mm width x
5 mm depth groove for complete length on four sides of front panel plate. This groove shall
house top panel plate, bottom panel plate & side panel plates.
7.2.3 Rear panel plate shall be of 10 thick SS 304 plate of 165 mm width x 715 mm length. This
plate shall have four grooves of 15 mm width x 105 mm length x 3 mm depth in which a
trapezoidal bars as shown in the drawing shall be screwed at suitable intervals for movement
of bottle holder. This trapezoidal block shall have ground finish. Six nos. SS 25mm cubic
blocks on top and bottom with suitable tapings shall be welded to this rear panel plate for
fixing the top and bottom panel plates & side panel plates at suitable locations. There shall
be 10 mm width x 5 mm depth groove for complete length on four sides of rear panel plate.
This groove shall house top panel plate, bottom panel plate & side panel plates.
7.2.4 Top panel plate shall be of SS 304 plate. This shall be of C shape of major length 715 mm &
minor length 525 mm. the leg lengths shall be 85mm & 115 mm length each as shown in
drawing. The web width shall be 150mm length. This plate shall be fixed to back & front
panel plates and side plates as shown in the drawing. A hole for inserting 1 ½” N.B. bottle
feed pipe shall be provided on the left hand side of this plate at specified location as shown
in the drawing.
7.2.5 Bottom panel plate shall be of 10 mm thick SS 304 plate of 150 mm width x 715 mm length.
The bottom plate shall be screwed to front panel plate, rear panel plate, and side panel
plates. A hole for inserting 1 ½” N.B. bottle delivery pipe shall be provided on the right hand
side of this plate at specified location as shown in the drawing. The bottle delivery pipe shall
be welded to bottom plate. A 6mm deep groove of suitable O.D. for housing gasket shall be
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provided on the bottom side of the bottom plate. The gasket shall be of EPDM in ‘O’ ring
7.2.6 Side panel plates shall be of 10 mm thick x 150 mm width x 175 mm height. The side panel
plates shall have four nos. SS 25mm cubic blocks on all four sides with suitable tapings
welded to these side panel plates for fixing the top and bottom panel plates & front and rear
panel plates at specified locations. There shall be 10 mm width x 5 mm depth groove for
complete length on all four sides. This groove shall house top panel plate, bottom panel
plate, rear plate and front plate. There shall be two holes for introducing linear movement &
lifting mechanism drive shafts. Bearing housings with bearings and proper sealing shall be
mounted external to this plate at shaft locations.
7.2.7 Lead Screw: Stainless steel 316 lead screw shall be provided for linear movement of the
bottle holder. A 40 mm dia lead screw shall be of stainless steel and shall be of sufficient
7.2.8 Lead nut: A stainless steel lead nut shall be mounted on the lead screw. The lead nut shall
have a trapezoidal groove for anti rotation lock. A cup holder shall be fixed to this lead nut.
7.2.9 Bottle holder: A stainless steel bottle holder (Cup) shall be mounted in the cup holder. The
bottle holder shall be 63.5 mm height (incl. flange) x 37.5 mm I.D. x 43.5 mm O.D. This shall
have a flanged end of 49.5 mm O.D. & 37.5 mm I.D.
7.2.10 Crank Assembly: There shall be four stainless steel crank assemblies installed on lifting
mechanism shaft in the LAS unit. The crank assembly shall have six parts viz. bottom
bracket, top bracket, bottom link, top link, pin for connecting bottom and top link and pin for
connecting top link and top bracket. The bottom bracket is fixed to the bottom plate at
specified locations. The top bracket is fixed to the lifting channel at specified location.
7.2.11 Lifting channel: The lifting channel shall be made of stainless steel 304 material. The lifting
channel shall be of ‘C’ section, having a length of 520mm. The rear portion of the web shall
have trapezoidal slots for a length of 110mm at four locations to accommodate trapezoidal
bars fixed to the rear panel plate. The opening of the web portion shall be 62.5 mm. The
internal top portion of the web shall have 4 mm slot through out the length. The external
bottom portion of the web shall be fixed to lifting hook top brackets. All dimensions shall be
as per the drawing provided.
7.2.12 All mating surfaces and parts which are having relative motion such as lifting mechanism
components, bearing housings, LAS wall shall be dowelled in assembly.
7.2.13 Special purpose machines like plano-miller, CNC turning center, Horizontal boring, slide way
grinders, shall be employed for the manufacture of precision parts of the auto sampler like,
guide-ways, cam parts, lead screws, LAS box, bottle holder etc. The vendor shall have all
these facilities in house and this point shall clearly mentioned in the offer.
8.0 APPLICABLE STANDARDS & CODES:
ASME Section II Materials
ASME Section V NDT
ASME Section IX Welding Qualification
ASTM A 240 Grade 304L Stainless Steel Plates
ASTM A 312 Grade 304L Seamless SS Pipes
ASTM A 371 Grade ER 308L SS Filler wires
ASTM B 297 Tungsten Electrodes
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ASTM A 233 Grade E-7018 Covered electrodes for MS welding
ASTM A 262 IGC test
ASTM E 165 Liquid Penetrant Examination
BS 970 EN 36 Case Hardened CS pins
ASTM A 516 Grade 70 MS plates
IS 808 MS Structural angles
IS 816 Metal arc welding in MS
ASME SFA 5.9 ER 308L Welding filler wire
ASME Sec.III Class ND (with Equipments supplementary requirements for
class A & B Equipment/ Components)
ASME Sec.VIII Div.1 Equipments
ANSI B 31.3 Piping
ASTM A 380 Cleaning of S Steels
ASTM E 1003 Hydrostatic testing
ASTM A 370 Mechanical testing
ASTM E 112, E 45 Grain size and inclusion control
ASTM E 30 Chemical analysis of steel
9.0 MATERIAL OF CONSTRUCTION:
The material of construction for enclosure walls shall be IS 2062 with internal walls lined with
3 thick SS 304L plate. The material of construction of the LAS unit shall be SS 304 / SS 304L
(as welded). The lead screw shall be of SS 316 with smooth surface finish, minimum
backlash & shall be machined true to its complete length. The bearings of LAS unit shall be
of SS 440 C. The loading and delivery chutes shall be Sch 40 SS 304L 40 N.B. pipes.
10.0 GENERAL REQUIREMENTS:
10.1 The work shall be carried out strictly in accordance with the approved drawings and codes /
standards. In the event of any conflict between any requirement in this specification and that
of the applicable codes/ standards the governing requirement shall be the more stringent of
the two at the discretion of the purchaser. The purchaser reserves the right to make minor
changes wherever necessary in the fabrication drawings and such changes shall be
considered as within the scope of the specified work and shall not be considered as extra
10.2 Sub-contracting shall not be preferred. In case sub-contracting is unavoidable, the same
shall be carried out with prior written permission of the purchaser. In such cases complete
details of the vendor along with the facilities available with him shall be furnished to the
purchaser for granting permission (Annex.-11)
10.3 Machining of LAS unit shall be carried out on CNC machining, DRO, Surface grinding
machine, Slotting machine as required. High degree of tolerances and surface finishes shall
be obtained for individual parts of this unit for smooth functioning of the unit.
11.0 FABRICATION / MACHINING REQUIREMENTS:
11.1 The vendor shall have appropriate machining and fabrication facilities required for welded
fabrication of heavy Mild Steel shielding blocks and Stainless steel components/
mechanisms. The machines shall conform to the highest grade and have current calibration
and test reports.
11.2 The machines shall be capable of machining of heavy and large sized blocks and assembled
enclosures of the order of 1.5m (L) X 1 m (B) X 1m (D).
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11.3 The vendor shall have the facility for automated oxy-acetylene gas cutting of thick mild steel
plates to accurate size and edges.
11.4 The vendor’s shop shall be equipped for welding of heavy MS plates apart from welding and
fabrication of Stainless steel equipment. The shop shall have adequate handling facilities like
EOT cranes etc. The vendor shall have testing and measuring instruments with latest
11.5 All the internals of the enclosure like, lining, supports, bottom tray, etc. shall have a
smooth finish to enable easy decontamination.
11.6 The vendor shall submit detailed fabrication process plan indicating process, machines used,
tolerances and valid current calibration certificates for the machines being employed for this
11.7 The vendor shall also submit all welding process details, assembly sequence of the
enclosures, inter-stage quality control and inspection checks.
11.8 Machining of LAS unit shall be carried out on CNC machining, DRO, Surface grinding
machine, Slotting machine as required. High degree of tolerances and surface finishes shall
be obtained for individual parts of this unit for smooth functioning of the unit.
11.9 All machines employed for this job shall have recent calibration certificates. The vendor shall
have all manufacturing facilities in-house and at one place.
11.10 Installation and commissioning of all four sampling enclosures will be in the scope of the
vendor. All the four sampling enclosures shall be installed at P3A, Kalpakkam.
11.11 The vendor shall submit a detailed installation plan. The vendor shall submit a
comprehensive offer covering the entire requirement, supply, and installation and
commissioning. Part offers will not be entertained.
11.12 Supply of hold fasteners and fixing shall be in the scope of the vendor.
11.13 Drivers (Motors) of reputed make are to be installed on the L/R side of the enclosure with
proper supporting from the side blocks. Control unit along with individual PLC shall be
installed on wall mounted unit. Fabrication & machining of such supports and stands shall be
in the scope of the vendor.
11.14 The vendor shall initially fabricate, machine & assemble first sample enclosure of the ordered
item, which will be subjected to thorough inspection, testing & approval by the purchaser.
Workmanship shall be in accordance with the best shop practices and standards as existing
in engineering industry. The assemblies shall confirm to all dimensional, geometrical and
quality requirements for ensuring sustained trouble free operation of system. Repeatability in
the dimensions and tolerances for all enclosure assemblies shall be ensured.
11.16 CUTTING AND STRAIGHTENING:
Marking of plates and other materials shall be done as per approved cutting plan. Each piece
shall be marked for identification. S.S. materials shall be cut by approved mechanical means
to ensure material integrity.
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S.S. to S.S. welding shall be done by GTAW process using SS filler wire ER-308L, high
purity argon gas (99.98% pure) and 2% thoriated tungsten electrodes. M.S. to M.S. Welding
shall be done by SMAW process using covered electrodes E-7018. M.S. to S.S. welding
shall be done by GTAW process using SS filler wire ER 309L. All weld edges shall be
machined to size and finished smooth. Primer shall be applied on both sides of laminations
(if any) before assembly of shielding blocks by welding. The welding procedure and
welders shall be qualified as per ASME code. Weld size shall be properly chosen for the
11.18 WELDER QUALIFICATION & WELDING PROCEDURE:
The performance qualification of the welders and the welding procedure shall conform to
ASME code (refer appendix). No production welding shall commence until WPS & PQR and
welder’s qualification are completed and the results approved by the purchaser. Vendor shall
submit to the purchaser three copies of the approved procedure and procedural qualification
11.19 REPAIR OF WELD DEFECTS:
Visible defects such as cracks, pinholes and incomplete fusion, as well as defects that can
only be detected by prescribed examinations and tests shall be removed and the joints re-
11.20 FITTING AND ALIGNMENT:
The weld geometry shall take into consideration the availability of sufficient strength after
final machining of door profiles. Edges to be welded shall be uniform and free from all foreign
materials. Parts to be welded shall be fitted, aligned and retained in position during the
welding operation. Bars, jacks, clamps, tack welds or other appropriate means may be used
to hold the wedges to be welded in line. Tack welds may be incorporated in the final weld,
provided they are free from visible defects. The edges of butt joints shall be held during
welding in such a manner that the tolerances stated in the approved fabrication drawings are
11.21 CLEANING OF SURFACES:
Surfaces to be welded shall be free from foreign material such as grease, oil, lubricants and
marking paints for a distance of at least 25 mm from the weld preparation area.
11.22 FINISHED JOINTS: Joints shall have complete penetration and shall be free from cracks,
undercuts, overlaps, abrupt ridges or valleys. Fillet welds shall have complete fusion at the
root of the fillet.
11.23 MISCELLANEOUS WELDING REQUIREMENTS:
All welds shall be checked by Dye-Penetrant test for root and final pass of welding.
12.1 FREE ISSUE MATERIAL (FIM):
List of FIM is given below. Issue of FIM shall be as per D.P.S. procedures. Subsequent to the
completion of work the FIM shall be accounted for, as per D.P.S. procedures. All other
material other than FIM required for execution of this work shall be in the scope of the
12.2 Material to be issued to vendor for use at Vendor’s Site during fabrication:
i) Needle blocks with needles assembled – 30 Nos.
ii) Sample bottles - 30 nos.
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iii) SS 304L 1 ½” Sch. 40 pipe - 3 meters
iv) SS304L Sch 40 9NB pipes - 30 meters
NOTE: The value of the Free Issue Material is Rs.100000/- Hence in the event of order
Insurance policy to be submitted for the value of free issue material.
12.3 SS Material such as pipes and plates as required for installation at site will be
issued by site engineer during installation.
12.4 MATERIAL PROCUREMENT:
The vendor shall procure all materials and bought out components as mentioned in the
specification and drawings. The vendor shall ensure the compliance of all bought out
materials to standards and quality stipulated in the specification. The materials shall be
procured from reputed manufacturer’s / authorized dealers with complete credentials of the
genuinity of the item. Relevant QA plans for bought out items shall be followed and testing
shall be done in consultation with the purchaser. Test reports and QA documents for these
items shall be submitted to the purchaser. The material shall comply with relevant ASTM
standard. Make, technical details and spares list of the bought out materials shall be
furnished to the purchaser for evaluation and granting permission for procurement.
Raw material used shall be from fresh stock and shall have been procured only after
the order has been placed
Material and standard parts that are not specifically described herein and are under the
scope of the vendor shall be of genuine quality. Mild steel used for fabrication shall be of
ASTM A 516 Grade 70. Materials used shall be of recent manufacture and shall be free from
defects. Test certificates for chemical composition and mechanical properties of all materials
used shall be submitted for approval.
The quality of SS / MS material shall be validated by a Govt. approved material testing
laboratory at vendor’s cost for chemical composition, mechanical properties and corrosion
resistance as applicable. All S.S. material shall be of SS 304 L. The corrosion resistance test
shall be performed as per ASTM –A 162 Practice A & C. The average corrosion rate of the
material shall not be more than 18 MPY for the average of five cycle test period.
Use of equivalent material shall not be preferred, in-case use of equivalent material is
unavoidable; the same shall be done with prior written permission from the purchaser.
Supply, testing & installation of suitable illuminating fixtures for installation in the enclosures
shall also be in the scope of vendor. The vendor shall provide all technical specifications of
the illuminating fixture for approval of the purchaser before procurement.
12.5 MATERIAL IDENTIFICATION:
The vendor shall document all the relevant records for proper trace-ability of origin for all
input materials in the manufacturing.
12.6 BOUGHT OUT ITEMS:
The bought out items like bearings, seals, SS Anchor fasteners & pipe fittings etc. shall be
from reputed manufacturer & of standard make. In case of non-availability of prescribed
make, the purchaser’s approval in writing for the change of make shall be sought prior to the
purchase. All technical details of the brought out items along with specifications for
procurement shall be submitted to the purchaser for approval.
13.0 INSPECTION AND TESTING REQUIREMENTS:
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13.1 GENERAL: Raw material used for this work shall be from fresh stock and shall have been
procured after the order has been placed. The vendor shall ensure dimensions, surface
finish, fitment, alignment etc. for shielding blocks, doors, brackets, all internals and other
items. The vendor shall carry out mock-up assembly of all the enclosures with plugs and
shielding doors on the respective support structure. The door shall open and close smoothly
over its entire range. The vendor shall also carry out mock-up assembly of all the sampling
enclosures with front door, Auto sampler unit, all shielding plugs, lighting arrangement,
sample block clip support, sampling blocks, for demonstrating smooth functioning of all
components. The vendor shall demonstrate sample bottle travel to desired location, smooth
piercing of sampling bottle with the needles, disengagement of the sample bottle from the
needles, delivery of the sample bottle to delivery chute, free fall of the sample bottle from the
delivery chute etc. The complete operation of sampling shall be demonstrated 100 times for
smooth trouble free operation. Inspection by the purchaser shall not relieve the vendor from
the responsibility of testing and supply of the items to the requirements of the specifications.
The fabricated items shall be transported to the site only after the purchaser’s inspector
inspects them and issues the shipping release duly signed. Records of all inspections carried
out by the vendor shall be made available prior to the purchaser’s inspection.
13.2 Lifting Mechanism: The lifting mechanism lifts the bottle aligned under the sample point and
the stationary needles attached to the needle block pierce the bottle. Motor for the lifting
mechanism operates at a lower torque for the upward movement of the lifting mechanism till
the bottle reaches the needle tips. The torque requirement momentarily goes up for piercing.
This point may be considered and a motor suitable to meet this requirement shall be
provided by the vendor.
13.3 MATERIAL TEST: All material designated to be in conformance with the standard shall be
tested as required by such standard for physical and chemical analysis. Additional test like
IGC test for stainless steel is also required as per ASTM A 262 practice A & C. Proof in the
form of certified test reports or mill certificates would be acceptable. However the purchaser
reserves the right to get the test repeated at any laboratory of his choice. These test
certificates shall be furnished to the purchaser. In case of MS blocks, UT of the blocks shall
be done as per standards given in codes to be followed.
13.4 SHIELDING REQUIREMENT TEST: Test for shielding requirement shall be carried out by
the purchaser and if at any place the shielding thickness is felt inadequate the vendor shall
correct defects by methods as approved by the purchaser’s engineers.
13.5 WELD INSPECTION: All welds shall be inspected by DP test layer–by-layer and shall show
no signs of defects. The Halogen and sulphur content of the DP test material shall be
restricted to 25 ppm and 1% respectively. All butt joints on the pipes shall be 100%
radiographed. Inspection standards for the welds shall be in accordance to the standards
given above and also given in the appendix. Welds on SS lining shall be vacuum box tested
as per codes.
13.6 QUALITY CONTROL: The vendor shall submit the detailed QA & QC plan for approval.
13.7 DIMENSIONAL INSPECTION: The vendor shall comply with the requirements of the
components conforming to required shape, thickness and dimension. During and after
fabrication, such dimensional inspections are necessary and shall be performed to ensure
that the completed portion of the fabrication conforms to the design drawings.
13.8 WELDING PROCEDURE & WELDER QUALIFICATION: The vendor shall qualify the
procedures and performance of welders as per ASME Section –IX. The weld shall be
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inspected and approved in accordance with the code. The inspector shall have the right, at
any time, to call for and to witness tests of the welder.
13.9 ACCESS FOR INSPECTOR: The purchaser’s inspectors shall be permitted free access at all
times while work on fabrication is being performed. The vendor shall formally inform the
purchaser in advance for inspections.
13.10 CLEANING AND PAINTING: All MS surfaces shall be epoxy painted after thoroughly
cleaning by approved methods as given in the appendix. Primer shall be applied on both
sides of laminations before assembly. The final assembled block shall be in accordance with
the paint manufacturers recommendations. The paint shall be from standard manufacturers
and the make and application procedures shall be approved by the purchaser before
14 ACCEPTANCE CRITERIA:
14.1 The vendor shall fabricate one number of enclosure complete with all internals and offer the
same for inspection. Any changes at this stage shall be incorporated and final accepted
design shall form the basis for manufacture and supply of remaining two sampling
enclosures. The manufacture of remaining two enclosures shall be taken up only after
written approval from the indenter for the sample enclosure.
14.2 An enclosure as per above approved design shall be considered acceptable if it meets the
shielding, smooth and free operation of the front door, flawless operation of the auto sampler
unit, smooth insertion of sample bottles into cup holder through loading chute and free
delivery of the sample bottle from the delivery chute, free and smooth operation of the auto
sampler unit. The positional accuracy repeatability for sample bottle location and complete
stroke achievement of the needle piercing mechanism etc. shall be a criteria for acceptance.
Installation of sampling enclosure after anchoring M.S. plate EP to cell wall & installation of
support structure on wall plate EP. The wall plate EP & sampling enclosure support structure
shall be issued as FIM at site The enclosure drain shall have proper slope and all the welds
shall be QA checked & passed. Installation of the drain shielding plugs in place.
14.3 Lifting Mechanism: The lifting mechanism shall be tested for smooth bottle piercing. Motor for
the lifting mechanism operates at a lower torque for the upward movement of the lifting
mechanism till the bottle reaches the needle tips. The torque requirement momentarily goes
up for piercing. The suitability of motor for this function will be a check point.
14.4 The following tests shall be carried out and form the acceptance criteria:
a) Each assembly shall be tested for smooth and fault free 100 repetitive cycles.
b) Testing of Auto sampler unit with all the postulated error conditions.
c) Free and smooth operation of the door.
d) Viewing window cut out for smooth insertion of dummy RSW.
e) Alignment of blocks on the sidewalls for accommodating the LAS shafts.
f) Alignment of the needle position with respect to cup positions during LAS operation.
g) Alignment of the loading / delivery chute positions with respect to cup positions during
LAS operation (100 times repetitive for each unit).
h) Adequate lift available for piercing the bottle.
i) Smooth and free remote & manual operations of LAS movements.
15.0 CONFIDENTIALITY CLAUSE:
No information concerning the matter in this contract shall be disclosed to any third party. In
particular, any information identified as “Proprietary” in nature by the disclosing party shall be
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kept strictly confidential by the receiving party and shall not be disclosed to any third party
without the prior written consent of the original disclosing party.
“Restricted information” categories under section 18 of the Atomic Energy Act, 1962 and
“Official Secrets” under Section 5 of the Official Secrets Act, 1923:- Any contravention of the
above mentioned provisions by any contractor, sub contractor, consultant, adviser or the
employees of a contractor will invite penal consequences under the aforesaid legislation.
Contractor shall not use BARC’S name for any publicity purpose through any public media
like Press, Radio, TV or Internet without the prior written approval of BARC.
Items covered under the purchase order shall be properly packed and safely transported to i)
Project P3A, BARC, Kalpakkam. All the shielding blocks shall be properly identified with
codes for each enclosure. The supplier shall be fully responsible for any damage occurred
17.0 PACKING AND INSTALLATION:
17.1 After carrying out the tests at manufacturing works as specified in this specification and after
match marking, the equipment covered in this contract shall be carefully disassembled into
major completed subassemblies and then packed, suitably crated and protected from
damage during transportation, transit and storage at site. The packing shall include adequate
cushioning, blocking, bracing, anti-skidding, hoisting and tie-down provisions with the
approval of the purchaser. Supplier shall be responsible for any damage to the components
during transport and transit and handling at site. Any short supply shall be compensated by
fresh supply of such components by the vendor without any extra cost.
17.2 The shipment of the enclosures along with internals & installation / erection shall be done at
(i) Project P3A, BARC, KALPAKKAM. The purchaser shall intimate the schedule of
installation at the site mentioned above. The supplier shall complete the erection job at the
site within two months from the date of commencement of erection job.
17.3 All manpower, material handling equipment, machines, consumables, tools and tackles
required for handling and installation of the system and transportation of all the material from
supplier works to erection site shall be arranged by the supplier at his cost. Only electricity
and water consumed during erection shall be provided free of cost. Supplier shall also
demonstrate the performance of the system after assembling & erection at site.
17.4 The supplier shall follow the Dept. of Atomic Energy Security & Safety Procedures during
erection. The supplier must quote the erection charges separately in Annex.14.
18.0 QUALITY CONTROL DOCUMENTATION:
The following documents shall form part of fabrication record.
a) Material Testing Certificate for Chemical and Mechanical properties.
b) UT reports for MS blocks.
c) Fabrication Procedure.
d) Fabrication and machining drawings in hard copy format and ACAD format on CDs..
e) Welder’s Qualifying Record.
f) Welding Procedure Qualification Record.
g) Dimension inspection reports.
h) DP test reports.
i) Test reports as mentioned in testing / system description headings. Repetitive functional
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j) Three sets of final as built and fabrication drawings in hard format and ACAD format on
Specifications and data sheets & drawings of brought out items, encoders, PLCs, Bearings,
Lead screw shaft & Lifting mechanism shaft, motors, etc.
All documents shall be submitted in original except for the three sets of drawings, which shall
be submitted as hard copies and in ACAD format on CDs.
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19.0 DELIVERY AND MANUFACTURING SCHEDULE:
19.1 The supplier shall clearly indicate a time schedule for the entire sequence of manufacturing
like procurement of materials, preparation and approval of fabrication drawings, various
stages of inspection, testing and delivery. The entire scope of contract shall be completed
within 12 calendar months from the date of award of contract.
19.2 The bidder shall indicate in his offer, the time required for the following, in the event of an
19.2.1 Submission of fabrication drawings.
19.2.2 Completion of work for first Enclosure after approval of drawings.
19.2.3 Completion of remaining two enclosures after approval of first enclosure.
19.2.4 Installation schedule.
20.0 DATA TO BE FURNISHED WITH THE OFFER:
20.1 Price schedule as per annexure 14.
20.2 Vendor evaluation Performa as per annexure 2.
20.3 Delivery and manufacturing schedule.
20.4 Proof of ability (Annex.7).
20.5 Agreement to comply with Requirements (see Annex.3)
20.6 Other data for evaluation as given in annexures.
21.0 DOCUMENTS TO BE FURNISHED AFTER AWARD OF CONTRACT:
21.1 Five sets of the following documents shall be submitted for approval before start of the
manufacture within 30 days of the issue of purchase order.
21.2 Detailed fabrication drawings showing bill of material, dimensions and
21.3 Q.A. plan, Inspection and testing procedures including DP test.
21.4 Material test certificates as per specification.
22.0 TRAINING OF PERSONNEL:
Training on complete programming of PLC from PLC manufacturer shall be arranged for two
engineers with out any extra financial burden to the purchaser.
23.0 FINAL DOCUMENTATION:
Three copies of all the below mentioned final documents shall be submitted.
a) Final dimensional drawings of all components and as built drawings in hard format & in
ACAD format on CDs.
b) Final as-built detailed drawings in hard format & in ACAD format on CDs.
c) Relevant material test certificates with parts identification.
d) Approved QA plan.
e) Inspection and test reports comprising mill test reports of chemical & physical properties for
all materials with identification, and DP test reports.
f) Variation report from the original tender and justification thereof.
g) FIM utilization statement & certifications as per DPS procedures.
h) Specifications of bought out items, drawings, data sheets, program listings, procedures for
O&M, procedures for program change.
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TECHNICAL SPECIFICATIONS FOR WELDING AND WELDING PROCEDURE
1.1 This specification shall apply to site/shop fabrication of all welded joints in Stainless Steel
304L plant piping and Stainless Steel to Carbon Steel welding for chemical and industrial
system & all welded joints for heavy steel plates and supporting structures in carbon steel.
Site fabrication also covers any fabrication in a shop set-up at site.
1.2 The welded joints include the following.
a) All butt welded joints of the longitudinal and circumferential type for attachments in piping.
b) Socket welding and fillet joints.
c) All types of branch welds
d) M.S. to Stainless steel lining welding.
e) Any other joints not specifically covered above.
1.3 For welding of materials not covered by this specification, reference shall be made to specific
project requirement covered in enquiry specification.
2.0 APPLICABLE CODES AND STANDARDS
2.1 The Welding of all piping system including equipment, welding consumables, other auxiliary
functions and welded personnel shall comply with all currently applicable statues, regulations
and safety codes in the locality where the system is to be installed. Nothing in this
specification shall be construed to relieve the CONTRACTOR of his responsibility.
Specifically, the latest edition of codes and standards listed in following paragraphs shall
a) ASME B & PV Code, Sec. III. Div – 1
Subsection NB for Class – 1 Components in the case of design of Piping and Piping
b) Standards of the Pipe Fabrication Institute.
c) BS 2633-Specification for Class I Arc Welding of Ferric Steel Pipe work for
d) ASME B & PV Code, Sec. IX: Welding Qualifications.
e) ASME B & PV Code, Sec. V: Non Destructive Testing.
f) Any other codes and standards specified specific in enquiry specification.
2.2 The codes and standards listed in Para 2.1 from an integral part of this specification. In the
event of conflict between this specification and the codes and standards, the more stringent
2.3 If no specific requirements are given in this specification, the requirement of the applicable
codes shall govern.
3.0 WELDING PROCESSES
The welding processes that are used in the fabrication are restricted to gas tungsten arc
welding only. For M.S. to Stainless steel lining the entire welding shall be carried out by
tungsten inert gas welding only. For other carbon steel structural systems manual metal arc
welding may be carried out for entire welding including root pass.
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The following welding processes shall be used for shop-fabricated and field-fabricated piping
systems. Welding by oxyacetylene process shall not be used. However Oxyacetylene gas
cutting of carbon steel plates and structural material is permitted.
a) Gas Tungsten Arc Welding (GTAW).
b) Shielded Metal Arc Welding (SMAW).
c) Oxy-Acetylene Gas cutting
3.1 GTAW process shall be used for the following:
a) On butt welds, fillet welds, in Stainless Steel 304L
b) On butt welds in alloy steels for the root pass in all sizes.
c) One fillet welds for M.S to S.S. welding.
3.2 SMAW process shall be used for the following:
All structural welding in carbon steel, in all sizes.
3.3 Oxy-Acetylene Gas Cutting Process shall be used for the following:
a) All Structural members & thick plates cutting in all sizes.
3.4 All butt welds shall be considered as full penetration welds.
3.5 Table 1 gives recommendations for welding procedure to be used for carbon, low alloy and
austenitic stainless steels. Welding from inside of the pipe after back gouging and chipping is
not envisaged. However, if the CONTACTOR proposes to use such a method, a detailed
written procedure shall be submitted for approval to the PURCHASER OR HIS
4.0 WELDING CONSUMABLES
4.1 The contractor shall provide at no additional cost all the welding consumables such as
electrodes, filter wires, oxygen, acetylene, argon etc., in order to complete the welding in all
respects. The consumables shall be from reputed and approved manufactures like ESAB /
ADVANI / PHILIPS only. The site project engineer or his authorised representative shall
approve all the consumables.
4.2 The electrodes and filter wires shall be of the class specified in the welding electrode chart.
4.3 Electrode qualification test records shall be submitted for project engineer or his authorised
representative’s approval. The contractor shall also submit batch test certificate from the
electrode manufacturer for physical and chemical tests.
4.4 Electrodes shall be in sealed containers and adequate care shall be taken for storage, strictly
in accordance with the manufacturer’s recommendations and once these are taken out, shall
be consumed within the time limits stipulated by the manufacturer. Care shall be taken in
handling the electrodes to prevent any damage to the flux covering. Portable ovens shall be
used for carrying the electrodes from the main oven to the field.
4.5 Electrodes, which have been removed from the original containers, shall be taken for storage
strictly in accordance with the manufacture’s recommendations.
4.6 The electrodes, filler wires and flux used shall be free from contamination such as rust, oil,
grease and such foreign matter.
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4.7 Low hydrogen electrode shall be used for weld joints in carbon steel if the wall thickness
exceeds 19mm, except that non – low hydrogen electrodes shall be permitted for the root
4.8 E 6010 electrodes may be used for root pass of butt welds and for fillet welds in carbon steel.
4.9 Fluxes recommended for single pass shall not be used for multi pass welds.
Refer Table 1 for welding specification and electrodes.
5.0 WELDING PROCEDURE QUALIFICATION
5.1 Qualification of the welding procedures to be used and performance of the welders and
welding operators shall conform to the requirements of the BPV Code, Section IX.
5.2 No production welds shall be undertaken until the qualification requirements are completed
to the satisfaction of the project engineer or his authorized representative.
5.3 When impact testing is required by the code or by the specification, these requirements shall
be met in qualification welding procedures.
5.4 The contractor shall be responsible for qualifying all welding procedures welders under him
would use. The CONTRACTOR shall submit the welding procedure specification (WPS) for
acceptance by the PROJECT ENGINEER OR HIS AUTHORIZED REPRESENTATIVE. The
CONTRACTOR shall carry out the procedure qualification test at his own expense after
approval by the PROJECT ENGINEER OR HIS AUTHORIZED REPRESENTATIVE. These
tests shall be witnessed by the PROJECT ENGINEER OR HIS AUTHORIZED
REPRESENTATIVE. A complete set of test results shall be submitted to the project engineer
or his authorized representative for approval immediately after successfully competition of
procedure qualification test. All tests as required by the BPV code Section – IX shall be
carried out. The Welding Procedure Specification (WPS) shall be re-qualified if any of the
essential variables or supplementary variables are altered.
5.5 Welders shall be qualified in accordance with BPV Code, Section – IX, as applicable. The
qualification shall be carried out in the presence of the project engineer or his authorized
representative. Only those welders who are qualified and approved by the project engineer
or his authorized representative shall be used on the job.
5.6 Welders qualified shall always keep their identification cards with them and shall produce
them on demand. The contractor shall issue the identity card after the project engineer or his
authorized representative duly certifies the same. The welder, who is not in possession of the
identity card, shall not be allowed to work.
5.7 The CONTRACTOR shall use forms as per BPV Code, Section – IX, from QW-482 from QW-
483 and from QW-484. Other forms are also acceptable subject to approval by the project
engineer or his authorized representative.
5.8 Unless otherwise agreed, the contractor shall intimate the project engineer or his authorized
representative, in writing, at least three (3) weeks before any welder is employed on the
work, the names and qualification of the proposed welders and welding supervisor. It shall be
the contractor’s responsibility to ensure that all welders employed by him or his sub-
contractor’s, on any part of the contract either in the contractor’s/ his sub-contractor’s works
or at site are fully qualified as required by the code. Each welder shall qualify for all types of
welds, positions and materials or material combinations he may be called upon to weld.
5.9 If the project engineer or his authorized representative demands testing or retesting of any
welder, the CONTRACTOR should make available, at no extra cost to the
PURCHASER/PROJECT ENGINEER OR HIS AUTHORISED REPRESENTATIVE, the men,
equipment and materials for the test. The cost of testing the welds shall be borne by the
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5.10 Welding supervisor shall have qualification such as Degree in Engineering or Diploma in
welding technology with adequate knowledge of non-destructive testing and minimum of five
(5) years of experience in supervising welding of pipe joints.
5.11 All welding, including the tack welding of all welds shall be carried out by approved welders.
Any weld performed by welder who is not qualified for that job shall be cut out and re-
5.12 For the purpose of identification and to enable tracing full history of each joint, each welder
employed on the work shall be given a designation. The welder’s designation and the date,
on which the joint was made, shall be stamped on the relevant piping/lining and marked on
the relevant drawing also. Copies of the drawings so marked shall be furnished to the project
engineer or his authorized representative for record purposes. For austenitic stainless steel,
welder’s designation shall be applied with waterproof paint that is not detrimental to the
material of the job. Alternatively, record charts may be used.
5.13 For each welder, a record card shall be maintained showing the procedures for which he is
qualified. These cards shall note the production welds, the date of welding done, the type of
defects produced and their frequency. The project engineer or his authorized representative
shall review the record once in a week and those welders whose work required a
disproportionate amount of repair shall be disqualified from welding. Re-qualification of
welders disqualified more than three (3) times shall be entirely at the discretion of the project
engineer or his authorized representative.
6.0 WELDER AND WELDING OPERATORS QUALIFICATIONS:
6.1 All welders and welding operators shall be qualified in accordance with the applicable codes
and these specifications, for carrying out tack, temporary and repair welds.
6.2 The contractor shall be responsible for qualification and certification of his own welders and
welding operators in accordance with the applicable codes.
6.3 The test records for all welders shall be made available at site.
6.4 The performance of qualification tests shall not be performed on production joints.
6.5 The contractor shall establish and maintain a welder identification system that is acceptable
to project authorities.
7.0 PREPARATION FOR WELDING
7.1 Surface to be welded shall be smooth, uniform and free from fins, tears and other defects,
which would adversely affect the quality of the weld. All welding faces and adjoining
surfaces, for a distance of at least 150mm from the edge of the welding groove or 12mm
from the toe of the fillet in the case of socket weld of fillet welded joints shall be thoroughly
cleaned of rust, scale, paint, oil or grease, both from inside and outside.
7.2 Joints for welding whether socket welding or butt-welding shall be as per the project piping
7.3 Butt joints shall be prepared as per ANSI-B-16.25 unless otherwise specified. Any other end
preparation, which meets the WPS, is acceptable.
7.4 Trimming shall reduce internal misalignment but such trimming shall not reduce the finished
wall thickness below the required minimum wall thickness. Root opening of the joint shall be
within the tolerance limits of the WPS.
7.5 On austenitic stainless steel, plasma cutting (shall be used on above 10mm thick plates and
shall not be used for edge preparation of pipes for any thickness), machining or grinding
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methods may be used for edge preparation. Cut surface shall be machined or ground
smooth after plasma cutting.
7.6 Before fitting up the weld joint, the profile and dimensions of the weld end preparation shall
be checked by the project engineer or his authorized representative. If the specified
tolerances are exceeded, this shall be corrected (with prior approval) by grinding, machining
or any other method acceptable to the project engineer or his authorized representative.
7.7 Fit – up shall be examined by the project engineer or his authorized representative prior to
welding the root pass.
8 TECHNIQUE AND WORKMANSHIP
8.1 Components to be welded shall be aligned and spaced as per the requirements of the code
and WPS. Special care is required when GTAW process is employed.
8.2 Alignment and spacing shall be achieved using suitable wires to maintain the gap. Theses
shall be removed after tack welding. The ends to be welded shall be held using suitable
clamps, yokes or other devices, which will not damage the surface in any manner. It shall be
ensured that welding operations do not result in distortions.
8.3 Tack welds at the root joint, for maintaining joint alignment, shall be made only by qualified
welders or welding operators and with filler metal equivalent to that used in the root pass.
Tack welds shall be used with the root pass weld, except that those, which have cracked,
shall be removed. Penning is prohibited on the root and finial passes of a weld. The required
preheat shall be maintained prior to tack welding.
8.4 No welding shall be done if there is any impingement in the weld area due to rain, snow, and
excessive wind or if the weld area is wet.
8.5 Irrespective of the class of steel, root runs shall be made without interruption other than for
changing the electrodes or to allow the welder to reposition himself. Root runs made in the
shop may afterwards be allowed to cool by taking suitable precautions to ensure slow cooling
e.g. by wrapping in a dry asbestos blanket. Welds made at site shall be allowed to cool until
the thickness of weld metal deposited exceeds one third of the finial weld thickness or 10mm,
whichever is grater.
8.6 When welding alloy steel, it is strongly recommended that interruption of welding be avoided.
Where such interruption is unavoidable, either the preheat shall be maintained during the
interruption or the joint shall be wrapped in dry asbestos blankets to ensure slow cooling.
Before recommencing welding, preheat shall be applied again.
8.6 Welded–on bridge pieces and temporary attachments should preferably be avoided. Where
approved by the PROJECT ENGINEER OR HIS AUTHORISED REPRESENTATIVE, they
may be used. Material of these shall be compatible with material with which they are
temporarily welded. All such pieces shall be removed after welding of pipe joints and the
weld area ground flush.
8.7 The arc shall be struck only on those parts of parent metal where weld metal is to be
deposited. When inadvertent arc-strikes are made on the base metal surface outside the joint
groove, the arc-strikes shall be removed by grinding and shall be examined by liquid
penetration or magnetic particle examination procedures.
8.8 Oxides shall not be permitted to from during welding or heat treatment or both, on the
internal surface of pipes, which will not be subsequently cleaned. Inert gas purging is an
acceptable method to prevent such oxidation. All joints in materials which contain more than
1% chromium shall be purged to assure that 1% of oxygen is present on the joint underside
before initiation of the welding. The purging operation shall be maintained for a minimum of
two (2) passes.
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8.9 Argon gas used in GTAW process for welding and purging shall be least 99.95% pure.
Purging shall be carried out at a flow rate depending on the diameter of the pipe until at least
(5) times the volume between dams is displaced. In no case shall the initial purging period be
less than 10 minutes. After initial purging the flow of the backing gas shall be reduced to a
point where only a slight positive pressure prevails. Any dams used in purging shall be fully
identified and removed after welding and accounted for in order to avoid leaving them in the
system. The rate of flow for shielding purpose shall be established in the procedure
8.10 Thorough check shall be exercised to maintain the required inter pass temperature.
8.11 All equipment necessary to carry out the winding, for supporting of the work, preheating and
post weld heating including thermal insulation for retaining the heat and for the protection of
the welder shall be provided by the CONTRACTOR at no extra cost. All necessary
precautions shall be taken during cutting and welding operations. It shall be ensured that
proper ventilation is available in the welding area and adequate protective gear such as
goggles, masks, gloves, protection for the ears and body are used at all times. For guidelines
refer ANSI standard Z49.1, “Safety in welding and cutting”.
8.12 After deposition, each layer of weld metal shall be cleaned with a wire brush to remove all
slag, scale and defects, to prepare for the proper deposition of the next layer. The material of
wire brush shall be compatible with pipe material. Stainless steel materials shall be cleaned
with grinding wheels. Special care shall be taken to secure complete and through penetration
of the fusion zone into the bottom of the weld. It is recommended that the root run be
checked by liquid penetrant or magnetic particle procedures for critical process piping.
8.13 Upon completion of welding, the joints shall be wrapped in dry asbestos blankets to ensure
slow cooling, unless post weld heat treatment is applied immediately.
8.14 No welding or welded parts shall be painted, plated, galvanized or heat-treated until
inspected and approved by the PROJECT ENGINEER OR HIS AUTHORISED
REPRESENTATIVE. Welds shall be prepared and ground in such way that the weld
surfaces merge smoothly into the base metal surface.
8.15 Except where necessary to grind flush for non-destructive examination reinforcement for butt
welds may be provided. The height of such reinforcement shall meet the requirements of the
code. The reinforcement shall be crowned at the center and tapered on each side of the
joined members. The exposed surface of the welds shall be ground where required to
present a workmanlike appearance and shall be free from depressions below the surface of
the joined members. The exposed surface of the butt welds shall be free from undercuts
grater than 0.5mm in depth, overlaps or abrupt ridges or valleys shall merge smoothly into
the pipe surface at the weld toe. However, undercuts shall not encroach on the minimum
8.16 Repair of weld metal defects shall meet the requirements of the code.
8.17 Any weld repair shall subject to the approval of the PROJECT ENGINEER OR HIS
8.18 In the event of several unsuccessful repair attempts or if the PROJECT ENGINEER OR HIS
AUTHORISED REPRESENTATIVE feels that a satisfactory repair is not feasible, the joint
shall be completely remade.
8.19 SEAL WELDS
8.19.1 Seal welding shall be done by qualified welders and in accordance with approved drawings.
8.19.2 Threaded joints that are to be seal welded shall be made without the use of thread lubricating
compound. Seal weld shall cover all exposed threads.
8.20 WELD ENCROACHMENT AND MINIMUM DISTANCE BETWEEN WELDS
8.20.1 Welded joints, more specifically longitudinal welds, shall be placed not closer than 50mm to
opening or branch welds, reinforcements, attachment devices or from support, etc. in case of
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deviation, the PROJECT ENGINEER OR HIS AUTHORISED REPRESENTATIVE may
specify additional non-destructive examination.
8.20.2 Intersection of welds shall be avoided as far as possible. If such welds are present, they shall
be subject to suitable NDT at the discretion of the PROJECT ENGINEER OR HIS
9. ELECTRODES & FILLER WIRES
9.1 The specification and size of the electrodes and filler wires, voltages and amperages,
thickness of beads and number of passes shall be specified in the approved welding
procedure or otherwise agreed in writing. Only basic coated electrode shall be used, which
will deposit weld metal having the same or higher physical properties and similar chemical
composition to the members being joined. The welding electrodes and filler wires shall be of
M/s Advani-O-erlikon, M/s Philips, M/s ESAB make only shall be employed. For each batch
of approved brand, certificate-showing compliance with the specification shall be submitted
to the PROJECT ENGINEER OR HIS AUTHORISED REPRESENTATIVE for review before
being released for use. All electrodes shall be purchased in sealed and stored properly to
prevent deterioration. All low hydrogen electrodes, after baking as per manufacturer’s
recommendations, shall be stored in ovens kept at 8000C – 10000C before being used.
Recommendation of the electrode manufacturer shall be strictly followed. Until the electrodes
are taken out for welding, they shall be stored in portable ovens. The electrodes shall not be
exposed to open atmosphere.
9.2 For welding of all grades of steel and alloys by the GTAW process, a 2% thoriated tungsten
electrode conforming to SFA-5.12-86 EWTh-2 (AWS-A5.12-80, EWTh-2) classification shall
9.3 All electrodes to be used on alloy and carbon steel shall conform to BPV Code Section – II
Part – C or any other equivalent code.
9.4 As welding electrodes deteriorate under adverse conditions of storage leading to dampness
in the electrode coating, they shall normally be stored in dehumidified air-conditioned rooms
or in hot ovens in their original sealed containers whose temperatures shall be maintained
within specified limits. The condition of electrodes shall be frequently inspected. Electrodes
with damage to coating shall not be used. Electrodes shall remain identified until consumed.
It is preferable to procure low hydrogen electrodes in hermetically sealed containers and
preserve them without damage to the containers.
9.5 Only those types of electrodes recommended by the manufacturer for the use in the position
in which the welds are to be made shall be used. Electrodes that have the areas of flux
covering broken away or damage shall not be used.
9.6 Table – 1 gives recommendations on electrodes to be used for carbon, low alloy and
austenitic stainless steel.
10. INSPECTION AND TESTING
10.1 The PROJECT ENGINEER OR HIS AUTHORISED REPRESENTATIVE shall have free
access to inspect welding or any other related operations at any time and at any stage of
10.2 The PROJECT ENGINEER OR HIS AUTHORISED REPRESENTATIVE at his discretion
calls for non – destructive testing of any other weld material for reasons other than those
given in the specification, the contractor shall comply with such requirement. The
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responsibility for the cost of such testing shall be mutually decided between the PROJECT
ENGINEER OR HIS AUTHORISED REPRESENTATIVE and the CONTRACTOR.
10.3 The CONTRACTOR shall inform the PROJECT ENGINEER OR HIS AUTHORISED
REPRESENTATIVE when the weld preparation and setting up for welding of various
members selected by the PROJECT ENGINEER OR HIS AUTHORISED
REPRESENTATIVE is in progress so that the PROJECT ENGINEER OR HIS AUTHORISED
REPRESENTATIVE can inspect the assembly, before the commencement of welding.
10.4 The responsibilities of the PROJECT ENGINEER OR HIS AUTHORISED
REPRESENTATIVE shall in no way reduce the CONTRACTOR’S responsibilities to ensure
that the work is carried out in accordance with the specification.
11. EXAMINATION OF WELDS
11.1 Examination refers to the quality control functions performed by the contractor during
fabrication, erection and testing.
11.2 The following shall be examined by visual examination:
a) Materials and components to ensure that these are as per the specification and free from
defects. If defects are noticed on free issue items these shall be brought to the notice of
the PROJECT ENGINEER OR HIS AUTHORISED REPRESENTATIVE without any
b) Joint preparation and cleanliness
c) Preheating as applicable.
d) Fit-up, joint cleanses and internal alignment prior to joining.
e) Variables specified by the welding procedure, including filler material, position and
f) Condition of the root pass after cleaning – external and where accessible internal.
g) Slag removal and weld condition between passes.
h) Appearance of the finished joint.
11.3 Acceptance for the visual examination shall be as per Code.
11.4 Other types of examination shall be as defined in Table 4 & 5, unless otherwise mentioned in
Section C of the enquiry specification. For the purpose of examination, fluids are categorized,
in accordance with Code.
12. QUALIFICATION AND CERTIFICATION OF NON-DESTRUCTIVE EXAMINATION
12.1 The CONTRACTOR’S examining personal shall have training and experience
commensurate with the needs of the specified examination. NDT supervisor / examiners
shall be qualified at Level – II or above.
12.2 The CONTRACTOR shall make available to the PROJECT ENGINEER OR HIS
AUTHORISED REPRESENTATIVE copies of the certificate of qualification of the examiner
he proposes to use for the PROJECT ENGINEER OR HIS AUTHORISED
13. METHODS OF EXAMINATION OF WELDS
The methods of examination for radiography (RT), liquid penetrant (PT) or magnetic particle
(MT), shall be in accordance with BPV Code, Section-V.
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14. ACCEPTANCE STANDARDS
14.1 Levels of acceptance of defects in pipe welds shall be in accordance with ANSI B 31.3 , and
for structural welds refer ASME Sec III class ND components.
15. WELDING REPAIRS:
15.1 All defects in MS welds requiring repair shall be removed by flame or arc gouging, grinding,
chipping or machining. The major repairs may involve:
a) Cutting through the weld.
b) Removing the weld metal down to the root depending upon the magnitude of the defects.
After removing the defects, the welds shall be examined by the same non-destructive testing
methods as specified for original weld and the same acceptance criteria shall hold good.
All the repair welds shall be made using the same or other specified welding procedures as
those used in making the original welds including preheating and stress relieving if originally
RECOMMENDED WELDING ELECTRODES:
SL BASE P. PROCESS MATERIAL
NO. MATERIAL NO. PURG SHELD
ROOT FILLER ROOT FILLER
a)Sizes ≤ 40
1 GTAW GTAW 0R 0R - - 1
NB & / Or 3mm
1 SMAW SMAW E 6010 E 6013 - -
Sizes>50mm ER70S2/ ER7018/
1 GTAW SMAW - - 2
Thick>19mm ER70S3 ER7016
4 GTAW SMAW ER80SB2 - -
1¼% Cr. 8018-B2
5 GTAW SMAW ER90SB3 9016/E ARGON ARGON 3 TO 8
8 GTAW GTAW ER308L ER308L ARGON ARGON 3 TO 8
3 Type 304L
Type ER 316 ER 316
8 GTAW GTAW ARGON ARGON 3 TO 8
316(316L) ER 316L ER 316L
S.S. TO 8-1 GTAW / ER309 ER309
4 SMAW - -
Carbon Steel SMAW
1) Electrodes and filler wires shall be reputed make like ADVANI/ESAB/PHILIPS
2) Fillet welds shall be done by SMAW process using E6013 for 150-Class system & 300 and
higher class system (refer Para 3.4).
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3) Low hydrogen electrodes shall also be used for critical system such as chlorine, hydrogen,
caustic and similar toxic inflammable fluids and also whenever the wall thickness is greater
than 19 mm.
4) Argon gas shall be 99.98% purity and shielding gas flow rate shall not be less than 0.34m3/hr
5) Nitrogen can be used as an alternative to argon for purging purpose only.
6) For fillet welds, electrode can be used instead of filler wire.
7) For GTAW process, electrode shall be 2% thoriated tungsten.
8) Initial purging prior to welding process shall be minimum of five (5) times the volume between
dams or ten minutes minimum whichever is higher. When welding commences., the purge
gas flow shall ensure that gas pressure is only marginally higher than atmospheric pressure
to ensure no roof concavity. Back purging of argon shall be maintained for a minimum of two
9) Back purging using wires manufactured by reputed firms duly approved by the
PURCHASER/PROJECT ENGINEER OR HIS AUTHORISED REPRESENTATIVE shall only
10) Electrodes shall have at least the same or higher physical properties and similar chemical
composition to the members being joined.
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LIQUID PENETRANT EXAMINATION PROCEDURE
This procedure covers 100% requirements for liquid penetrant examination using the solvent
removable, visible type dye penetrant material for detection of surface discontinuities on
metallic surfaces including weld surfaces.
2. APPLICABLE SPECIFICATIONS / CODE
a) ASME Boiler & Pressure Vessel Code, Section III NB & Section V,
b) ASTM E-165
3 AREAS OF APPLICATION
Plate edges after grinding for weld preparation, welds (root, intermediate and final passes),
crown and knuckle areas of dished ends, bent areas of formed parts like pipe bends etc.
4. CHEMICAL USED
All chemicals used in the testing shall conform to requirements specified in the referencing
codes and standards and shall be supported with relevant material test certificates. The total
halogen content in the chemicals shall not exceed 25 ppm and sulphur content shall not
exceed 1% by weight.
5.1 SURFACE PREPARATION
Prior to liquid penetrant examination the surfaces are to be cleaned and dried to make it free
from dirt, grease, lint, scale, oil, welding spatter etc that can obscure surface openings and
interfere with the test results. Cleaning shall be carried out by wiping with the cleaner and
then wiping it dry using cotton waste or lint free cloth.
5.2 APPLICATION OF PENETRANT
5.2.1 The liquid dye penetrant shall be applied over the areas to be examined by spraying or
5.2.2 The temperature of area to be examined shall be between 15 deg. To 50 deg. C.
5.2.3 A minimum dwell time of 10 minutes shall be required.
5.3 EXCESS PENETRANT REMOVAL : The area where the penetrant has been applied shall be
wiped with a clean lint free cloth / cotton waste and cleaning shall be continued till all visible
traces of penetrant are removed. Final cleaning shall be done with lint free cloth or cotton
waste dampened with cleaner. Care shall be taken to avoid application of excess cleaner &
deposition of any contaminating material which may affect test results.
5.4 APPLICATION OF DEVELOPER
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5.4.1 Developer shall be applied on the surface only by spraying to give a thin uniform coat. Dwell
time for bleeding out of the penetrant after application of developer shall be a minimum of 10
minutes. Prior to application of suspension type wet developer, the container shall be
agitated thoroughly to ensure uniform dispersion of suspended particles.
5.4.2 A dwell time of minimum 10 minutes shall be given after application of developer before
examination of the area for discontinuities. Examination shall be carried out within 60
minutes after application of developer.
5.4.3 Surface shall be dried at normal evaporation rate.
5.5 INTERPRETATION OF INDICATIONS
Interpretation and acceptance/rejection of indications shall be as per requirements specified
in the referencing code/tender specification.
5.6 POST EXAMINATION CLEANING
On completion of examination and interpretation of results the surfaces shall be thoroughly
cleaned of all traces of chemicals used for the test using clean cotton waste and cleaner
Inspection personnel carrying out this work shall be suitably qualified experienced and
certified as per ISNT requirements.
6. ACCEPTANCE STANDARD
Acceptance standard for defects/discontinuities as revealed by penetrant test shall be as per
requirements given in the referencing code viz. ASME Sec. VIII Div.1 and ANSI B 31.1 and
7. DOCUMENTS & RECORDS
The results of the liquid penetrant examination shall be submitted in a report in which all
relevant details shall be submitted. The purchaser’s Quality inspector will review the report.
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SPECIFICATIONS FOR RADIOGRAPHIC EXAMINATION
This procedure covers requirements for materials, methods and techniques to be used for
the radiographic examination of welds in piping system.
2. APPLICABLE CODES, STANDARDS & SPECIFICATIONS
Refer Para- 4 (Requirements).
3. SURFACE PREPARATION
The weld ripples or weld surface irregularities on both inside (where accessible) and outside
shall be removed by suitable process of grinding/polishing to such a degree that the
radiographic image due to any irregularity should not mask or camouflage with the image of
the discontinuity. However, the weld shall retain on its outside surface reinforcement not less
than the values given in the referencing code.
4. RADIATION SOURCE
As a standard requirement the radiation source used in this procedure shall be an X-ray
machine of a suitable kilo-voltage and mA rating to cater to the material thickness range
covered. Gamma radiography shall be employed only where deployment of X-ray
requirement becomes non-feasible and after clearance by the quality inspector. In such case
a separate written procedure for the same shall be submitted by the Inspection Agency for
approval by the QA inspector.
The personnel employed for radiographic examination shall be suitably qualified, trained &
certified by the appropriate agency like ISNT and in compliance with requirements of T-170
of ASME Sec. V.
Films used shall be of fine grain / ultra fine grain, high contrast, medium/low speed (type 2 or
better of table-2, SE-94. ASME Sec. V) used in industrial radiography. Brands used may be
KODAK M 54, A 54 & C 54, AGFA D7 & D4, Du-Point Cronex 65, 55 & 45. INDU NDT 65, 55
& 45. Fast films with coarse grain size are not permitted in weld radiography. All the
films/radiographs shall be free from mechanical, chemical or other blemishes as described
below to the extent that they do not mask or be confused with the image of any discontinuity
in the area of interest of the object being radiographed such as:
a) Fogging, (b) Streaks, water marks, chemical stains (c)Scratches, finger marks, static
marks, smudges or tears, (d)Loss of detail due to poor screen to film contact.
Lead screens of 0.005 inch thick (from & back) for X- Ray radiography and 0.010 inch for
Gamma radiography shall be used as intensifying screens. Fluorometallic screens are not
a) Processing shall be done in a controlled atmosphere (air conditioned) dark room fitted
with the required safe light alarm timer etc.
b) In the case of manual processing chemicals should be maintained at 68 deg. F and in
the case of automatic processing this shall be set as per the instructions of the machine
c) In case of manual processing the film washing tank shall be such that the rate of water
flow to displace the water per unit time of running condition is eight times its volume. A
separate tank of wetting agent should be used where the films after washing shall be kept for
a minimum of 1 min. to avoid water marks etc. before taking to the drier.
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9. IMAGE QUALITY INDICATORS
a) Penetrameters (Image Quality Indicators) for radiography shall be made out of
radiographically similar material as that of the material under test. They shall be identified
by lead numbers 3/32 in. high and by its metal or principal alloy composition on the surface
of the penetrameter. Hole or wire type penetrameters as per ASTM specifications may be
b) Penetrameter selection and essential hole requirement shall be as per relevant clauses of
ASME Sec. V.
c) Penetrameters shall be placed on the side nearest to the radiation source i.e. source side
of the object. If it is impracticable to do so it may be placed on the film side of the object
with a lead letter “F” placed beside the penetrameter. Penetrameter shall be placed
adjacent to or on the weld seam. Where the weld is having reinforcement the penetrameter
shall be shimmed and the shim thickness shall be such that the total thickness being
radiographed under the penetrameter is the same as the total weld thickness.
d) As a normal practice each film should have one penetrameter placed such that the plane of
the penetrameter is normal to the radiation beam. Each penetrameter shall represent an
area of uniform radiographic density as judged by a densitometer and if the film density
through the area of interest varies by more than –15% or +30% from the density through
the body of the penetrameter an additional penetrameter shall be used for such areas. For
panoramic exposure of a complete circumferential joint at least 3 penetrameters located at
120 deg. positions shall be used.
e) Radiographic examination of circumferential butt welds in pipes, tubes, fittings and nozzles
of size 3.5 inch O.D. or less shall be performed by single wall viewing only. The radiation
may pass through one or both walls. When the source is located outside a minimum of 3
exposures separated by 120 deg. are required for single wall viewing.
f) Where radiation passes through one or two walls and it is impractical to place the
penetrameter inside the vessel, the penetrameter may be placed on the film side except as
required in (g) below.
g) Butt-welded joints in pipes with an outside diameter of 3.5 in. or less may be radiographed
using the double wall double image technique in which the radiation passes through the
two walls and welds in both walls are viewed on the same film for acceptance. The
penetrameter shall be placed on the source side. The angle of the beam of radiation shall
be offset from the plane of the weld centerline to the minimum required to separate the
images of the source side and the film side portions of the weld so that there is no overlap
of the areas to be interpreted. A minimum of 2 exposures should be taken at 90 degrees to
each other for each weld joint.
h) Where the double wall double image technique is not feasible for effective results, double
wall superimposed image technique in which the radiation beam is located such that the
images of both walls are superimposed shall be followed. A minimum of 3 exposures shall
be made at 60 degree to each other in such cases.
10. IDENTIFICATION MARKS
Lead letters and lead numbers shall be used for identification. These numbers and letters
kept in parent material adjacent to the weld at least by 3 mm away from the weld edge.
11. FILM DENSITY
Film density requirements shall be as per T-234 of ASME Section-V and shall be verified
using a calibrated densitometer.
12, GEOMETRIC UNSHARPNESS
Geometric un sharpness shall be defined and calculated as given in ASME Sec V and
Table T-285 of Article 2.
13. ACCEPTANCE STANDARD
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Acceptance standard for defects/discontinuities as revealed by radiography shall be as per
requirements given in the reference code viz. ASME Sec. VIII Div.1.
14. DOCUMENTS & RECORDS
The results of the radiographic examination shall be submitted in a report form All relevant
details like source, technique, penetrameter, film type/brand used description of defects
shown, radiographic shooting sketch, etc. shall form a part of the report. The Purchaser’s
Quality Inspector will review the report.
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TECHNICAL SPECIFICATION : PAINTING OF M.S. EQUIPMENT & STRUCTURES
1.1 This specification establishes the minimum requirements for surface preparation, application
and inspection of painting for equipment with a continuous operation with temperature less
than 1200C. Painting shall be applied for corrosion service / temperature indication and
warning for specific hazards.
1.2 Stainless steel surface shall not be painted. Machined parts of operating equipment and
gasket contact surfaces shall not be painted.
1.3 Painting in this project shall conform to this section and section D of this specification. The
vendor shall submit a detailed plan for surface preparation and painting for review in specific
cases where painting shall be as per ‘manufacturer’s standard’
2.0 CODES & STANDARDS
IS 8629 : Codes of practice for protection of iron and steel
structures from atmospheric corrosion.
ISO8501.1/1S : Preparation of steel substrates before application of
Paints and related products.
SSPC : Steel Structure Painting Council – Surface preparation
3.0 SURFACE PREPARTION
3.1 Surface preparation of steel surface shall be done by removal of mill scale together with all
rust and surface contaminants, such as grease, dirt and all pollutants.
3.2 All weld spatter. Rough welds, sharp edges shall be removed or ground smooth prior to blast
3.3 The surface shall be blast cleaned to SA 2½. Near white blast cleaning as in ISO 8501.1 / 1S
3.4 Blast cleaned surface shall have good adhesion for the primers but shall not show excessive
roughness. Anchor pattern shall be RZ: 40 – 70 for zinc silicate primer and RZ: 35 – 50 for all
3.5 Machinery shall not be grit blasted. The use of power tools on machinery shall be limited so
as to avoid chances of ingress of particles in sensitive areas such as labyrinths of seals.
3.6 Blast cleaning shall not be executed when the surface temperature is less than 300 C above
dew point of surrounding air or the relative humidity is above 90%. Compressed air used for
blast cleaning shall be free from water oil or other contaminants.
3.7 Blast cleaning shall be executed using abrasives like steel / malleable iron shots steel /
crushed chilled or chopped wire.
4.1 All steel structures shall be painted as follows:
• One coat of inorganic Zinc Silicate primer with an average dry film thickness (DFT) of 75
microns per coat after initial surface preparation.
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• One coat of high build MIO epoxy with a minimum dry film thickness of 125 microns per
• One coat of polyurethane finish with minimum dry film thickness of 40 microns.
4.2 Care shall be taken to ensure that the quality of prepared surface shall not deteriorate before
application of paint.
4.3 Sufficient time as recommended by the paint manufacturer shall be provided for curing of
paint before application of next coat of paint. All painted surfaces shall be cured at ambient
4.4 Primer, intermediate and finish coats shall be fully compatible with each other. Appropriate
paint materials shall be obtained from the reputed paint manufacturers like Asian
4.5 Any paint, crayon or tape used for colour coding of stainless steel surface shall be free of
lead, zinc, sulphur and chlorides. Solvents used for cleaning the stainless steel surfaces for
such codes shall be indicated.
4.6 In case where shop coating has been damaged while handling, damaged and blistered
coating shall be removed by blast cleaning wherever possible or by hand or power tool
cleaning. Edges of breaks shall be feathered and specified number of primer and finish coats
shall be applied again.
5.0 INSPECTION & TESTS
5.1 Visual examination of surface preparation shall be carried out in accordance with ISO 8501.1
/ 1S. Profile checks of prepared surface shall be done by using ‘profilometer’ of comparator
5.2 DFT check for intermediate and finial coating shall be carried out and offered for Purcahser’s
5.3 Painted portions shall be checked for porosity and adhesion visually. If the number of pores
per square meter exceeds three. Entire area shall be blast cleaned and painted again.
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CLARIFICATIONS FROM THE VENDOR
1) Enclosure walls shall be step machined on horizontal planning machine.
2) All step machining shall be aimed at achieving perfect right angles at the steps.
3) Bottom tray shall be drawn from 3mm thick S.S. 304L sheet without any welds.
4) Needle clip support plate shall be installed perfectly at right angles to back face.
5) All internals shall be lined with 3 thick S.S. 304l plate.
6) Side walls of the sampling enclosure shall have rectangular opening for insertion of LAS unit.
7) Vacuum box test for checking lining welds.
8) LAS unit shall be fabricated in all S.S. including the bearings, lead screw etc.
9) The lead screw and all rotating faces shall be lined with titanium nitride coating more than 3
10) Two drive motors along with drive units for LAS operation
11) Programming of LAS operation and complete sampling sequence of the PLC with interlocks.
12) Encoders, Sensors for positional accuracies.
13) Supply of panel with mimic showing bottle positions.
14) Relays 20 nos. for Solenoid valves operation of the sampling circuit.
15) Wiring of the unit with PLC
16) Ready to install & use condition.
17) Illuminating fixture 2 nos.
18) Fabrication of dummy RSW for dimensional check.
19) Smooth functioning of shielded doors
20) Finish upto 0.8 microns
21) Installation at site including making of pipe insertion holes in the cell walls at site.
22) Fabrication and installation of bracket supports for enclosure installation.
23) Needle block pipes to be connected to the pipes coming from the cell with radiograph quality
weld joints or alternatively a complete 2 meter length pipe with suitable bends shall be welded
to the needle block support plate.
24) Testing & acceptance criteria
25) Testing of the unit for 100 fault free operations.
26) Testing for all error condition generation & visual indication on panel.
27) Free & smooth operation of the door
28) Checking of viewing window cutout for smooth insertion of dummy RSW.
29) Alignment of blocks on side walls for accommodating LAS shafts
30) Alignment of needle position with respect to cup positions during LAS operation
31) Alignment of Loading and delivery chute positions w.r.t. cup positions during LAS operation.
32) Availability of adequate lift for piercing of the sample bottle.
33) Smooth and free remote & manual operations of LAS movements.
34) The vendor shall have a segregated stainless steel fabrication and machining facility.
35) The vendor shall have experience in PLC programming and in-house programming engineers.
36) All the vendors are requested to submit in writing whether they have considered all the above
points before submitting this tender.
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APPENDIX - P
PLC is required for operation sequencing and interlocking of linear auto assembler. This involves
operation of many solenoid valves as per program requirement. These solenoid valves will in turn
operate air ejectors, air cylinders etc. Operator push button action, proximity sensors used for
position sensing and encoder feedback (discrete positions) are digital inputs to the PLC.
User interface for operation is from an operator panel consisting of pushbuttons, status indicating
LCD and alphanumeric display. PLC will be behind panel in this case. Optionally a graphical LCD
panel with operator interface which can display HMI may be quoted.
Scope for PLC
PLC shall have the following brief specifications.
A micro PLC with single processor CPU and power supply with modules for Ethernet communication
to network and suitable I/O interface shall be used. There shall be a separate programming port.
The supplier has to provide necessary racks and panels to mount the PLC hardware. The front facia
of the rack should have provision for actuations, LED indications, alphanumeric text displays.
Application software programming as per user requirements for SCADA/HMI
PLC logic programming
Hardware software integration
Commissioning of system at BARC KALPAKKAM, TAMILNADU.
Reference Standard : IEC 61131 for manufacturing, hardware testing
Power Supply : 230V 50Hz
DC voltages : to be generated internally
Operating temperature : 0 to 50 °.C
Storage temperature : 0 to 70 °.C
Mounting : 19” rack mountable
Component : Industrial proven with SMD components
Environmental : Dry heat tested IS 9000 part III at 55 °.C 50% RH
Damp heat IS 9000 part V at 40 °.C &95%RH
Processor : 32/64 bit 600MHz or better
Watchdog : Inbuilt
Programming interface : Serial (RS 232) /USB 2.0/ETHERNET
Capacity Discrete I/O: 1024 I/O max.
Analog I/O: 192 max.
User logic memory 32 Kilo byte min., expandable up to 64 KB;
Boolean execution speed 0.5 ms/k
Internal coils 2048 minimum
Timers 512 minimum
Counters 250 minimum
Connection ports Inbuilt ½
Battery backed clock Required
Communications It shall support modbus, profibus DP
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Diagnostic indication LEDs
Selection for Run/Pro With key
Floating point math Shall be available
PID capability To be specified by bidder
Programming port RS 232 from PC/USB/ETHERNET.
Networking / communication Ethernet – RS485 etc. to be detailed by bidder
Mounting of CPU Shall fit to suppliers back plane bus
Backplane crt consumption: 5V output : 50mA max.
Input Voltage : 24V DC
Configurable filter time : 0ms, 1.0ms (default), or 7.0ms
Input impedance : 10kOhms maxi.
Status/diagnostics indication: Front panel
Board status indication : facia
No. of inputs 16
Input voltage range 0-30 v
Trigger voltage 12-30 v
Input current 10 mA max
Response time 15 ms max. for ON
30 ms max for ON
Optical Isolation 1500 v AC
Status of I/Os By on board LEDs
Power up indicator By LED on module
Connector type Terminal suitable up to 3.0 mm conductors whole TB shall be
pluggable to module so as not to disturb the wiring while module
is being replaced.
No. of outputs per 8 relays
Comm. per module 2 (isolated)
Operating voltage load 48 v DC
Out put type Relay contact suitable for switching inductive loads
For mA (SPST, NO)
Relay contact rating 2A max. inductive load
Response time 15 ms ON – to- OFF and OFF- to- ON
Status indication Separate LED for each o/p
Isolation 1500 v AC, optical
Protection With fuse
Input type 4 – 20 mA DC from DP transmitter
No. of channels 4/8 per module
Resolution 12 bit
Accuracy +/- 0.1 %
Sampling MIN 100 ms for all channels
Input impedance 250 ohms max.
Isolation 1500 v AC from I/O to Bus
CMMR > 100 db at 50 Hz
Protection Reverse polarity
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Output range 4-20 mA DC
No. of channels 4/8
Update rate 8 ms. All channels
Resolution 12 bit
Accuracy +/- 0.1 %
Load driving 550 ohm
Isolation 1500 v AC
DO (Relay output) board
Points : 8 channel
Isolation : 1.5 kV
Outputs : Two change over contacts per relay.
Output rating : Relay 230 V, 2A rating
ON response time : 0.5 ms maxi.
Off response time
Status/diagnostics indication : Front panel LEDs
Board status indication : facia
Fail safe : Programmable output for CPU failure
Ethernet : IEE 802.3 MAC implementation
Protocol : ModBUS on TCP with on board processor
Speed : 10/100Mbps auto negotiating
Operator panel shall be 14/15” TFT LCD based capable for displaying general purpose SCADA/HMI.
This will be used as user interface for operation of valves and motors.
Size : 14/15”
Resolution : 1280 x1024 pixels
Backlight : Cold Cathode Fluorescent (CCFL)
- rated half life: 50,000 hourst
Touch Screen : Resistive, 12 bit X axis- 1280 cells Y axis - 1024 cells
Inbuilt : 300 MHz or better
Memory : Physical flash 64MB OR HIGHER
SRAM 512KB (Power off retention is life of the battery)
512KB (Boot loader)
Communication : Ethernet IEE 802.3 10/100 MHz ModBUS TCP
Programming port : RS 232 Modbus/ETHERNET/USB
Humidity : 10% to 85% RH, non-condensing -4 to 70°C
Operating temp : 0 to 50 °C
Enclosure : IP 56
Operational Vibration : 4, 4x, and 12 when mounted in a comparably rated
Operational; shock : IEC 68-2-6
10- 57Hz, 0.012" peak to peak displacement 57 - 500Hz,
1g acceleration, IEC 68-2-27 15g 11 ms sine wave
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Programmable Logic Controller
The raw materials and any bought out parts required for the fulfillment of this specification shall be of
high quality traceable to National / International Standards. Manufacturing Processes and
workmanship shall be traceable to the state of art practices. All electronic components, active and
passive, and any bought out electronic / electrical sub-assemblies shall be quality assessed and
conform to relevant National / International standards. PLC hardware shall conform to technical
specification mentioned in IEC 61131. For equipment requirement and tests reference standard will
be IEC 61131 Part-2
1. POWER SUPPLY:
The power supply to the PLC system shall be of 230V AC, +10%, -15%, 50 Hz + 3 HZ.
The various D.C. levels required within PLC system shall be generated in the system and not in the
scope of purchaser. The power supply required to operate various loads switched through outputs
of the PLC is in purchaser’s scope. The failure of power supply shall be indicated by LED. The PLC
shall drive a number of SVs connected to loads.
2. Operating Conditions:
The maximum ambient operating conditions for continuous operation of the system shall be as
follows. The temperature varies between 5 and 45° C and relative humidity is 95% non-condensing.
3. Surge Voltage:
Surge withstanding capability shall be as per IEEE standard 801-2.
4. Insulation Resistance and Isolation:
An Isolation of 1500 AC shall be provided. The Insulation Resistance between live terminals and
others shall be better than 100 M Ohms.
5. Functional Requirements:
All the physical (analog and digital) I/O’s are located near LAS unit room situated in floor-2 and floor-
3 P3A building. PLC CPU panels are to be located in the same area. The architecture offered by the
vendor shall be clearly mentioned in the offer.
5.2 Modular construction:
The PLC shall be modular in construction, easily accessible for maintenance and servicing. The
CPU of PLC shall be based on 32/64 bit processor.
The hardware and software design of the system shall govern the basis criteria like fail safe design,
system availability, Modular expandability, user friendliness and exhaustive fault monitoring and
diagnostic capability. Here Fail means ‘Open’.
It shall comply for general requirements, regarding service conditions, Mechanical constructions etc.
as per IEC draft standard.
6. Input and Output Section:
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The I/O modules shall be plug in type connected to CPU through I/O bus. All cards shall be
mounted in standard rack type system cabinet or suppliers special back plane. CPU section shall
work on its own industry standard Bus Structure suitable for the requirement.
All field I/O’s shall be terminated in PLC cabinet. It shall be possible to replace I/O modules on line
without influencing other control functions than that covered by I/O modules being replaced. All I/O
modules shall have on card LED indication for status of each I/O in addition to fault indication.
Digital inputs and outputs shall comply with the requirements of the standard voltage rating. It shall
be possible to interconnect inputs and outputs by means of correct selection of above digital I/O’s.
All cards shall be suitable for mounting either in standard rack system cabinet or suppliers special
cabinet. All the cards shall be of plug in type for easy removal or insertion. I/O modules are
connected to CPU through I/O Bus.
All I/Os are discrete in nature e.g. NO/NC contacts of relays, push button actuators, limit switch; and
contacts for switching the loads like solenoid valves, Relay Coils, motors etc.
All the I/O modules, CPU, and power supply modules shall have pilot type of LED indicator to show
The PCB of all I/O modules shall be conformal coated as a minimum means of protection.
Each rack shall have at least 10% expansion capacity.
Each input interface module shall have either 8 or 16 discrete inputs. As already mentioned, these
modules shall be plug in type that can be directly inserted in or removed from the I/O slots. The
galvanic isolation between plant and PLC shall be 1500 V AC. These modules shall provide filtering
against contact bouncing - 10 m. sec (Typical). DIN-IDC type connector in each module shall be
provided for taking connections to the field inputs terminal block with screw type terminals unless the
field inputs are directly terminated on the X cabinet itself. Any Module fault annunciation shall be
available. Current through closed input contact shall be typically 10 mA.
Output shall be short circuit proof. Outputs shall be through relay contact with contact rating of 2 A
max. at 230V AC. Isolation, dielectric strength, insulation resistance shall be as per IEE standards.
Like input modules these output modules also shall accommodate either 8 or 16 output channels.
Module fault annunciation shall be provided. The power supply to output circuitry shall be separate
and shall be protected against short circuit, overload, etc.
6.4 Control System Software:
The software for operating system of the PLC shall be of high performance and stable to provide
efficient control. The operating system shall be such that it is possible to program, configure,
operate, etc. in a convenient and user-friendly way. The operating system shall be responsible for
all internal functions - I/O scanning, application program execution, memory management, system
configuration, communication with peripherals, diagnostics, debugging, forcing the I/O etc. It shall
support all redundancy features of the system. It shall be possible to switch over to standby CPU
when operating CPU fails. There shall be a provision to give a message during such switching.
6.5 Programming method:
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The method of programming the PLC shall be based on relay Ladder logic. The PLC shall evaluate
different rungs of ladder logic functions sequentially and update the outputs accordingly. The
elements of ladder logic rungs shall be as follows:
- one or more NO/NC PLC inputs (contact elements)
- one or more of direct or inverted values PLC outputs
- one or more direct or inverted values of internal coils
- one of the following as function blocks.
* ON-DELAY Timer
* OFF-DELAY Timer
* UP/DOWN COUNTER etc.
Each rung of logic will actuate one output or one internal coil. The later one are bits of PLC memory
(R/W type) dedicated for storing intermediate results of complex logic functions.
It should be possible to force any contact element of any ladder rung to ‘O’ or ‘1’ during running of
unit from the MMI keyboard. The channel number / label of each logic element and rung output shall
appear against the respective items. The timer and counter blocks shall display its parameters like
preset value(s), current run value etc. User application program shall conform to IEC - 61131
providing portability among systems of different make and model.
Programming of PLC shall be possible from programming unit on-line, and the access being
protected by software password. The methods of programming shall be as per the requirement
given in specification. Any deviation from this shall be clearly mentioned in the bid. The
programmer shall be IBM compatible Pentium PC. It shall be possible to directly connect the
programmer anywhere in the network and be able to access any PLC. All necessary connecting
hardware like cards, standard connectors etc. are in the scope of supplier. Monitoring, forcing of
inputs and outputs, configuration, editing, debugging and loading of application S/W shall be through
the programmer. The diagnosis messages shall be displayed on the screen of the programming unit.
The supply of programming unit is not under the scope of the supplier, but necessary software shall
be provided without any extra charge. Programming shall be user friendly, menu driven. The
created application S/W shall be compiled in the programming unit and then transfer to the fully
backed (EEPROM) memory of PLC. It shall also be possible to retrieve the programs running in
PLC for on line editing and reloading the edited programs on line with password protection.
6.7 Memory and Back up:
All memories shall have at least 25% spare capacity considering full capacity of the system. All
operating system software codes including system monitor and diagnostic software shall be stored
in EPROM. All application software and data memory shall be stored in EEPROM. Quotation shall
be for both types of memory, eg. EEPROM and RAM with battery backup, so that the purchaser
would opt for either of it.
6.8 Internal coils, Timers and Counters:
The timers will be triggered either by a single contact element or PLC output or an internal coil or by
a series / parallel combination of these.
The counters however will be operated only by a single contact element or a single PLC output or an
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ON DELAY / OFF DELAY timer is envisaged as a software function block with a trigger input, an
output and a preset time delay value. Functionally it shall be identical to conventional ON DELAY /
OFF DELAY timers. The trigger input could be either a single contact element or a PLC output or an
internal coil or series parallel combinations of these. The output could be either a PLC output or an
Range of present delay 0.1 sec to 999.9 sec
Resolution of delay setting shall be 0.1 sec
Accuracy of delay time shall be + 1% or 0.01 sec whichever is better.
UP/DOWN Counter is also envisaged as a software function block with an UP input, DOWN INPUT,
an Enable input, a reset input and output and a preset count value. It shall be functionally identical
to conventional UP/DOWN counter.
Preset Value Range and maximum counting speed shall be 0000 to 9999 and 2 counts per second
7. Execution time:
All input scan rate and output refresh rate shall be 20 m. sec. or better. The system response for
control output shall be within 40m.sec i.e. in case of any change in input signal, a change in
corresponding logic output command shall be within 40 m. sec. under worst data loading condition.
8. Communication Port
PLC shall have a built in RS-232/ETHERNET/USB communication port so that a programming
device can be connected separately to it. It shall be possible to program, configure and operate
through this port.
All the necessary hardware and software to realise the communication shall be provided.
The CPU section shall have adequate spare capacity for modification or extension during
commissioning when fully expanded, CPU loading shall not exceed 80% of its capacity.
10. Noise immunity:
The system shall have very high noise immunity in order to ensure safe and reliable operation.
When subjected Electrical and Electromagnetic disturbances which are expected in the plant
Contact bounce filtering shall be available for all digital inputs.
For analog I/O’s, the CMMR and normal mode rejection shall be a minimum of 100 db and 80 db
The system shall be highly reliable with very high Mean Time Between Failures (MTBF) and low
Mean Time To Repair (MTTR). The bidder shall clearly indicate these values in his offer.
12. Power Supply Interruption:
For short disturbances of the power supply as per IEC draft standard, I/O’s and peripherals shall
maintain the normal operation.
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For longer interruption of the supply, the PLC System shall either maintain normal operation or go to
the predefined stage and have a clearly specified behavior until normal operation is resumed.
Tolerable power supply interruption time shall be mentioned in the offer.
Adequate redundancy in the DC power supply to be provided. Voltage levels are 230 V AC and 24 V
13. Diagnosis features:
Exhaustive diagnostic features shall be available up to the lowest level with detail reporting on MMI.
Appropriate message shall appear; on programming unit if any of the modules in the CPU section or
I/O section is missing or not in correct position. Operator altering messages shall be available in the
system during switch over to stand by unit.
14. Interrogation Voltage:
Reverse connection of contact interrogation power supply shall be available. The contact
interrogation voltage shall not be more than 24 V DC only.
15. Documentation and Training:
Complete documentation for assembling, configuration and programming shall be provided without
any extra changes. The manuals shall contain all the aspects related to hardware and software.
Training shall be provided for two people to gain familiarity with the systems supplied with no extra
charges at supplier’s premises.
PLC’s with Redundant CPU, Power Supply, and communication Modules and firmware in EPROM.
25% spare additional I/O (discrete & analog) shall be provided each PLC panel.
Make: Schneider, GE Fanuc, Messung, Mitsubishi and Siemens.
17. PROGRAMMING :
The programming shall be carried out by the vendor before supply, as per the logic given by the
18. OUTPUTS :
Relay board for supporting 64 SVs (O / P) with OEN / PHOENIX relays with 2 amps. rating shall be
The unit will be programmed by the supplier.
The unit shall be installed to link with the Sequential Indexing Unit at vendor & purchaser’s site
followed by testing to check programmed logic.
All the man, material, tools & tackles etc. required for the above job is in the scope of
contractor. Supervision of the works shall be the responsibility of the supplier.
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VENDOR EVALUATION PERFORMA
LINEAR AUTO SAMPLER ENCLOSURES
Page 47 of 79
S. No. Title Page
2 Period of Execution
3 Vendor Evaluation criteria
4 Important Notes
5 General Information
6 General Requirement for Fabrication Erection and Testing
7 Instruction to Vendors
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The linear auto sampler unit along with enclosures as per specifications given in this document are
required for Project P3-A at BARC Facilities Kalpakkam.
The tender covers work of composite nature involving manufacture enclosures of thick MS plates,
providing SS 304L lining on the inside of the enclosure, providing of accurately located internals like
supports, rails, etc., manufacture and installation of equipments like linear auto sampler unit.
Procurement and installation of drive motors, encoders, sensors, PLC, Programming of PLC for
required functions of the unit. Training of purchaser’s man power for programming, fault finding and
rectification of PLC. Manufacture, testing, supply installation of complete LAS unit at Project P3-A,
BARC facilities Kalpakkam.
The LAS units have been designed for remote sampling of process solutions. This design is being
incorporated for the first time and hence certain amount of changes are expected at the initial stages
of fabrication. This point may be taken into account by the bidders. It may also be noted that since
remote sampling is being planned in all the LAS units, it is imperative to achieve high levels of
accuracies and repeatability in component dimensions in all the enclosures.
Based on technical / commercial considerations BARC reserves the right to accept or reject offers.
Offers are invited from experienced & financially sound parties having experience in heavy
machining, fabrication, SS lining / automation & machine building jobs. Complete details of the work
are given in Technical Specifications.
Requirement: The external sizes of enclosures with categorisation and numbers required are given
a) M.A. Enclosure: 1065 mm (L) x 640 mm (H) x 367 mm (D). Qty. – 4 noS.
2. Period of execution:
Period of execution shall be as follows:
Submission of drawings: 1 month from award of order.
Fabrication of first MA Enclosure: 3 months after approval of above drawings.
Complete manufacture: 6 months after approval of sample enclosure
Installation At Site: 1 month after shipping clearance.
3. VENDOR EVALUATION CRITERIA
EVALUATION CRITERIA FOR SELECTION OF VENDORS
1. Financial strength and capacity of vendor to take up the tendered work.
2. Industrial Experience & Technical capability to fulfill requirements of tender
3. Project resources like shop infrastructure, manufacturing capacity for mass production &
adequate qualified man-power to meet delivery schedules.
4. Structured Organisation
3.1 Financial Soundness :
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Bidder shall be financially sound. Bidder shall fill up all financial information in Questionnaire.
Bidder shall enclose the audited balance sheets supporting the information filled up.
The bidder shall submit the financial history of the company for the preceding 3 years.
The bidder must have undertaken and successfully executed job orders of similar nature and
The bidder shall have turn over adequate for investment in raw material cost.
3.2 Industrial Experience:
Bidder shall fill up this information in annexure- 5 & 6. Bidder shall enclose the supporting
documents as required.
3.2.1 The bidder shall have experience of automation stainless steel precession machining and
3.2.2 The bidder shall have experience in handling, machining and fabricating equipments from
thick MS plates.
3.2.3 The bidder shall have experience of supplying equipment to nuclear installations for BARC,
NPC and IGCAR in respect of systems equivalent to class I components.
3.2.4 The bidder shall have experience of Chemical Process Industry involving handling of nitric
acid & fertiliser industry.
3.2.5 The bidder shall have experience in remotisation and machine building.
3.3. Project Resources:
The vendor shall have a well laid out machine shop with adequate space and segregation of
M.S. & S.S. fabrication & machining facilities. The machine shop shall consist of heavy
machines to handle enclosures during machining and assembly. The machine shop shall have
adequate CNC machining facility like CNC turning center, DRO and CNC milling facility. The
machines employed for this job shall be able to meet the requirements of achieving high
accuracy levels to produce repeatable and identical enclosures.
The vendor shall submit a detailed list of heavy machinery indicating type, capacity, accuracy,
duty, year of Manufacture & valid recent calibration certification.
The vendor shall have a manufacturing capacity for mass production to meet the delivery
schedules required for this work. The vendor shall submit past record of meeting delivery
schedules for similar value orders. The vendor shall indicate shop capacity reserved for
completion of tender jobs as per committed schedules.
The vendor shall have adequate handling facility for thick MS blocks and enclosures on shop
The vendor shall have adequate, permanent skilled manpower. The vendor shall have qualified
design engineers & electrical & Electronics group. The same shall be clearly brought out in the
The vendor shall have adequately qualified managerial and supervisory staff which shall be
employed to look after the work covered under the tender. The vendor shall have qualified
engineers with experience for design and qualified drafting personnel for drafting work
The vendor shall have qualified, experienced and skilled machine operators / welders /
fabrication personnel. He shall have adequate number of trained and certified QA personnel.
The vendor shall have PLC programming & training personnel.
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The list of manpower with qualifications and experience available for undertaking the work shall
be submitted with offer. Bidder shall fill up this information in annex. -1 & 2. Bidder shall
enclose the relevant documents supporting the information filled up.
The vendor shall have a proper structured organisation with departments for important functions
like design, drafting, production, QA & inspection and procurement.
The vendor shall have a well-established Quality Surveillance, Quality Control and Quality
Assurance set-up. The vendors Quality System should preferably have an appropriate ISO-
Vendor shall fill up this information in annexure- 4 & 10. Vendor shall enclose the relevant
documents supporting the information filled up.
A) FIRMS HAVING FOLLOWING EXPERIENCE AND IN-HOUSE FACILITIES SHALL BE GIVEN
a) CNC machines for machining.
b) Automation and remotisation & machine building experience.
c) Handling facility for heavy blocks.
d) Experience in stainless steel lining and fabrication.
B) INSPECTION & ASSESMENT OF VENDOR’S WORKS:
The purchaser shall evaluate the manufacturing facilities of the vendor, to assess the adequacy,
for undertaking the tendered work. The vendor shall submit all the details as per the attached
Annexure-8 & 9. The purchaser reserves the right to reject or accept the offer.
4. IMPORTANT NOTES:
4.1 Materials and Services by BARC
Materials, facilities and services that will be supplied by BARC for execution of the package
are indicated in Technical Specifications.
Reference drawings are supplied along with tender. The vendor shall prepare fabrication
drawings and get them approved by the purchaser. The drawings may under go certain
changes during the fabrication and approval of the sample enclosure. These finally approved
drawings shall form the basis for bulk manufacture and supply.
4.3 Package execution Time frame
The package work shall commence and shall be completed in accordance with the time
frame as indicated.
4.4 Security Rules
The vendor shall follow at site all security rules as may be framed by the BARC from time to
time regarding movement of materials and equipment to and from site, issue of identity
cards, control of entry of personnel and all similar matters. The vendor and his personnel
shall abide by all security measures imposed by the engineer or his duly authorised
representative from time to time. The Vendor shall also follow all rules and regulations
applicable to the area being declared / pronounced from time to time by the authorities or
authority of BARC in the vicinity or any other statutory orders. Nothing extra will be payable
Page 51 of 79
on account of stoppage / hindrance of the work due to the enforcement of security measures
/ emergency conditions. The Vendor, his employees and agents shall not disclose any
information or drawings furnished to him by BARC. Any drawings, reports and other
information prepared by the Vendor or by BARC or jointly by both for the execution of the
contract shall not be disclosed without prior written approval of the Engineer. No photographs
of the works or plant within site premises shall be taken without prior written permission of
4.5 Liability for loss, damage, accident, etc.
The Vendor shall note that if the work is awarded to him, he shall be liable to take a
Contractor's All Risk Insurance (CARl) policy covering, inter-alia, not only his men and
material but also the materials supplied on free or chargeable basis by BARC and BARC
shall be named as the co-assured. A policy shall be taken progressively to cover the full
value of the material and should cover the third party liability also.
4.6 Rights of other agencies
The vendor shall note that several other agencies may also be simultaneously working within
and around the areas covered under the jurisdiction of his work. No extra claim during the
tenure of the work will be entertained by BARC for hindrances on account of such interfaces
with other / allied agencies.
4.7 Safety Measures,
To avoid possible accidents to staff and labour employed on the construction site, it is
imperative to observe all the safety practices that may be laid down from time to time by
BARC / Statutory Bodies.
4.8 The Contractor shall provide all the transport facilities for their employees by their own
means and at their own cost.
5. General Information
5.1 The vendor shall be deemed to have carefully examined the specification in it's complete
form and to have been fully informed and satisfied himself as to the details, nature, character
and qualities of the work to be carried out, site conditions and other pertinent matters and
5.2 The vendor shall furnish all the data called for in the relevant standard pro-forma to facilitate
correct evaluation of his offer in a most expeditious manner. It is in the interest of the vendor
to submit the offer in the above manner, failing which it is likely that his offer may not be
5.3. Option for Placement of Order:
Based on technical / commercial considerations BARC reserves the right to accept or reject
5.4. General Requirements, relating to testing & inspection:
5.4.1 The equipment / material covered by this contract shall be subjected to stage inspection and
final inspection and testing. The Contractor shall provide all services to establish and
maintain quality of workmanship in his works and that of his Sub-Contractors to ensure the
mechanical accuracy of components, compliance with drawings, identification and
acceptability of all materials, parts and equipment.
5.4.2 The Contractor shall perform his internal inspection/testing as per checklist before offering
equipment / material for Purchaser's inspection. Only after ensuring that his inspection / test
results are satisfactory, Contractor shall offer the equipment / material for Purchaser's stage
However, this clause is not applicable in case of such tests, which are required to be done
only once in the lifetime of the equipment.
5.4.3 The minimum inspection requirements for all components/ equipment shall conform to the
design and fabrication requirements as defined in the technical specification document in the
tender. The type of inspection shall be as prescribed in Quality Control Plan and as agreed
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upon by the Purchaser and shall include, if applicable, inspection procedures prescribed by
codes and specification document.
In the case of stage inspection wherever Purchaser's hold points are specified, the
Contractor shall proceed from one stage to another only after the component is inspected by
the Purchaser or his representative and permission given to proceed further. The same
procedure shall be adopted for any rectification and repairs suggested by the Purchaser or
his representative. At all customer hold points, the Contractor shall compulsorily offer for
inspection to Purchaser and, if any waived by Purchaser, shall be obtained in writing for
record purposes. None of the equipment to be furnished or used in connection with the
contract shall be dispatched until shop inspection, satisfactory to the Purchaser or his
representative has been made and specific shipping release for the equipment is issued by
6. General Requirements for Fabrication, Erection and Testing
6.1 Erection, inspection and testing shall meet the requirements of all currently applicable codes,
standards and the purchaser’s specifications.
6.2 The Contractor shall ensure compliance with all statutes, laws, rules and regulations of the
Central or State Government or any other authority.
7. Instructions to Vendors
7.1 Vendors are required to give a complete Offer highlighting their organizational set up,
experience, technical personnel employed, spare capacity, competence, financial standing,
7.2 BARC will evaluate the credentials of the intending bidders based on the documents
submitted by them and physical verification if so desired. Among other things, emphasis will
be given to qualified personnel, availability of machinery, equipment and testing facilities,
financial strength, experience and expertise in executing quality works within the specified
time schedule. It is preferable that subcontracting of any or part of the work be avoided or
kept to the minimum. In their bids, bidders must clearly identify the extent and scope of work
they propose to subcontract, and identify the subcontractor. Evaluation of the subcontractors
by BARC will also be along the same lines as for those of the main bidders.
7.3 Information furnished by the vendors will be kept strictly confidential between the clients and
7.4 Vendors. shall provide a definitive answer to the following questions:
7.4.1 Has the vendor or any of its officers during the last five years: :
• default on a contract ?
• been declared bankrupt ?
• assigned a contract for the benefit of creditors?
• been a party to litigation involving the non-payment on account of wages,
materials, equipment or supplies?
7.4.2 If the answer to any of the above questions is "yes", an explanation of the circumstances and
disposition shall be given. Any incorrect or false information may lead to disqualification or
cancellation of contract forthwith.
7.4.3 Vendors are required to advise whether within the preceding three years they (including any
joint venture partner) have ever been debarred, suspended, or otherwise prohibited from
contracting with any Central, State, or other governmental agency or entity. Vendors shall
also advise whether within the last ten years they (including any joint venture partner) have
been charged with, or convicted of, any serious crime or felony.
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8.1 Of Title
The Contractor warrants that the goods are not subject to any security interest, lien or other
8.2 Against Patent Infringements
Except when the Purchaser furnishes design specifications to the Contractor, the Contractor
shall at his own expense, defend and save the Purchaser harmless from the expenses and
consequences of any suit or procedure brought against the Purchaser, so far as said suit or
procedure is based on a claim that the goods furnished constitute an infringement of any
patent In existence on the date of the order. In addition, the Contractor shall secure at his
own expense a fully paid up license or licenses that will permit the Purchaser to continue use
of the goods furnished free of further claim for infringement.
8.3 Of performance
The Contractor shall guarantee that the goods furnished by him shall be in full accordance
with the requirements of the enquiry specifications.
8.4 Of Quality
The Contractor warrants that the goods are new and of high quality and that the goods will
be free of defects in design, materials or workmanship for a period of twelve (12) months
from the date of commissioning of the corresponding equipment system.
8.4.1 If within the expiry of the above stipulated guarantee period, the subject goods or any parts
thereof are found defective because of design, workmanship or materials, the Contractor at
his own expense, shall repair or furnish and install replacement parts of design, workmanship
and with material approved by the Purchaser. The guarantee period for replaced parts or
repair work shall be the same as above.
8.4.2 The guarantee period shall be extended by the length of time required to make any
adjustments, changes or repairs necessary to fulfill the guarantee.
9.1 The Contractor shall be responsible for transportation of equipment from Manufacturers
works to site, unloading of material at site, transport to his store, joint inspection of material
by Purchaser and Contractor, lodging insurance claims against losses damages during
transport, safe storage and preservation during storage and erection till the system is handed
over to BARC.
9.2 No material shall be dispatched without prior consent in writing (shipping release) of the
purchaser or its authorised representative.
9.3 It is the responsibility of the contractor to insure all the equipment / material during transit.
The purchaser will pay as per the terms and conditions of contract for only such equipment,
actually received at site in acceptable condition.
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VENDOR EVALUATION CRITERIA
SELECTION OF VENDORS
Page 55 of 79
1. EVALUATION CRITERIA FOR SELECTION OF VENDORS:
1.1 Financial strength and capacity of vendor
1.2 Industrial Experience & Technical capability to fulfill requirements of tender
1.3 Project resources like shop infrastructure , manufacturing capacity for mass production &
adequate qualified man-power to meet delivery schedules
1.4 Structured Organisation
1.1 Financial Soundness :
The bidder shall submit the financial history of the company for the preceding 3 years.
Firm shall be a profit making organisation of adequate size.
Vendor shall provide information in support of the above requirements.
1.2 Industrial Experience:
Information supporting the vendor’s strength in the following areas.
1.2.1 Experience of stainless steel lining work.
1.2.2 Experience in handling, machining and fabricating equipments from thick MS plates.
1.2.3 Experience of supplying equipment to nuclear installations for BARC, NPC and IGCAR or
1.2.4 Experience of Chemical Process Industry.
1.2.5 Experience in remotisation and machine manufacture.
1.2.6 Experience in work including mechanical, electrical instrument and control components.
1.3 Project Resources:
The vendor shall have a well laid out machine shop with adequate space. The machine shop shall
consist of heavy machines to handle enclosures during machining and assembly. The machine shop
shall have adequate in-house CNC machining facility like CNC turning center and CNC milling
facility, slide-way grinder, plano-miller etc. The machines employed for this job shall be able to meet
the requirements of achieving high accuracy levels to produce repeatable and identical LAS units.
The vendor shall submit a detailed list of heavy machinery indicating type, capacity, accuracy, duty,
year of Manufacture & valid recent calibration certification.
The vendor shall have a manufacturing capacity for mass production to meet the delivery schedules
required for this work. The vendor shall submit past record of meeting delivery schedules for similar
value orders. The vendor shall indicate shop capacity reserved for completion of tender jobs as per
The vendor shall have adequate handling facility for thick MS blocks and enclosures on shop floor.
The vendor shall have adequate, permanent skilled manpower.
The vendor shall have adequately qualified managerial and supervisory staff which shall be
employed to look after the work covered under the tender. The vendor shall have qualified engineers
with experience for design and qualified drafting personnel for drafting work
Page 56 of 79
The vendor shall have qualified, experienced and skilled machine operators / welders / fabrication
personnel. He shall have adequate number of trained and certified QA personnel.
Vendor shall provide information in support of the above requirements.
The vendor shall have a proper structured organisation with departments for important
functions like design, drafting, production, QA & inspection and procurement.
The vendor shall have a well-established Quality Surveillance, Quality Control and Quality
Assurance set-up. The vendors Quality System should preferably have an appropriate ISO-
Vendor shall provide information in support of the above requirements.
2. FIRMS SHALL HAVE FOLLOWING EXPERIENCE AND IN-HOUSE FACILITIES:
a) CNC machines for machining MS blocks of the enclosure.
b) Automation and machine building experience.
e) Handling facility for heavy blocks.
f) Experience in stainless steel lining and fabrication.
g) Experience in handling orders with mechanical, electrical instrument and control components
including programming of PLC.
Page 57 of 79
VENDOR EVALUATION ANNEXURES
LINEAR AUTO SAMPLER ENCLOSURES
Page 58 of 79
(To be submitted along with this tender)
(Please attach separate sheets wherever space is not sufficient)
1. Name of Vendor:
2. Whether sole Proprietorship/ Partnership/
Limited Company/Co-operative Body/Joint Venture:
3. Names of Proprietor/Partners/ Directors :
4. Structure and Organization :
5. Address, Telephone and Fax Nos
Annexure Title Page No
2. Vendor Evaluation Performa
3. Acceptance to Comply with Specifications
4. Organisational Structure
5. Experience in Nuclear Industry
6. Experience in Chemical Industry
7. Proof of Ability of Vendor
8. List of Plant & Machinery
9. Machinery Details
10. Details of QA Set up
11. Details of Subcontractor
12. Information to be submitted with Tender
13. List of FIM
14. Price & Schedule of Quantities
15. Particulars of Contract Works Executed during last 5 years
Particulars of contract works in hand
16. Particulars of staff employed since 3 years
17. Particulars of Managerial/Engineering & construction
and e-mail of Registered Office :
6. Address, Telephone and Fax Nos. and
e-mail of Office through which the proposed
work (if entrusted) will be handled with name
and designation of person-in-charge :
Page 59 of 79
7. Registration particulars of Partnership/
Limited Company/Co-operative Body/Joint Venture :
8. Whether registered for works with Govt./
Quasi Govt. / Public Institutions, etc. : (Give details)
9. Experience in handling machining &
fabrication of thick plate components,
SS lining, remotisation and SS Piping.: (Give details)
10. Areas of other business activities if
any and place of such business:
11. Detailed engineering and drafting
12. Evidence to indicate financial capacity
to undertake the proposed work (if entrusted)
and names (with address) of the Bankers :
13. Latest income-tax clearance certificate
(attach copy). Also indicate receipts from
contracts during last five years:
14. Core competence of business Engineering / :
manufacturing / trading / projects
a) Capital - Authorized/Paid-up
:b) Auditor’s report, audited balance sheets
and profit and loss statement for three (3) years:
c) Turnover 2010 --2011
2009 – 2010
2008 - 2009
16. Approximate value of all the works executed
during the last five (5) years:
2010 : Rs. ...................
2009 : Rs. ...................
2008 : Rs. ...................
2007 : Rs. ...................
2006 : Rs. ...................
17. Approximate value of all (remaining)
works committed for execution during the next 36 months :
18. Particulars of Contract works
executed :As per Annexure-3 & 4
Cost of engineering
Cost of supply
Page 60 of 79
Cost of erection
19. Particulars of Contract Works in hand
Please attach separate sheet if required.
20. Particulars of Managerial/Engineering
Personnel and Technicians in continuous
employment since last three years : Please give detailed list
21. Particulars of tools, plants and machinery
owned which would be available for the
proposed work (if entrusted) : As per Annexure-5
22. Details of Quality Assurance set-up
for carrying out the work : As per Annexure-6
23. Particulars of sub-contractors : As per Annexure-7
24. Any special expertise or technology
available for carrying out work of this
type : (Give details).
25. Number of supplementary sheets attached:
Signature of Vendor With Seal
Page 61 of 79
ANNEXURE - 2
VENDOR EVALUATION PERFORMA
(To be filled in & submitted along with the offer)
Reference Tender Enquiry No. :
Quotation No. :
1. Vendor Details :
2. Registration details with Registration No. :
i) Small scale industry
ii) Directorate of industries
iii) DPS – DAE
3. Organization Details
i) Nature (Proprietary, Partnership, Pvt. Ltd.
Public Limited, State / Central Govt. Undertaking)
ii) Organizational structure
iii) List of man-power (indicate clearly the designation,
Qualification and experience)
4. Annual turn over of last three years along with the income tax return.
5. Give a list of similar jobs executed in the recent three years for DAE / Govt. organization / Public
Sector units. Indicate the value of order and date of delivery.
6. Details of facilities available:
a) Floor Space
c) List of machines, equipments etc. available for design and fabrication.
d) Quality control facilities available.
Signature of Vendor With Seal
Page 62 of 79
ACCEPTANCE TO COMPLY WITH SPECIFICATIONS
1. Whether vendor fully agrees to comply with the Drawings and Technical Tender
Specifications: YES / NO
1.1 If yes, put the official seal and signature:
1.2 If not please indicate the deviation clearly point wise and put the official seal and
Signature of Vendor With Seal
The following information shall be submitted along with the quotation:
Whether vendor proposes to engage the services of a sub-vendor: If yes, provide all the
details technically relevant to the indent.
Signature of Vendor With Seal
Page 63 of 79
ANNEXURE – 4
Please indicate below or attach the organization chart showing the company structure including :
a). Communication and responsibilities
b) Structure of engineering group
c) Production group
d.) Machining building
e) Electronics and instrumentation group
f.) Finance group
g.) QA group
h.) Positions of Directors and relevant key personnel (by name).
Specifically bring out the line of reporting.
Signature of Vendor With Seal
Page 64 of 79
Annexure – 5
Experience of Nuclear Installations like BARC, NPC ,IGCAR
S. Name of the Year of Contract Description of services
No. company execution Value
Civil / Mechanical / Piping /
Rs . Electrical / Instrumentation
TOTAL (Rs. Lacs)
Experience of nuclear installation for NPC, BARC and IGCAR in respect of systems
equivalent to class I components.
Signature of Vendor With Seal
Page 65 of 79
Annexure – 6
Experience of Chemical Process Industry involving handling of
nitric acid & fertilser industry.
S. Name of the Year of Contract Description of services
No. company execution Value
Civil / Mechanical / Piping /
Rs . Electrical / Instrumentation
TOTAL (Rs. Lacs)
The order with contract value equal or more than 5.0 crore each shall be considered
for evaluation . Hence, bidder shall list those orders only in the above mentioned
Signature of Vendor With Seal
Page 66 of 79
ANNEXURE - 7
PROOF OF ABILITY OF THE VENDOR
(Use one form for each work carried out)
Part – A
1. Name of work :
2. Name of the firm / project for which :
work was done.
3. Address for reference :
4. Value of total work : Rs.
5. Value of fabrication work, if it is a : Rs.
6. Value of equipment erection work : Rs.
If it is composite one.
7. Date of commencement :
8. Date of completion :
9.Name of sub-contractors if any, employed:
a. Fabrication work
b. Machining building
c. Electronics and instrumentation
d. Erection work
10. Brief description of various requirements
of piping / fabrication work as carried out :
i) Radiography : 100% 50%
ii) Liquid dye penetrant examination : Done Not Done
iii) Use of consumable insert with TIG : Done Not Done
iv) Stress relieving of pipes &
Equipment : Done Not Done
11. Has the work been completed and final
Payment received : Yes No
12. Was there any Arbitration? : Yes No
13. Any major M.S. Shields fabricated and
erected? : Yes No.
Signature Of Vendor With Seal
Page 67 of 79
ANNEXURE – 7 (Contd.)
Part - B
PARTICULARS OF CONTRACT WORKS
EXECUTED DURING LAST FIVE YEARS
Sl. Name of Type of Name Contract Completion period Reasons
No. Project Work Main and Amount (stipulated and for delay, if
and Features Address actual any
Location and of
of the Work
Original Final Stipulated Actual
PARTICULARS OF CONTRACT WORKS IN HAND
Provide information about all projects in progress.
Sl. Name of Type of Name and Contract Completion period Present
No. Project Work Address stage of
and of Owner
Estimated Cost work with
of Balance reasons
for delay (if
Signature of Vendor With Seal
Page 68 of 79
LIST OF TYPICAL PLANT AND MACHINERY
Equipment/Tools for Construction
Machines: Fabrication Machines contd.
Slide way Grinders (finish 0.8μ) Stress Relieving Recorders
Surface Grinders (finish 0.8μ) Passivation facility
Horizontal boring machine Sandblasting facility
Plano miller Coating, painting equipment
CNC turning center Compressors (@100 cfm)
Bevelling Machines Portable Compressors
Bending Machines for Pipes
Machines with DRO Inspection Equipment
Material handling items Precision level gauges
Mobile cranes MPT Machines
Scaffolding Radiography cameras
Trucks X-Ray Machines
Trolleys U.T. Machines
Chain pulley blocks, hoists Chemical Testing Facility
Dark Room Facilities
Fabrication Machines Radiography Interpretation
Welding machine(s) Special purpose Cameras
TIG Sets, High Frequency Sets
Automatic Welding Machines
Electrical & Instrumentation
Above is a typical list of plants / machinery for mechanical works. Bidder to indicate
complete list of equipment for Machining / Fabrication / Erection & testing available with
Signature of Vendor with Seal
Page 69 of 79
ANNEXURE – 9
The details of the relevant major machinery available with the vendor shall be
furnished in the format given below:
Sr. Name of Make and Year Type of Operation Date of Remarks
No. Machine of Installation Performed by This Calibration
Of machine machine
Signature of Vendor With Seal
ANNEXURE – 10
DETAILS OF QUALITY ASSURANCE SET-UP FOR CARRYING OUT THE WORK
Contractor’s Facilities Own/Hired
(1) (2) (3) (4)
1. Engineering, Drafting &
I f h k
2. Procurement of Materials
3. Pre-fabrication and erection
f i i
4. Examination and testing of
i i d i
5. Other testing facilities
1. In addition to giving particulars regarding above facilities, the tenderer shall submit company
quality assurance manual and briefly indicate quality assurance programme he proposes to
follow during engineering, procurement and erection of the proposed work.
2. Any imposition / agreement with respect to restrictive use of technology and validity periods
should also be brought out.
3. If the bidder is having graded QA / QS Systems, the details should be furnished.
4. Add separate sheets for details, if required.
Signature of Vendor With Seal
Page 70 of 79
If it is foreseen that any part of the contract will be sub-contracted, state the type of work to be
undertaken by the sub-contractor(s) and give below name and address of the probable sub-
contractor(s) to be used along with their scope and financial and man-power resources.
Work to be sublet Name and address of Proposed
1. Attach additional sheets to provide information regarding financial, Qualified man-power
and other resources of the proposed sub-contractor. If the sub-contractors have not
been finalized, give details of all prospective sub-contractors.
2. More than one sub-contractor’s name can be given.
3. Sub-contractors evaluation will be done by BARC. If found unsuitable for the job, can be
4. Attach list of engineering, manufacturing, erection, inspection and testing facilities
available at sub-contractors with their signatures appended to it.
5. Man-power (Qualified) available with main Contractor to supervise and guide Sub-
Contractors work should also be given.
Signature of Vendor With Seal
Page 71 of 79
ANNEXURE - 12
INFORMATION TO BE SUBITTED WITH THE TENDER
In addition to the pertinent details the following information is required to be submitted with
the tender by the intending bidders. Tenders received without this information are liable to be
rejected. Submission of the tender in two separate sealed envelopes as indicated in the
1. Positive confirmation by the intending bidder of having understood and accepted
all the various stipulations and conditions contained in various parts of the tender
In case a bidder(s) wishes to exclude one or more conditions / stipulations
contained in this document from the scope of his work the same must be clearly
indicated item wise giving reasons for requesting such exemption.
2. A list of equipment, testing and inspection facilities, which the contractor can
deploy at ROP site, BARC, Tarapur for carrying out the job.
3. Brief description of the organizational set up. Which the contractor intends to use
for carrying out the job.
4. Source of supply of Radiographic films.
5. Brief preliminary proposed procedure for :
a) Welding procedures
b) Liquid Dye Penetrant examination
c) Radiographic examination of welds
d) Vacuum box test procedure for lining
e) Tray forming & nozzle drawing procedure
f) Procedure for solution annealing of the fabricated S.S. tray.
g) Procedure for fabrication of M.S. shielding doors
h) Achieving dimensional accuracy for internals.
6. Maximum Electrical Power and water requirements for installation of enclosures at
site. Electrical requirements to be specified in terms of average capacity. Three
Phase 400/440 Volts, 50c/s system will be made available for this purpose.
7. Space requirement for storage of materials at site.
8. Space requirement for any facility that the contractor wishes to set up at site for
carrying out this job and details of such facilities.
9. Complete item wise schedule with rate, unit, quantity and amount in duplicate.
10. Proof of Ability: A brief list of similar jobs executed by the contractor as a proof of
ability for carrying out the job specified in this tender document as per format given
in Appendix ‘C’.
11. The locations and addresses where shop fabrication will be carried out.
12. Names and addresses of the sub-contractors, if any, with details of jobs to be
subcontracted and previous experience of the sub-contractor.
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13. Agreement w.r.t. completion of the work within the stipulated period as per the
14. Document of registration with MES/Railways/Central Govt./State Govt./PWD.
15. Unit rates in case the quantity variation in + 25%
16. Additional items or any equipment / materials required (other than specified in
Tender) for satisfactory work completion as per specifications.
17. Validity of the offer for acceptance shall be for a period of at least 180 days from
the date of opening of tender.
Signature of Vendor with Seal
Page 73 of 79
LIST OF FREE ISSUE MATERIAL
S.NO. DESCRIPTION OF FIM ITEM QTY.
1 Needle blocks assembled with needles 40 sets
2. Sample bottles 20 nos.
NOTES: 1. Total cost of FIM works out to about RS. 1,00,000/-
B. Material to be issued to the vendor at purchaser’s site during installation.
1. SS 304lL Sch. 40 9 NB pipes As required for installation
2. SS 304L Sch. 40 25 NB pipe As required for installation
Material to be issued at site will be as per requirement for installation and at the discretion of the site
NOTE: 2. Please note that Insurance policy towards FIM value of Rs. 1 Lakh with validity till
accounting and final acceptance of the item shall be provided for which premium charges shall
be in the account of the supplier.
Page 74 of 79
A N N E X U R E - 14
P R I C E & S C H E D U L E OF QUANTITIES
The bidder shall submit the price & schedule of quantities containing the following
information. The price schedule shall be submitted as per the format given
1. Ex- works cost (fabrication, testing etc.)
as per drawings and tender technical
Specifications for each type of enclosure
2. Extra cost (if any):
3. Packing and forwarding charges:
4. Transportation charges
Including transit insurance etc.
5. Erection and commissioning charges:
6. Training / Testing charges:
7. Excise duties:
8. Sales tax:
9. Total cost:
10. Delivery period (days):
a) Submission of drawings:
b) Fabrication of Sample Enclosure:
c) Bulk manufacture:
d) Installation At Site:
11. Validity Period (days):
(Signature of the Vendor with Seal)
Page 75 of 79
A N N E X U R E - 14 (Contd.)
Sr. Description Qty. Cost of Supply Cost of Erection Total cost
No. (enclosure Nos. (Lakhs) (Lakhs) (Lakhs)
Unit rate Total Unit Total
1. MA Enclosure 4
2. PLC 2
3. Erection and installation at
5 Excise Duty
6. Packing & Forwarding
7. Sales Tax.
9. Testing & Commissioning
10. Grand Total
(Signature of the Vendor with Seal)
Page 76 of 79
ANNEXURE – 15
PARTICULARS OF CONTRACT WORKS
EXECUTED DURING LAST FIVE YEARS
Sl. Name of Type of Work Name and Contract Amount Completion period Reason Reference to
No Project and Main Address of (stipulated and s for Certificates by
. Location Features Owner actual) delay, if Consultants
and (whether any and Owner
Quantities of Govt./Quasi about
the Work Govt./Private satisfactory
Body and completion
Name of (attach Copies)
Original Final Stipulated Actual
(1) (2) (3) (4) (5a) (5b) (6a) (6b) (7) (8)
(Signature of the Vendor with Seal)
Page 77 of 79
ANNEXURE – 16
PARTICULARS OF CONTRACT WORKS IN HAND
Provide information about all projects in progress, including those where the Company has received a letter of intent, but a formal contract
has not yet been awarded.
Sl. Name of Type of Work Name and Address Contract Completion Name and Present stage of
No. Project and of Contract Person/ period address of
Amount and work with reasons
Location Consultant with
Estimated Cost the banker for delay (if any)
Govt./Quasi Govt./ Work
Private Body and
(1) (2) (3) (4) (5) (6a) (6b) (7) (8)
(Signature of the Vendor with Seal)
Page 78 of 79
ANNEXURE – 17
PARTICULARS OF MANAGERIAL/ENGINEERING AND CONSTRUCTION PERSONNEL
AND TECHNICIANS EMPLOYED AND IN SERVICE SINCE LAST THREE (3) YEARS
Sl. Name Age Qualification Experience Nature of Work Previous Projects
No Handled Employment Handled
(1) (2) (3) (4) (5a) (5b) (6) (7) (8)
(Signature of the Vendor with Seal)
Signature of Indentor Signature of Approving Authority
Page 79 of 79
Sl.No Title Drawing No
1 Shielding block assy. For 150 thk A2/NK.04.01.02.62/GA/R0
2 Details of 150 thk enclosure internals (1of 2) A1/NK.04.01.02.63/DD/R0
3 Details of 150 thk enclosure internals (2of 2) A1/NK.04.01.02.63/DD/R0
4 Linear auto sampler unit assembly A2/NK.04.01.02.64/GA/R0
5 Details of linear auto sampler unit A1/NK.04.01.02.65/DD/R0
6 Typ. Drain line for tray A4/NK.04.01.02.66/DD/R0