NUCLEAR POWER CORPORATION OF INDIA LTD. ( A Govt. of India Enterprise ) SPECIFICATION NO : PC-E-674- Rev.0 TECHNICAL SPECIFICATION FOR

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1 . ( A Govt. of India Enterprise ) SPECIFICATION NO : PC-E-674- Rev.0 TECHNICAL SPECIFICATION FOR REF. USI NO. : REVISION NO. : DATE OF REVISION : (MONTH/YEAR) TOTAL NO. OF PAGES : (Including Cover Sheet) 0 Nov, ORIGINAL PREPARED BY : R. ANANDA NARAYANAN CHECKED BY : S.K.SAXENA REVIEWED BY : A.ROY CHOWDHURY APPROVED BY : A.K.CHAKRABARTI (Name & Designation) (Signature) (Date) File Name : PC-E-674-R0.Doc (For Revisions see Revision Control Sheet )

2 REVISION CONTROL SHEET DOCUMENT TYPE : ENGINEERING SPECIFICATION NO. : PC-E-674-Rev.0 TITLE : REV. NO. & DATE DESCRIPTION OF REVISION PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

3 Page No. : 1 of SCOPE This specification establishes the general technical requirements for the design, preparation of drawings, manufacture, inspection, testing, painting, guarantee, supply, packing & forwarding, transportation and delivery to site of Manual (Hand Wheel Operated/ lever operated) Gate, Globe, Swing Check, lift check, Needle, Butterfly, Diaphragm, Air operated ON-OFF Plug, Ball, Foot valves, Safety relief valves, Pressure reducing valve and Control valves as described in the Valve Specification Sheets (VSS) required for Waste management plant of 700 MWe Atomic Power Station. 2.0 CONTENTS The requirements of this specification are presented under the following headings: Section Scope 1.0 Contents 2.0 Applicable Specifications and standards 3.0 Materials & Workmanship 4.0 Technical Requirements 5.0 Inspection, Tests and Reports 6.0 Packing and Shipment 7.0 Information Required along with the Bid 8.0 Manufacturing and Inspection History Docket 9.0 Guarantee 10.0 Quality Assurance Plan (QAP) Annexure APPLICABLE SPECIFICATIONS AND STANDARDS The latest edition of the following specification / standards as on the date of tender shall be referred. ANSI B 16.5 : Steel Pipe Flanges & Flanged fittings ANSI B : Face to Face and End to End dimensions of Ferrous Valves ANSI B : Forged Steel Fittings Socket welding and threaded ANSI B : Butt welding ends ANSI B : Valve flanged / Butt welding ends ANSI B : Taper Pipe threads

4 Page No. : 2 of 18 ASTM A 105 : Standard specification for Carbon Steel Forgings for Piping Components ASTM A 182 : Standard Specification for Forged or Rolled Alloy Stainless Steel Pipe Flanges, Forged Fittings and Valves & Parts for High Temperature Services ASTM A 193 : Standard specification for Alloy Steel & Stainless Steel Bolting material for High Temperature service ASTM A 194 : Standard specification for Carbon & Alloy Steel Nuts for Bolts for High pressure & High Temperature Service ASTM A 216 : Specification for Carbon Steel Casting suitable for fusion welding for High Temperature Service ASTM A 276 : Standard specification for Stainless Steel Bars and Shapes ASTM A 351 : Standard specification for Stainless Steel Castings for High Temperature Services ASTM E 165 : Standard Practice for Liquid Penetrant Inspection Method ASME Sec.VIII, Div.1 : Rules for Construction of Pressure Vessels API 598 : Specification for Valve Inspection & test API 599 : Specification for Steel and Ductile Iron Plug Valves API 600 : Specification for Steel Gate Valve, flanged or buttwelding end API 602 API 603 API : : : Specification for Compact Carbon Steel Gate Valves Corrosion resistant, bolted bonnet Gate valves-flanged and butt welding ends. Butterfly valves, double flanged, lug-and wafer-type. BS 1868 : Specification for Steel Check Valves (flanged and butt weld ends) for Petroleum, Petrochemical and Allied Industries BS 1873 : Specification for Cast Steel Globe Valves BS 5156 : Specification for Diaphragm Valves BS 5352 : Specification for steel wedge Gate, Globe and Check

5 Page No. : 3 of 18 Valves 50 mm and smaller for Petroleum, Petrochemical and allied Industries BS 5353 : Specification for Steel Plug Valves BS 6755 BS-2080/BS EN 558 BS EN BS 5155/ BS EN 593 MSS SP 25 MSS SP - 67 : : : : : : Standard for testing of Valves Face to face dimensions of metal valves for use in flanged pipe systems. Diaphragm valves made of metallic materials. Specification for butterfly valves Standard marking system for Valves, Fittings, Flanges & Unions Butterfly valves In case Manufacturer refers to any other standards, these shall be equal to or better than the standards listed above. However, use of such standards shall be subject to the Purchaser's approval. The Manufacturer shall indicate date of issue of standards he proposes to use at the bidding stage itself. In the event of any conflict between the requirements of this Specification and the documents listed above, generally this Specification shall govern. 4.0 MATERIALS & WORKMANSHIP 4.1 All the material used must conform to the applicable Indian / International Standard / Codes and must be new and first class in all respects. Parts shall be free from flows and objectionable imperfections. Workmanship shall be in accordance with best practice adequate to ensure satisfactory operating service life and ease of maintenance and in accordance with provision of the specification. 4.2 All workmanship shall be of high grade quality and in accordance with the best methods of manufacture. 5.0 TECHNICAL REQUIREMENTS 5.1 General a) The valves covered under this specification are meant for systems with radioactive environment. Hence adequate care shall be taken by the manufacturer during all the stages such as raw material selection, manufacture, assembly, inspection, testing, packing, forwarding and

6 Page No. : 4 of 18 transportation to meet the technical requirements for its intended application. b) Casings / forgings shall be free from blow holes, porosity, cracks, shrinkage or other defects. c) The design and material for valve trim shall provide maximum protection against the effect of corrosion, corrosion-erosion, galling, and leakage. d) Valve seats (including back-seats), plug and discs shall be hard faced. There shall be hardness difference between seat and disc/plug. e) Before starting manufacture of valves, the Contractor shall submit drawings showing general arrangement and cross sectional details of valves with bill of materials for Purchaser's approval. After drawings are (after incorporating NPCIL's comments, if any) four additional sets of all drawings shall be submitted to Purchaser for his record. f) Gasket design shall ensure leak tightness in all service conditions. g) Flow direction shall be clearly embossed on the valve body for valves whose function and serviceability are affected by fluid flow direction. h) For flanged end valves, unless otherwise specified in the valve specification sheets, the flanges shall be in accordance with the requirements of ANSI B 16.5, 150 #, RF (concentric). i) For socket weld end valves, unless otherwise specified in the valve specification sheets, the socket welds ends shall be in accordance with the requirements of ANSI B j) For screwed (NPT - female) end valves, unless otherwise specified in the valves specification sheets. The screwed ends shall be in accordance with the requirements of ANSI B k) Unless otherwise specified, end to end dimensions and face to face dimensions shall be in accordance with ANSI B l) Components and spare parts of valves shall be interchangeable among valves of one size to the maximum practical extent. m) All valves shall be so designed that the handwheel moves in a clockwise direction to close the valve. The face of the handwheel/ lever shall be clearly marked with the words `OPEN and `CLOSE and an arrow to indicate the direction for opening. All handwheels/ levers shall be fitted with name plate.

7 Page No. : 5 of 18 n) All welding qualifications and welder performance qualification shall be in accordance with Section IX of the ASME Boiler Pressure Code. Any repair on casting / forging by welding shall require and performance qualification. l) Wherever required, IBR certificate in Form III-C shall be submitted in original along with the IBR valves. m) Minimum wall thickness of body and bonnet shall be as per ANSI B for the particular rating. n) All the fasteners shall conform to ASTM A 193 Gr. B7 (bolts and studs) and ASTM A 194 Gr. 2H(nuts) with cadimum plating or as mentioned in the valve specification sheets. o) For air operated valves, the actuator details with torque values (Make, Type, etc.) should be submitted with the offer. Only NPCIL make of limit switches, and actuators shall be used. The O ring seal material shall be of EPDM. Diaphragm material shall be EPDM with hardness of shore A Durometer of 60 to 80. Diaphragm shall be adequately reinforced to withstand full supply air pressure to the actuator. 5.2 Gate, Globe, Needle and Check Valves All gate globe and needle valves shall be of rising stem, outside screw and yoke type. The design of valves shall ensure a streamlined passage. All the valves shall be designed to ensure low pressure drop. The seats and discs shall be either easily renewable or shall be suitable for easy refacing and grinding. Valve discs shall be of such designs so as to keep the seats tight when the valve body is subjected to pressure and temperature variations Design and manufacturing of forged / cast steel valves shall conform to API 600 / API 602 / API 603/ BS 5352 / BS 1873 / BS 1868/ ANSI B as indicated in the valve specification sheets All globe valves shall be capable of being closed against pressure Differential hardness shall be provided between seats and wedge/disc/plug to prevent galling All gate, globe and needle valves shall have back-seating arrangement to facilitate easy replacement of packing with the valve in service. 5.3 Diaphragm Valves

8 Page No. : 6 of Diaphragm valves shall be of weir type or straightway type as indicated in the valve specification sheet and shall be provided with sealed bonnet Valve design and manufacturing shall conform to BS 5156/ BS EN Stem shall be of indicating type. An adjustable travel stop shall be provided to limit stem travel. This is to avoid over compression of diaphragm on the body weir. The indicating stem shall be threaded to take a stop nut and a lock nut Bonnets should be pack less (no gland packing) and be sealed with EPDM rubber. Positive support of diaphragm (to protect from ballooning) against high line pressure and line pressure surges shall be provided by alternate fingers of compressor and finger plate in smaller size valves and by fingers cast with the bonnet in larger sizes The diaphragm material shall be as mentioned in individual valve specification sheet. For straightway valves conical diaphragm shall be used to provide extra stretch. Diaphragm and O ring seals shall have a minimum design life of 20,000 full stroke cycles and shall be of EPDM material Diaphragm shall have strong adherence to the reinforcing fabric and the stud head. Diaphragm shall have shore A durometer of 60 to 80. One diaphragm from each batch shall be subjected to a flexing test of 5000 cycles (if called for in the valve specification sheet) and the diaphragm shall be examined visually for any deterioration, cracks etc. and also by hydro seat leak tests. This diaphragm after testing shall be discarded The supplier shall mark each diaphragm with the batch No. and the date of manufacture of the diaphragm to facilitate identification. Spare diaphragm supplied should have high shelf life. The contractor should indicate shelf life of diaphragm used and also give instructions/precautions for storage Bonnet shall be provided with 'V' notch plug to permit checking diaphragm integrity without valve dis-assembly The body and bonnet castings of the diaphragm valves shall be made by investment casting process. 5.4 Plug Valves Plug valves shall be of cavity-less valve and non-lubricated type with teflon sleeve.

9 Page No. : 7 of Valve design & manufacturing shall conform to BS 5353 / API Stem sealing shall be provided by a reverse lip diaphragm Valve sleeve shall be provided with raised ribs, grooves and recesses, so that it locks with the body positively Valve position indicating (open or closed) device shall be provided In case of wrench operated valve, wrench shall be suitable for maximum torque of the valve. 5.5 Butterfly Valves Butterfly valves shall be of wafer type unless otherwise specified Valve design & manufacturing shall conform to API-609/ BS- 5155/ MSS-SP-67. Inspection standard shall be BS:5155/ BS: 6755/ API: Valve position indicating (open or closed) device shall be provided. Manual valves shall be of wrench operated Seat Seal : SS Body seat with Disc seal (Nitrile rubber fitted at the periphery of Disc) OR Nitrile rubber lined body with SS Disc shall be provided. Contractor shall clearly furnish the construction details of seat seal. The valves shall be of flexible metal seats and the design shall be such that a good amount of seating pressure is achieved by the disc even along the axis of the shaft. For low pressure application 'O' ring stem packings may be provided, however, for high pressure application the stem packings shall be provided with live loading arrangement Body disc design shall provide uniform flow with least turbulance and hence minimum pressure drop Suitable stops shall be provided to prevent movement of the shaft beyond the limits corresponding to the fully open and closed position of the disc Bearings shall be of self lubricating type Internal bolting material and stem material shall be of stainless steel. External bolting shall be conforming to ASTM A 193 Gr. B7 / ASTM A 194 Gr. 2H Pipe flanged ends are provided, conforming to ANSI B 16.5 Class 150 (RF)

10 Page No. : 8 of 18 Pressure reducing valves The pressure regulators shall be spring loaded, diaphragm type and shall be pilot operated. Apart from hydrostatic and air body and seat tests, the valves shall be subjected to performance test i.e. pressure and flow regulation tests. The outlet pressure shall not vary more than + 1% from the set point for an inlet pressure variation of + 10%. 6.0 INSPECTION, TESTS & REPORTS 6.1 Quality Surveillance and expediting relating to all aspects of the contract will be carried out by the Purchaser or his authorised representative to ensure the mechanical accuracy of components, compliance with drawings, QAP and technical specifications for which purpose, the Contractor and his Sub-Contractor shall allow access at all reasonable time during manufacture, assembly, inspection and testing to the premises in which the work is being carried out. The Contractor shall also allow access to the drawings and tooling involved. All the instruments used for conducting the shop tests shall be calibrated and calibration test certificate be furnished from a NPCIL lab. All valves shall meet the inspection and testing requirements as indicated in QAP. Hydrostatic, air leak tests shall be carried out as per latest applicable standard. 6.2 All materials shall be identified with co-relating original mill test certificates indicating chemical analysis, mechanical properties and any other test specified in the standards. In case mill test certificates with proper identification of the material is not available, the Contractor shall arrange to carry out all physical, chemical and other tests as per applicable specification, at no extra cost to the Purchaser. Certificates of special tests asked for are also to be supplied along with material. 6.3 Contractor shall prepare and submit Quality Assurance Plan (QAP) in line with the sample QAP enclosed as Annexure-1 of this specification and get approval of NPCIL. 6.4 Inspection and testing shall be conducted in a manner satisfactory to the Purchaser and as per technical specification and QAP. 6.5 All test certificates and test reports shall be submitted to the Purchaser. 6.6 The performance (or waiver) of quality surveillance activities by NPCIL, QS or its authorized representative does not relieve the supplier of any obligations to perform in accordance with and meet all requirements of the procurement documents and also all the codes / referencing documents mentioned in the procurement document. 6.7 The supplier shall maintain records of all inspection and tests which shall be made freely available to NPCIL or its authorised representative.

11 Page No. : 9 of Liquid Penetrant Examination shall be carried out on machined surfaces of body and trim materials. NPCIL chemicals for liquid penetrant examination shall only be used. Examination is to be carried out by NDT qualified Level-II person. Acceptance criterion for liquid penetrant examination shall be as per ASME Sec. VIII, Division -1, Appendix All valves shall be tested hydrostatically for strength, tightness of seats and tightness of backseating at the pressures indicated in the respective valve specification sheet, in the presence of Purchaser's representative Hydrotest of body shall be conducted first and seat test shall be conducted subsequently After completion of seat leakage test (with no seat leakage) and depressurisation of valve, adjustable travel stops shall be locked for diaphragm valves Low pressure seat test as per BS : 6755 shall be carried out on the check valves Quality surveillance by NPCIL or its authorized representative includes, but is not limited to Witness and Hold Points. Additional witness and Hold Points can be established by NPCIL if manufacturing or related activities or examination/ inspection test results warrant so Witness Points are critical steps in manufacturing and examination / inspection / testing where the supplier is obliged to notify in sufficient advance of the start of operation / Test so that it may be witnessed The supplier may proceed with the work past a Witness Point if the NPCIL, QS or its authorized representative is not available at the appointed time Hold Points are critical steps in manufacturing and examination / inspection/testing where the supplier is obliged to notify NPCIL, QS or its authorized representative in sufficient advance of the start of operation / test so that it may be witnessed. Final release prior to shipment is a mandatory Hold Point. The supplier is not to proceed with the work past a Hold Point except by written waiver / agreement by NPCIL On completion of manufacture the items can be despatched only after issue of shipping release by NPCIL Vacuum test shall be conducted on diaphragm valves (as indicated in the valve specification sheet) as per the indicated below to establish the quality of diaphragm so that it retains the necessary mechanical and chemical integrity to successfully perform in the vacuum environment Procedure for vacuum testing of Diaphragm valves (wherever specified in valve specification sheet) :

12 Page No. : 10 of 18 Vacuum Flexing Test The purpose of this test is to establish the quality of diaphragm as manufactured in each batch, so that it retains the necessary mechanical and chemical integrity to successfully perform in the vacuum environment. The test shall be conducted by mounting the valve on the vacuum testing machine and maintain a vacuum at 10-2 Torr (abs.). Carry out 5000 cycles of full opening and closing of the diaphragm valve under the above mentioned vacuum. After the above mentioned cycling test, dismantle the valve and carry out visual examination of the diaphragm for any deterioration or defects like cracks, lack of bonding, stud bonding or any other imperfection. In case the diaphragm successfully passes the above mentioned cycling test and visual examination, this particular batch of diaphragms shall be considered acceptable. In case the diaphragm fails during the vacuum flexing test or subsequent visual examination, carry out vacuum flexing and visual tests on two more diaphragms from the same batch. If both the diaphragms are successfully tested, the batch of diaphragms shall be considered acceptable. In case any one of the diaphragms fails during vacuum flexing and visual examination, the whole batch of the diaphragms shall be rejected. Testing of Valves Once a particular batch of diaphragm is successfully tested, each individual valve, having acceptable diaphragm, shall be tested as per the drawing. Vacuum Body / Seat Test The vacuum body / seat test shall be carried out as under. With a combination of rotary and diffusion pumps, evacuate the valve to 10-4 to 10-5 mm Hg (abs) pressure. Spray acetone on the entire surface of the valve. If there is any leakage, the volatile liquid will be absorbed inside the valve, which will evaporate showing a sudden and clear indication of increase in pressure on the penning vacuum gauge attached to the test system. The valves shall be accepted only if there is no indication of abrupt change of pressure on the vacuum gauge. Each diaphragm valve shall have a metal tag attached to it, to identify the diaphragm batch number with date of manufacture and individual valve tag number.

13 Page No. : 11 of 18 Helium leak test Helium leak test shall be carried out by the contractor/ manufacturer as specified in the valve specification sheets. Manufacturer shall prepare the for helium leak test and submit it for purchaser s approval. 7.0 PACKING AND SHIPMENT 7.1 After hydrostatic testing and before shipment, all the valves shall be thoroughly cleaned internally and externally of oil, grease, dusts, chips, moisture and other harmful foreign matter. 7.2 Unless otherwise specified elsewhere, one coat of primer and two coats of epoxy paint shall be applied to all Carbon steel and cast iron exposed surfaces to prevent corrosion before despatch. 7.3 All valves shall have permanent name plates indicating details as per MSS SP 25 Standard Marking System for valves, fittings, flanges and Unions. In addition, a permanent Stainless Steel tag shall be fixed on the valve body indicating valve tag number. 7.4 The Contractor shall make adequate packing and provisions to protect the valves and actuators supplied as per this specification to ensure that on arrival at the destination specified in the tender specification and after storage the same will not suffer any corrosion or damage of any sort. 7.5 The valves shall be packed in weather proof wooden crates with adequate bracing to prevent movement within the box. Materials should not undergo any damage or rusting during shipment, handling and site storage. 7.6 Valves shall not be dispatched unless the same have been finally inspected, tested, accepted and shipping release issued by the Purchaser or his authorised representative. 7.7 Prior to hydrostatic and pneumatic testing all valves shall be thoroughly cleaned internally and externally of oil, grease, rust, chips and other harmful foreign matters. Cleaning and other degreasing agents shall essentially be sulphur and halogen free. 8.0 INFORMATION REQUIRED ALONGWITH THE BID 8.1 General arrangement and cross sectional drawings for each type of valve indicating dimensional details, bill of material, design code and test requirements. 8.2 Catalogues and other literature pertaining to the valves, actuators and limit switches.

14 Page No. : 12 of The bidder shall submit all supporting information, complete technical data and specifications to permit the purchaser to make a detailed evaluations of the bid. 8.4 List of casting, forging and bought out items, manufacturer s name from whom the bidder intends to procure the raw material. 8.5 Any deviation from technical requirement and suggested Quality Assurance Plan (QAP) must clearly be brought out in the bid, otherwise it will be presumed that the bid is fully in conformity with the tender requirement. 9.0 MANUFACTURING & INSPECTION HISTORY DOCKET 9.1 Six copies of bound history docket shall be prepared for Valves duly signed by NPCIL s QS Engineer for completeness. The history docket shall consist of the following as minimum: a) General Arrangement and cross sectional drawing of valves and actuator assembly wherever applicable b) All non-destructive test reports c) Material test certificates d) Hydrostatic, pneumatic, helium and vacuum leak test reports. e) Guarantee Certificate from manufacturer f) Copy of purchase order g) Copy of technical specification h) Quality Assurance Plan i) Design Concession Request j) Non-conformance Report k) Shipping Release Note l) Instruction and maintenance manual (if any) 10.0 GUARANTEE The supplier shall guarantee that the valves shall conform strictly to the requirements of this specification and will be guaranteed for twelve (12) months from the date of final acceptance. The supplier shall also guarantee that during guarantee period he will replace / repair all the defective stores at no extra cost.

15 Page No. : 13 of 18 Rev. No. : 1 ANNEXURE 1 : QUALITY ASSURANCE PLAN (SAMPLE) PURCHASER : NUCLEAR POWER CORPORATION OF INDIA LTD., MAIN VENDOR S : PURCHASER P.O. No. : MAIN VENDOR S REF. P.O. NO. : REF. NO. : SUB-VENDOR, IF ANY : SUB-VENDOR REF. JOB NO. : SCOPE AND PURPOSE The purpose of this Quality Assurance Plan (QAP) is to describe general practices, resources and sequence of activities (such as inspection, testing, control, etc.) to be performed during the manufacture of the equipment. This QAP is a generic document and should be tailored by suitable addition, deletions or modifications for specific contract keeping in mind the capabilities of the manufacture and the requirement of NPCIL. Accordingly P / W / V should be decided by the Vendor and the Purchaser. Vendor/Sub-Vendors shall prepare and submit detailed QAP, including for items / activities, those which are not included in this Annexure, for approval from Purchaser. WHILE FOLLOWING THIS QAP, ABBREVIATIONS and NOTES MENTIONED ON LAST PAGE OF THIS ANNEXURE SHOULD BE REFERRED. ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 7 ) ( 8 ) ( 9 ) ( 10 ) ( 11 ) Sl. Component & Characteristic Class Type of Quantum Reference Acceptance Format of Agency Remarks No. Operation Check of Check Document Norms Record P W V 1.0 RAW MATERIAL & BOUGHT COMPONENTS 1.1 Body and Bonnet Chemical composition Mech. Properties T.C Review / Sample check See Note (ii) Material Spec. Applicable Spec. MTC / Lab T.C ,1 2-2,1 Random check by NPCIL (QS). CHP. 1.2 Trim Material (Stem, disc & Seat Ring) Surface defects Chemical composition Mech. Properties Visual T.C Review/ sample check 100% See Note (ii) Material Spec. Applicable spec. I.R. MTC / Lab TC ,1 2-2,1 Random check by NPCIL (QS). (CHP). Surface Finish Visual 100% I.R. 2-1 USI : / PC-E-674 Nov, 2010

16 Page No. : 14 of 18 Rev. No. : 1 ANNEXURE 1 CONTD.. ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 7 ) ( 8 ) ( 9 ) ( 10 ) ( 11 ) Sl. Component & Characteristic Class Type of Quantum Reference Acceptance Format of Agency Remarks No. Operation Check of Check Document Norms Record P W V 1.3 Diaphragm Shore Hardness 1.4 BELLOWS Material Soundness CHEMICAL COMPOSITION T.C. Vacuum flex test Chemical Analysis One batch per One/Heat Material specn. spec./ Approved Drg. / Specn Mechanical properties Physical Test One/Heat Approved Drg./ Specn LPE (if welded) Critical NDE 100% Approved Before and after Procedure convolution CYCLIC TEST (for predetermined Cycles) EXTERNAL PRESSURE TEST HYDRO TEST (after Cyclic Test) Type Test One/Lot/ Size Approved Procedure Type Test 100% Approved Procedure Type Test 100% Approved Procedure spec spec./ material spec./ applicable Spec. material spec. Lab. TC I.R. Test Certificate ,1 2/3-2,1 - Compliance certificate for EPDM shall be furnished. Test Certificate 2/3 2 2,1 Test Report 2/3 2,1 - Random check by NPCIL. Test Report 2/3-2,1 Test Report 2/3-2,1 Test Report 2/3-2,1 USI : / PC-E-674 Nov, 2010

17 Page No. : 15 of 18 Rev. No. : Fasteners, Bolts, Gaskets Packing Material & Handwheel 2.0 IN PROCESS HELIUM LEAK TEST (after Hydro Test) FAILED CYCLES TEST Type Test 100% Approved Procedure Type Test One/Lot/ Size Approved Procedure (after Cyclic Test) DIMENSION Measurement 100% Approved Drg. Chemical composition Mech. Properties TC Review/ sample check One per batch See Note (ii) Material spec. Approved Drawing Applicable spec. Test Report 2/3-2,1 Test Report 2/3-2,1 Inspection Report MTC / Lab. T.C. 2/3 2,1 2, ,1 2,1 2.1 All Machined Components (a) Workmanship & finish (b) Dimension Visual Measurement 100% 100% Mfr s drg. Mfr s drg. I.R Machined Surfaces of Body and Trim Materials Surface Defects LP Test 100% ASTM E 165 / Approved 3.0 FINAL INSPECTION & TESTING 3.1 Assembled Valve a) Assembly Visual 100% Approved Drawing Approved drg. T.C. 2 1 Random check by NPCIL. I.R % random check by NPCIL. USI : / PC-E-674 Nov, 2010

18 Page No. : 16 of 18 Rev. No. : 1 ANNEXURE 1 CONTD.. ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 7 ) ( 8 ) ( 9 ) ( 10 ) ( 11 ) Sl. No. Component & Operation Characteristic Class Type of Check Quantum of Check Reference Document Acceptance Norms Format of Record Agency Remarks 3.1 Contd. b) Integrity Hydro body test, hydro seat leak test, air seat leak test, back seat test and helium leak test & vacuum hold test (wherever applicable), c) Performance / Operation of Manual & Air Operated Valves 100% Approved drg. / Operation 100% Approved Drawing / appd. Drg. / drg./ P W V T.R C.H.P. Review of certificate only for IBR valve T.R CHP 3.2 Valve assy. test Valve assy. leak tightness for bellow sealed valves 3.3 PNEUMATIC ACTUATORS Critical Leak Detection through Bellows Seal Weld by Hydro./Air a) Strength & leakage Performance, Minimum air pressure reqd, travel, accessories fuctions, etc. 100% Approved Procedure 100% Approved Procedure / spec. Test Report 2 2,1 - CHP Test Report 2 2,1 - CHP USI : / PC-E-674 Nov, 2010

19 Page No. : 17 of 18 Rev. No. : 1 b) Overall Dimen-sion (Face to face, end connection, overall height, etc.) 4.0 Packing, Shipping Release & Shipment 5.0 Final Documentation Compilation of Document Operation 100% Approved Drawing c) Cleanliness Visual 100% Approved Drg./specn. drg. drg./ specn. I.R Random check by NPCIL I.R. 2-1 d) Painting Visual 100% Specn. specn. I.R. 2-1 Visual 100% Specn. specn. I.R. 2-1 Packing quality Visual 100% Specn. specn. I.R. 2-1 Minor Verification 100% Tender Document Tender Document I.R. 2-1 ANNEXURE 1 CONTD.. USI : / PC-E-674 Nov, 2010

20 Page No. : 18 of 18 Rev. No. : 1 Abbreviations : CRITICAL : The characteristic of a component, process or operation failure of which will surely cause operating failure or intermittent troubles which one difficult to rectify at site or render the unit unfit for use or cause safety hazards. MAJOR : The characteristic of a component, process or operation whose failure may cause operation failure which cannot be readily corrected at site or cause substandard performance, increased erection and maintenance cost, reduced life or seriously affect aesthetics MINOR : The characteristic of a component, process or operation whose failure neither materially reduces the usability of the product in operation, nor does it affect the aesthetic aspects. TR - TEST REPORT, MTC - MATERIAL TEST CERTIFICATE CHP - CUSTOMER HOLD POINT P - PERFORMED BY PT - PENETRANT TEST IR - INSPECTION REPORT W - WITNESSED BY V - VERIFICATION OF REPORT RT - RADIOGRAPHY TEST 1 - PURCHASER (NPCIL, QS) 2 - PRIME SUPPLIER 3 - SUB-VENDOR / EXTERNAL LAB Failure of a characteristics means failure to meet the Acceptance norms NOTES : i) All test reports, test certificates and quality control records shall be reviewed and signed by Prime Supplier before submission for review by NPCIL. ii) Co-relating material test certificate is acceptable. In the absence of co-related material test certificates, two samples per lot (lot means all materials having same heat mark / as mentioned in the material specification), for chemical and physical test, shall be drawn and witnessed by main PC Contractor. Chemical and physical test shall be carried out in NPCIL lab. only and main PC Contractor shall witness the physical test. PC Contractor's QS shall submit all material verification report and test reports to NPCIL, QS for checking / verification and clearance. However, NPCIL, QS reserves the right, if felt necessary to physically verify such activities by surprise visit and by retesting the material. iii) Chemical and physical test shall be carried out in NPCIL Labs. only. Schedule for physical tests shall be intimated to the Purchaser. Purchaser reserves the right for witnessing the physical test. iv) QAP shall be signed by Sub-Vendors (if any) and Vendors s representatives, responsible for preparation, checking and finalizing the QAP, before submitting the QAP for Purchaser s approval. v) Sample selection shall be done by the Purchaser. vi) Whenever Witnessed by NPCIL (QS) is mentioned, this will not be construed as Customer Hold Point. The supplier shall give advance intimation to intimate NPCIL for such stages and NPCIL (QS) would witness if so desired. vii) Whenever CHP is specifically mentioned, further work shall be taken up only after witness / review and clearance by NPCIL, QS. USI : / PC-E-674 Nov, 2010