Section 4. Annex to IAEA Request for Proposal STATEMENT OF WORK. Primary/Secondary cooling water Heat Exchangers

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1 Section 4 Annex to IAEA Request for Proposal STATEMENT OF WORK Primary/Secondary cooling water Heat Exchangers WWR-SM Research Reactor, UZBEKISTAN Page 1 of 17

2 1. Scope 1.1 This Statement of Work (SOW) describes the requirements for the design, manufacture and supply of two numbers of Primary cooling water/secondary cooling water Shell and Tube type Heat Exchangers to the end user, who is WWR-SM reactor at INP, Tashkent, Uzbekistan. 1.2 Design, preparation of manufacturing/as-built drawings, procurement & testing of material, manufacture, inspection, shop testing, packing, supply, guarantee and delivery to site at INP, Tashkent, Uzbekistan of 2 (Two) numbers of Primary cooling water/secondary cooling water Shell and Tube type Heat Exchangers as per technical requirements indicated in this specification and site dimensions. The heat exchangers shall be complete with matching counter flanges for all the nozzles along with gaskets & nuts, bolts and also including spare sets of additional gaskets as start-up & maintenance spares for all the joints of heat exchangers, 2 (two) sets of wrenches for every kind of nut used in construction and 2 (two) sets of tube expander tool. 1.3 It is not the intent to specify completely herein all details of design, manufacturing and installation of the equipment. However, the equipment shall conform, in all respects, to high standards of engineering design and workmanship and be capable of performing continuous operation in a manner acceptable to the end user. 1.4 The material, manufacture, inspection, testing and performance of the heat exchanger shall comply with the requirements of this specification and the latest edition of codes and standards, as also other relevant specifications, if any. 2. Scope Background: 2.1 WWR-SM has requested the IAEA under the technical cooperation project UZB 1001 to provide assistance in replacing the aged heat exchangers in order to maintain the safety of the reactor. Failure of heat exchangers can result in the release of radioactivity via the secondary system to environment or contaminate the primary system components with the secondary water based on the operating conditions of the reactor. 2.2 The present requirement specification has been created for the replacement of the current heat exchangers that are in service at WWR-SM reactor, INP. Tashkent. 3. Description of the heat exchangers: The operating & design parameters of heat exchangers are summarized in table 1.Figs 1, 1a, 2, 3, 4, 4a, 4b provide the details of the present heat exchangers. Page 2 of 17

3 TABLE-1 Basic design data and boundary conditions Equipment: Primary Water / Secondary Water Heat Exchanger Type : Shell & Tube, Horizontally installed No. of Units : 2 (Two) Position : Horizontal P nominal : 10 MW Shell Arrangement : Parallel Operating & Design Parameters Shell Side Tube Side Fluid Circulated Primary Water Technological Water Fluid (Light water) Flow m 3 /h Q nominal = m 3 /h Q nominal = m 3 /h Temperature-IN o C T inlet = C 55 0 C T inlet = 20 0 C 30 0 C Temperature-OUT o C T outlet = 50 0 C 40 0 C T outlet = C C T o C o C Operating Pressure MPa P inlet = MPa P inlet = MPa Design Pressure Min. 1 MPa Min. 1 MPa Allowable Pressure Drop P = MPa MPa Surface area of the heat exchanger: Not less than 500 m 2 Weight of the heat exchanger: Not more than kgs. Material of construction of the heat exchangers (Shell, tube sheets, tubes, baffle plates, tie rods, shell covers, nozzles) shall be 12Х18Н10Т (Intergovernmental standard, Russian type ) or its foreign analogue. Relevant site details Overall size (absolute maximum dimensions where the new heat exchangers shall be installed). Overall size of the accommodation place can be seen in Fig.1. Maximum total length: 8500 mm Maximum total width: mm Maximum total height: 4000 mm Entry hole from the reactor hall into the pump room of the primary circuit: Total size of the hole can be seen in Fig. 1a, and Fig. 2. Maximum total width: 1570 mm Maximum total length: 3500 mm Connection specifications: General requirements: with respect to the pipe line connections, the new heat exchangers shall be interchangeable with the old one. Geometrical lay-out of the connection flanges can be seen in Fig.3. Page 3 of 17

4 Primary inlet/outlet pipeline size with connection flanges: DN300 (Fig. 4, 4a, 4b) Secondary inlet/outlet pipeline size with connection flanges: DN300 (Fig. 4, 4a, 4b) Seismic requirements Operated in 8 force zone of seismic scale MSK-64 in effective peak speed up 5.0 m/s2. Quality Heat exchangers must have quality certificate, and also execution code A (Atomic, higher reliable) Safety class Two Dimensions Heat exchangers shall have dimensions similar to the given dimensions in the figures provided, which include the tube dia and thickness (25 x 2) mm, baffle spacing, pitch of the tubes and other relevant dimensions. The drawings furnished are for general reference and internal details. Supplier shall take site dimensions for exact location of nozzles & foundation bolts and prepare as-built drawing for each heat exchanger separately to ensure correct fitment of both the heat exchangers at site with existing foundation bolts & piping nozzles. End connections/ nozzles shall be fabricated in a manner such that they match in orientation, bolt holes and fit-up with the existing connections without any undue strain on the pipes. 4. Applicable Documents The following documents shall be applicable for the work to be performed: 4.1 Safety of Research Reactors, Safety Requirements, No. NS-R-4, IAEA Safety Standards 4.2 Safety in the Utilization and Modification of Research Reactors, Specific Safety Guide, No. SSG-24, IAEA Safety Standards 4.3 Commissioning of Research Reactors, Safety Guide No. NS-G-4.1, IAEA Safety Standards 5. Definitions, Acronyms, and Abbreviations The following definitions, acronyms, and abbreviations shall apply throughout this SOW unless defined otherwise hereinafter: IAEA: International Atomic Energy Agency INP: Institute of Nuclear Physics Sanoatgeokontechnazorat: Atomic Inspection Unit (AIU) of the State Inspectorate of Uzbekistan SOW: Statement of the Works 6. Technical requirements 6.1 Design requirements: The potential supplier/designer/manufacturers shall take into consideration the site conditions including the maximum allowed size of the heat exchangers that can be Page 4 of 17

5 brought in the primary pump room. The INP, upon agreed times in advance, will provide access to the site and consultations. The detailed design shall include the safety assessment and also shall comply with the requirement of the local nuclear regulations in content and formality. The detailed design will be submitted by the INP for approval to the related Nuclear Authority in Uzbekistan. The existing shell & tube heat exchangers are horizontally installed. The new heat exchangers are to be installed in place of existing ones and have to operate under same operating conditions. Hence the hydraulic parameters like primary / secondary side pressure drop etc. of new heat exchanger shall remain similar to the existing ones so that no alterations are required to be done in the existing system. The new heat exchangers shall be designed and constructed as per the standard codes. Detailed parameters are specified in Table-1 and Figures1, 1a, 2, 3, 4, 4a, 4b. Also refer to Table 1 regarding dimensions and other requirements. Supplier has to submit mechanical design calculations for all the components like tubesheet thickness, main shell & channel shell thickness, dished end thickness, girth flange thickness, shell & nozzle loose/integral flanges thickness, channel flat cover thickness, nozzles wall thickness, nozzles reinforcement size & thickness, gasket sizing & torque requirement calculations etc. Supplier may suggest modifications or improvements according to the latest manufacturing techniques to enhance efficiency and increase the life span of the heat exchangers. Outer dimensions from site installation point of view like location of foundation bolt holes and location & orientation of all the inlet/outlet nozzles has to match exactly with existing site dimensions. Supplier shall carry out vibration analysis for the heat exchanger and has to show that heat exchanger is safe against flow induced vibrations for the selected manufacturing and process parameters in different regimes. Heat exchangers must meet requirements, demanding to the equipment that is operated in 8 force zone of seismic scale MSK-64 in effective peak speed up 5.0 m/s 2. Heat exchangers, in secondary circuit part (technical water) shall be equipped with valves for air releasing. Suitable eye bolts or drilled lugs shall be provided for channel cover, channel, shell etc. for use in assembling and dismantling the heat exchangers. 6.2 Manufacturing: The heat exchanger manufacturing can be started only after the design approval and the permit for manufacturing issued by the related Nuclear Authority in Uzbekistan. The INP representative have right to conduct inter-manufacturing review at the Supplier s site. Material of construction of the heat exchangers (Shell, shell covers, tube sheets, tubes, baffle plates, tie rods, pipes, flanges) shall be stainless steel conforming to 12Х18Н10Т (Intergovernmental standard, Russian type ) or its foreign analogue. For other components, suitable & compatible material has to be suggested / selected by the Supplier. These Heat Exchangers are required as replacement of the existing Heat Exchangers. The piping connections & foundation bolts already exist and the supplied heat exchangers shall be interchangeable as per the site conditions. Tube to tube sheet joint details is shown in Fig. 4b. Page 5 of 17

6 Sealing materials/ Gaskets to be used shall be radiation resistant and specified in the technical bid. The Supplier shall prepare detailed fabrication drawings and inspection procedures including stages of inspection by the Supplier and also by the representative of end user. Residual stress shall be kept to a minimum to ensure dimensional stability and minimum stress corrosion. Excessive force shall not be used to achieve a fit. Welding shall be performed in such a manner as to control and minimise distortion and locked-in stresses. Stress relieving shall be carried out when required as per standards. Interior surfaces of the heat exchangers, namely shell, channel and cover shall be cleaned of all mill scale, rust and foreign matter. All fluids used for testing and cleaning shall be drained off and surfaces dried. Flanges, screwed threads and other similar parts shall be protected from mechanical damage & ingress of dust/debris by suitable covers /caps. Welding materials and procedures shall meet the requirements based on the material to be welded to achieve radiographic quality weld joints. 6.3 Testing and inspection The supplier shall be responsible for and shall provide for and perform all the examination, inspection and testing as required. The heat exchangers shall be carefully examined during and after manufacture to determine its conformance with this specification with respect to material and workmanship, finish, marking and dimensions and to assess its conformance with other requirements stated or reasonably implied and not covered by specific examinations and tests. The examination, inspection and testing shall be conducted in a manner satisfactory to and shall be subjected to approval of the end user. The end user and his authorized agents shall have access to the supplier s premises at all reasonable times to the extent necessary to assess compliance with the provision of this specification. All the materials designated shall be subjected to all tests mandatory as per the relevant specifications and any additional tests specified. Examination, inspection and test reports shall be submitted by the supplier to the end user for approval. Pre-Service Inspection of assembled Heat Exchangers by way of Eddy Current Testing (ECT) shall be carried out as part of the FAT. The non-destructive examination shall be carried out by qualified personnel as per the requirements of relevant standards. The end user shall have the right to conduct any additional examination, inspection or testing he deems necessary. At the request of the end user the supplier shall reexamine, re-inspect or re-test any component of the heat exchanger. Defects so revealed which do not meet the requirements of this specification shall be cause for rejection of the component or alternatively for repair as per the procedure approved by the end user and subsequent re-examination, re-inspection and re-test. If defects are revealed all such re-examination, re-inspection and re-testing both before and after repair shall be at the expense of the supplier. Page 6 of 17

7 6.4 Quality control The supplier shall submit the Quality Assurance Plan (QAP) for approval before commencement of fabrication. Supplier shall be responsible for quality control and carrying out required tests and inspections. All test and inspection results and reports shall be submitted. QAP and manufacturing programmes shall indicate various stages at which internal inspection is carried out by supplier. Based on this programme, end user shall decide and advise the supplier on the stages at which end user s quality-checks shall be required. QAP shall include all the relevant tests and inspections on raw material, in-manufacture stages, and finished products and specify standards against which these inspections and tests are to be carried out. Heat exchangers must have quality certificate, and also execution code A (Atomic, higher reliable). Supplier shall demonstrate the conformity of the heat exchanger to the design documentation. It shall be ensured that the goods are new and of high quality and that the goods shall be free of defects in design, materials or workmanship for a period of twenty four (24) months after delivery at job site. Materials and standard parts which are not specifically designated herein and which are necessary for the fulfilment of this specification, shall be of good quality and in accordance with the best practice pertinent to the manufacture of heat exchangers. All these materials shall be subjected to approval by the purchaser. Tubes shall be of seamless manufacture as per the relevant standards and be subjected to all relevant quality control checks. The quality check data shall be supplied to the end/user. Manufacturer s design, fabrication, inspection and testing requirements shall meet the latest Standards. Detailed assembly/manufacturing drawings along with design calculations, of all heat exchangers shall be submitted for approval of the end user. 7. Commissioning 7.1 The supplier shall provide detailed installation and commissioning procedure taking into account site conditions. 7.2 The supplier shall provide all necessary tools required for smooth installation and commissioning including any special instrumentation that may be necessary for installation and commissioning. 7.3 The supplier shall provide site supervision during installation and commissioning activities. 7.4 The supplier shall contribute in Installation, Adjustment, Pre-operational tests, Start-up and Commissioning of the heat exchangers and SATprocedure organized by the end-user. Page 7 of 17

8 8. Deliverable Items 8.1 Handover shall be carried out in the frame of a factory acceptance test (FAT) procedure organized by the supplier. 8.2 Two numbers of heat exchangers as detailed in this SOW in complete assembled condition with sealing gaskets, fasteners, caps. All input and output flanges of the heat exchangers must have in set response flanges (mother-father) with fasteners and sealing gaskets, which (if necessary) will be mounted to piping. Heat exchangers shall be delivered to the site in suitable package to avoid any damage during transport and handling. 8.3 Detailed documentation in accordance with the end product; installation and maintenance instructions, material and welding certificates; pressure test, QC certificates and FAT protocol. 8.4 Spare parts: 2 extra sets of sealing gaskets 5 pieces of each type of screw fasteners 1 set of each individual functional element (if any) 8.5 Supplier shall provide INP with shipping documents including Certificate of Country of Origin Form CT Delivery location: Tashkent, Uzbekistan 9. Responsibilities of End-User (INP) 9.1 Premises preparation, Installation, Adjustment, Pre-operational tests, Start-up and Commissioning of the heat exchangers and SAT shall be carried out by the End-User supported by the Supplier documentation and Supplier supervision services during the above mentioned tasks and activities; 9.2 Additional Actions/Tasks to be performed by the End User are as follows: o The End-User shall perform the tasks of civil works, preparation of the premise, installation, adjustment, preoperational tests, start up and commissioning of the heat exchangers on the basis of the submitted documentation by the Supplier. o The End-User will update the operating documentation. o For all the tasks mentioned above, the Supplier shall provide supervision services. 10. Responsibilities of the Supplier 10.1 The supplier shall prepare the design of the heat exchangers on the basis of data presented by INP. The design documentation shall be presented to the End-User for further submission to the national regulatory body (State Inspectorate Sanoatgeokontechnazorat of Uzbekistan) for approval The supplier shall be responsible for design, preparation of manufacturing/as-built drawings, procurement & testing of material, manufacture, inspection, shop testing, Page 8 of 17

9 packing, supply, guarantee and delivery to INP in Tashkent, Uzbekistan of 2 (Two) numbers of Primary cooling water/secondary cooling water Shell and Tube type Heat Exchangers as per technical requirements indicated in this specification and site dimensions The Supplier shall provide site supervision services for installation, adjustments, site testing, end connections to existing piping on both primary and secondary side and commissioning of heat exchangers. 11. Documentation 1. All technical documentation shall be provided in English and Russian languages. 2. A set of documentation including as-built drawings providing all details of the supplied heat exchangers shall be provided. 3. Detailed documentation in accordance with the end product; equipment specification and user manual, as well as installation-, commissioning- and maintenance instructions, material and welding certificates; pressure test, QC certificates and FAT protocol. 4. Detailed specifications of spares for future procurement with drawings, material specifications and the applicable standards shall be provided. 5. Pre-service inspection records shall be provided. 12. Warranty The Warranty period of the provision shall be 2 years. The warranty period shall start on the date of the SAT but no later than 36 months from the date of the delivery of the goods to the end-user site. Page 9 of 17

10 Annexure A TECHNICAL DETAILS FOR THE OFFERED HEAT EXCHANGERS (To be filled by the bidder and submitted along with the Technical Bid) I. DESIGN & FABRICATION CODES: II. CONSTRUCTIONAL DETALS SL. NO. PARAMETERS DETAILS OF CONSTRUCTION 1 Material of construction for each component. 2 Manufacturing process for each component. 3 Type of tube expansion. 4 Length of tube expansion in tubesheet. 5 Tube hole dia in tube-sheet along with tolerances. 6 Tube hole dia in transverse support baffles along with tolerances. 7 Diametrical clearance between transverse baffle and shell ID. 8 Shell ovality tolerance. 9 Machine to be used for tubesheet drilling & its tolerance values like drill drift etc. 10 Source of tubes. 11 Source of tube-sheet material. 12 Source of dish-end fabrication / plate rolling. 13 Tube diameter, tube thickness and pitch 14 Number of cross baffles 15 Dimensions: Shell diameter, thickness of shell, tube sheet, and end covers Page 10 of 17

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