NUCLEAR POWER CORPORATION OF INDIA LIMITED (A Government of India Enterprise) Coolant Channel Design Group. SPECIFICATION No: PP-C-00003

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1 NUCLEAR POWER CORPORATION OF INDIA LIMITED (A Government of India Enterprise) Coolant Channel Design Group SPECIFICATION No: PP-C TECHNICAL SPECIFICATION ON MANUFACTURE OF ROLLER OF END FITTING PRESSURE TUBE ROLLED JOINT EXPANDER ASSEBLY FOR 220 MWe PHWR COOLANT CHANNEL REVISION NO. 0 REF. USI NO: DATE OF ISSUE (MONTH / YEAR) (NUMBER OF PAGES (INCLUDING COVER SHEETS) MAY = 14 ORIGINAL Prepared by: Agnish Ghosh S. Khandave Checked by: Jijo K. Thomas Reviewed by: Dipti Bhachawat Approved by: Nemani Prasad Name Signature File Name: PP_C_00003_R0 (For Revisions See Revision Control Sheet)

2 REVISION CONTROL SHEET DOCUMENT TYPE : TECHNICAL SPECIFICATION NO: : PP-C TITLE : ROLLER OF END FITTING - PRESSURE TUBE ROLLED REV NO DESCRIPTION OF REVISION PREPARED CHECKED BY BY REVIEWED APPROVED BY BY

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4 NPCIL PROPRIETARY This document contains confidential and protected information and that the same are the intellectual property of Nuclear Power Corporation of India Limited (NPCIL). No part of this document including notably any editorial elements, verbal and figurative marks and images included herein, shall be reproduced or transmitted or utilized or published or stored in any form or by any means now known or hereinafter invented, electronic, digital or mechanical, including photocopying, scanning, recording or by any information storage or retrieval system, without prior written permission from NPCIL, by any person or entity. Unauthorized use, disclosure or copying is strictly prohibited and may constitute unlawful act and can attract legal action.

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6 PAGE 1 OF 9 1. SCOPE This specification covers the technical requirements for material, manufacturing, inspection, testing, packaging and shipment of Roller of End Fitting-Pressure Tube Rolled Joint Expander Assembly for 220MWe PHWR Reactors Coolant Channel Installation (CCI). This specification is applicable for Roller of End Fitting-Pressure Tube (EF-PT) Expander Assembly for KAPS-2 EMCCR project. This specification can be applied to Rollers of End Fitting-Pressure Tube (EF-PT) Expander Assembly of other 220 MWe PHWR Reactors if the mandrel & cage of expander assembly are dimensionally same as KAPS-2 expander assembly cage & mandrel. 2. CONTENTS This specification contains the following Sections Section Purpose 3 Applicable Codes specifications and drawings 4 General Requirements 5 Inspection, tests and reports 6 Submission of technical documentation 7 Suggestive Quality Assurance Plan (QAP) 8 Quality surveillance by purchaser 9 Packing and shipment PURPOSE Purpose of this specification is to provide detailed technical information regarding the manufacturing of roller of EF-PT rolled joint expander assembly for 220 MWe PHWR Reactor Coolant Channel and to ensure that the manufactured roller performs its intended functions effectively. 4. APPLICABLE SPECIFICATIONS AND DRAWING: 4.1 Specifications ASTM A 561 ASTM E 18 ASTM-E-92 ASTM A ASTM E-08 Macro-etch testing of tool steel bars Rockwell hardness test method for metallic materials Test Method for Vickers Hardness of Metallic Materials Standard specification for tool steel alloy Standard test methods for tension testing of metallic materials

7 PAGE 2 OF 9 ASTM E3-11 Standard Guide for Preparation of Metallographic Specimens 4.2 Reference Drawings KAPS-2/31170/2404/DD: Coolant Channel Installation (CCI) - Roller of EF-PT rolled joint expander assembly The Supplier shall prepare all necessary drawing required for manufacturing and testing of rollers to meet the requirements of this specification. These drawings shall be approved by NPCIL prior to start of manufacture. 5.0 GENERAL REQUIREMENTS 5.1 Material The raw material for roller of EF-PT rolled joint expander assembly shall be High Carbon High Chromium Cold worked D2 Tool Steel (ASTM A ). Raw material shall be in form of round bars. Raw material shall have sufficient allowances to take care of post heat treatment, decarburization, machining, cutting and trimming. 5.2 Chemical Composition The chemical composition shall meet the following requirements: 5.3 Heat treatment C : 1.4%-1.6% Mn : % (max) Si : % (max) P : 0.03% (max) S : 0.03% (max) Cr : 11%-13% Mo : 0.7%-1.2% V : (max) Heat Treatment of the D2 material is to be carried out using Vacuum Furnace as per ASTM A standard. Suggested Heat Treatment process details are as:

8 PAGE 3 OF 9 Stress Relieving: 650⁰C, Holding for 1hour,Furnace Cooling thereafter Pre Heating(1): 650 ⁰C, Holding for 50 minutes Pre Heating(2): 850 ⁰C, Holding for 1hour Austenitizing : 1030⁰C, Holding for 30 minutes Quenching: By nitrogen at 5 bar Tempering(1): Heating to 250⁰C, Holding for 4 hour Tempering(2) : Heating to 520⁰C, Holding for 2 hour Tempering(3) : Heating to 520⁰C, Holding for 2 hour Any change in the above heat treatment procedure shall be subject to Purchaser s approval before going for mass production. 5.4 Plasma Nitriding Suggested Plasma Nitriding process parameters shall be as follows: Pre-cleaning 200⁰C onward, Duration 2 hour (using Argon) Cleaning 400⁰C onward for 1 hour (Using Argon & Hydrogen) Nitriding Process Temperature: 500⁰C for 12 Hours(Using Nitrogen & Hydrogen) Cooling with Nitrogen for 2.5 Hrs. Gases Used : Argon, Hydrogen and Nitrogen 5.5 Mechanical properties After heat treatment standard approved test samples for Tensile Test, Fatigue Test, Wear Test shall be taken out. The supplier shall prepare the drawing of test specimen for mechanical testing and this drawing shall be approved by NPCIL. Tensile tests results shall be recorded. Fatigue and wear tests shall meet following requirements Fatigue test: The test specimen shall be subjected to 10 5 cycles with peak cyclic stress equal to the yield strength of the pressure tube material. Wear test : Wear test specimens shall be evaluated for wear sliding distance equivalent to fabrication of 800 joints. The above tests shall be conducted at supplier s shop or at Purchasers End.

9 PAGE 4 OF Decarburization examination Extent of decarburization during heat treatment shall be estimated as per the guidelines given in the latest edition of ASTM standard A681. It should satisfy the requirements of the said standard. 5.7 Hardness Test Hardness of the as received annealed or cold drawn material should correspond to the respective values as specified in the latest edition of ASTM A681. Hardness after heat treatment shall satisfy the requirement of HRC. Sample for hardness test shall be taken out as per guidelines given in the latest edition of ASTM 681 and Hardness Test shall be carried out as per guidelines given ASTM A370. Hardness shall be taken at 3 points on each prolongation and the average of three readings shall be reported. It shall meet the Core Hardness requirement of HRC. Average hardness values of the plasma nitride coating layer shall be in Vickers scale (100 kg load). 5.8 Requirement of archive samples In addition to the normal samples for testing two nos. of rollers at each stage (i.e. before Heat Treatment, after Heat Treatment and after Plasma Nitriding) and additional archive piece of length 100 mm from raw material shall be supplied for preservation as archive samples with appropriate identification engraved on the material. 5.9 Manufacturing requirements Surface finish requirement The cylindrical surface of the roller including the taper end shall have the surface finish of 0.8 microns or better Workmanship Workmanship of finished components shall be of high quality compatible with best standard of manufacturing and quality assurance practices Manufacturing Procedure The methods for manufacture and machining of the rollers are the responsibility of the supplier. All work shall be done in accordance with the best shop practices for each specific operation. The complete manufacturing plan showing complete sequence of actions and detailed procedure shall be made by the supplier and shall be submitted to and got approved from NPCIL before start of manufacturing.

10 PAGE 5 OF Manufacture of Prototype rollers The manufacturing, heat treatment procedure and surface treatment shall be established on prototype rollers. Prototype rollers shall meet all the requirements of this specification and shall be inspected and tested as required in this specification. The supplier shall provide one full set of prototype rollers for checking the performance by carrying out actual rolling operations on minimum 6 joints. The joint shall be inspected visually to see the performance of rollers. After rolling operation, the rollers shall be DP checked. No relevant indications are acceptable. After rolling operation the rollers shall be UT inspected as per the requirement given in section 6.6. Post rolling scratches in the joint/rollers or deformation of rollers shall be cause of rejection. Based on successful visual/ndt examination result of joint and rollers after rolling operations, actual production shall be taken up. 6.0 INSPECTION, TESTS AND REPORTS 6.1 General The supplier shall be responsible for all of the testing and inspection specified herein. Inspection shall be under the control of a competent chief inspector whose primary responsibility is inspection, reporting directly to the management and not the production department. The inspection shall be carried out in a manner satisfactory to and shall be subject to approval by the purchaser. The supplier shall submit an inspection plan for approval by the purchaser. In addition to the tests performed by the supplier, the purchaser shall have the right to ask for additional inspection or testing as he deems necessary and the additional cost of such tests will be borne by the purchaser. The supplier shall maintain records of all inspection and tests, which shall be made freely available to the purchaser or his authorized representative. 6.2 Inspection and Test Failure In the event of any failure to meet an inspection or test requirement specified herein, the supplier shall notify NPCIL or its authorized representative. No repair of any kind shall be done on rollers. 6.3 Macro-structural Examination Specimens for the determination of the macrostructure shall represent the entire crosssectional area in the annealed condition and be prepared in accordance with the latest issue of Practice A561. Material supplied to this specification shall be capable of exhibiting a structure free of excessive porosity, segregation, slag, dirt or other nonmetallic inclusions, pipe, checks, cracks, and other injurious defects. Macroetch severity levels for center

11 PAGE 6 OF 9 porosity and ingot pattern, illustrated photographically in Practice A561, shall not exceed the ratings specification as given the standard ASTM A Microstructural Examination Microstructural analysis shall be done on the raw material and on the test piece after heat treatment and plasma nitriding to ensure the uniform distribution of grains before and after heat treatment. The undissolved carbides shall be uniformly and finely distributed over the matrix, with no network or cluster.microstructure test results shall be approved by NPCIL. Any test specimen showing unacceptable microstructure shall be cause of rejection. Reheat treatment may be carried out by supplier for compliance of microstructure requirement. After plasma nitriding, the transverse section shall be examined for uniformity of nitride layer thickness, presence of any micro-cracks at the interface between the nitride layer and substrate shall lead to rejection. The nitriding layer shall be free from detrimental defects / micro cracks. 6.5 Dimensional Inspection: Each roller after final surface treatment shall be subjected to a complete dimensional inspection to verify that the dimensions are in accordance with the Purchaser s drawing. 6.6 Surface finish and profilometry The surface finish and profile of rollers shall be examined by appropriate techniques and shall conform to as shown in the applicable drawing. The electronic data generated during examination of surface finish and the roller profile shall be recorded. The records shall be permanent. 6.7 Visual Examination A thorough visual examination of the outside surfaces of rollers shall be carried out. No repairs of any kind shall be done on the rollers and the rollers shall be rejected in case of any visual imperfections. 6.8 Ultrasonic Inspection After rough machining the material shall be ultrasonically tested for internal soundness and after Final Machining, Heat Treatment and Plasma Nitriding the rollers shall be ultrasonically tested for internal flaws by 2mm FBH, DAC method using normal beam. 6.9 Dye Penetrant Testing The raw material and finished roller shall be tested by visible dye solvent removable method. No relevant indications are acceptable.

12 PAGE 7 OF Identification: Each roller shall bear the identification mark correlating the parent heat number, heat treatment batch number, serial number etc. as shown in the drawing. 7.0 SUBMISSION OF TECHNICAL DOCUMENTATION 7.1 General The supplier shall submit the following details and drawings for approval by Purchaser before start of production. These shall be submitted in the form of a consolidated bound technical docket as well as in the form of a soft copy in PDF format as well. 1. Manufacturing procedure including all heat treatment and surface treatment procedures / route in detail indicating step by step complete activities of the manufacturing flow chart. 2. Quality assurance / inspection plan and detailed inspection/examination procedures indicating step by step complete quality assurance / inspection programme at all stages of job. Approval of above technical documentation by purchaser shall not relieve the supplier from full responsibility for correct interpretation of purchaser s specifications. It shall be the total responsibility of the supplier to ensure that the product supplied is in accordance with the governing specifications. 7.2 History Docket At the completion of the contract, the manufacturer shall furnish to the purchaser two copies of bound documents covering all the aspects of material, manufacture, inspection and testing such as material testing, heat treatment, surface treatment, mechanical testing, nondestructive testing, dimensional inspection etc., duly signed by authorized person of supplier. History dockets shall also include P.O. with all amendments, NCRs, SRs etc. History dockets shall also be provided in soft form in PDF format. All documents in the history docket shall be fully identified and suitably cross referenced. 8. SUGGESTIVE QUALITY ASSURANCE PLAN (QAP) The supplier shall submit a detailed QAP for approval by purchaser. Quality assurance plan for the work covered by this specification shall meet the minimum requirements of control and tests as given below. Final QAP as approved by purchaser shall be used during manufacture.

13 PAGE 8 OF 9 Suggestive Quality Assurance Plan (QAP) Sr. No Control and tests Action by supplier Quality surveillance by purchaser or his authorized representative 1 Submission of technical documentation inclusive of manufacturing plan/procedure and quality control and inspection procedures Submission by supplier Approval by Purchaser 2 Calibration of working zones and instruments for all Heat Treatments I R, C, H 3 Calibration of instruments for various inspection / examination activities, testing machines etc. I R, C, H 4 Chemical composition I R, H 5 Process parameters, plasma nitriding parameters, heat treatment parameters and time temperature charts for R, C I all heat treatment operations 6 Personnel qualification for non-destructive testing I R,H 7 Hardness of coating and substrate, hardness profile, wear test, fatigue test, tensile test, microstructure, I R, C, H plasma nitride layer thickness and examination etc 8 Tensile test I R,C 9 visual, Dimensional, Profile verification, surface finish, UT, DPT, of prototype rollers I R, C, H 10 Performance qualification of rollers and Approval of prototype I R, C, H 11 Dimensional, Visual, NDT (ultrasonic inspection, DP inspection for raw material and finished rollers, hardness check etc.), checking of roller profile on I R, C production rollers. 12 Identification I R, C 13 Documentation I R, H 14 Shipping release Issue 15 Packing I R, C Legend I R C H : Complete action and inspection by supplier on a 100% basis. : Review of test records, test reports, procedures, test certificates, records of process parameters etc. : Checking the actual component or witnessing the inspection / testing activity on a suitable percentage / random basis. : Hold point by purchaser

14 PAGE 9 OF 9 9. QUALITY SURVEILLANCE BY THE PURCHASER 9.1 All work covered by this specification shall be subject to quality surveillance by the purchaser or his authorized representative for which purpose the supplier shall: a) Allow access at all reasonable times during manufacture to (i) (ii) (iii) The premises in which the work is being carried out The drawings and the tooling, wherever involved Gauges, instruments etc. required for inspecting the work. b) Produce an inspection and quality control plan to the purchaser s satisfaction and notify him when the check points on the plan are imminent so that purchaser s authorized quality surveillance representative can be present during salient intermediate stages of the job. 9.2 Inspection and tests shall be carried out as per the requirements of governing specifications. 9.3 Shipment must not take place until the purchase has been notified and release of material for shipment has been obtained from the purchaser or his authorized representative in writing. 9.4 Quality Surveillance by the purchaser or his authorized representative shall not relieve the supplier from the responsibility of meeting the specifications or the inspection duties called herein PACKING AND SHIPMENT The supplier shall be responsible for protecting the roller against corrosion and damage of any kind throughout all stages of manufacturing, inspection, handling, storage and transport. The rollers shall be properly packed to ensure no damage during transit and trouble free storage and handling at NPCIL.

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