Nuclear Power Corporation of India Limited

(A Government of India Enterprise)

Narora Atomic Power Station
Coolant Channel Replacement Group

PROCEDURE NO.NAPS-2/EMCCR/P#114/R0

PROCEDURE FOR PRESSURE TUBE TRIMMING FOR NAPS#II

M.K.Sharma (SO/D,CCRG)
Prepared by :

N.Agrawal (SO/D,CCRG)

Checked by :
(S.Patra)
SO/G, CCRG

Reviewed by : (R.D Bhatt)

MS

Approved by : (L.K.Jain)
Chief Superintendent

Doc Ref. No.:- NAPS-2/EMCCR/P#114/R0

Procedure For Pressure Tube Revision No. 0 Page No. 1
Topic
trimming Issue No. 1 01-01-09

NAPS-2/EMCCR/P#114/R0 Page 1 of 10
 CONTENTS

S.NO. DESCRIPTION PAGE NO.

1 SCOPE 3

2 REFERENCE DRAWING 3

3 PRE-REQUISITES 3

4 GENERAL TOOLS/CONSUMABLES 4

5 GAUGE TUBE PREPARATION 4

6 COOLANT TUBE TRIMMING 6

7 CHECK LIST 8

NAPS-2/EMCCR/P#114/R0 Page 2 of 10
1.0. SCOPE :

This procedure defines the site procedure for the Zr-Nb coolant tubes
inspection, marking and trimming operations for the en-masse coolant
channel replacement in Unit-2 of NAPS.

2.0 REFERENCE DRAWINGS AND SPECIFICATIONS:

2.1 DRAWINGS

1. NAPS-1/31120/2402/DD Zr-Nb reactor coolant tube as pilgered

2. NAPS-1/31120/2422/GA
3. NAPP-1/31170/2026/DD
4. NAPS-1/31170/2407/DD
5. NAPS-1/31170/2404/DD
2.2 SPECIFICATIONS
& finished.
End fitting sub-assembly.
Coolant tube GO gauge.
Coolant tubeVBlock for length mark-off.
Scribing tool for PT cut-off

1. PP-P- 2125 Technical specification for coolant channel re-

installation requirement for NAPS # 2
2. PP-E-2223 Zr-2.5 Nb Cold worked seamless pressure tubes
and coolant tube spools for rolling qualification
for NAPS-2.
3. PP-C-2094 Nuclear Clean Room Conditions

3.0 PRE-REQUISITES :
3.1 Clean room conditions are established and maintained for the trimming of
coolant tube at CCR shop.
3.2 Lathe with trimming tool (duplex cutter) especially for facing purposes
installed and commissioned. Also PT supports installed in line with lathe
centre line at CCR Shop to support and guide the pressure tube during
machining.

NAPS-2/EMCCR/P#114/R0 Page 3 of 10
3.3 The required work benches for PT visual inspection, bow measurement,
marking of PT w.r.t. pre-calibrated gauge tube and storage of trimmed
tubes are installed.
3.4 End fittings are pre-assembled. Route cards are available with all
necessary dimensions recorded, especially dimension C N and CS.
3.5 Dimension D collected from Unit-2 construction PT rolling route
cards/records.
3.6 Average dimension D computed from the above records and the D
dimension is taken as 7235 mm.
3.7 End Fitting & PT allotment done for lattice locations meeting various
requirements.

4.0 GENERAL TOOLS/CONSUMABLES :

4.1 TOOLS :
a) Duplex cutting tool b) Bore dial gauge
c) Stick micro meter (6M) d) Micrometer (100 mm)
e) PI tape/ O.D. Micrometer f) Verniers
g) Smooth files h) 2.5/3 mm / number punch set
i) 500 gm nylon hammer j) 6 Try square
k) Allen key set l) 6 long feeler gauge
m) Torch n). Foot ruler (12)
o) Roller stands for bow measurement.
4.2 CONSUMABLES :
a) Emery sheet grade 180/200 b) Polishing emery sheet (zero
emery)
c) Cleaning agents (Acetone) d) Lab coats
e) Shoe covers f) cotton caps
g) Cotton gloves h) Lint free cloths
i) White handkerchief j) Brass shims

5.0 GAUGE TUBE PREPARATION:

5.1.0 Dimensional requirements for gauge tube:

5.1.1 Calculate the required length of the gauge tube using the given formula:

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Trimmed Length of coolant tube, L = D - CN - CS + 386 mm 0.40 mm

NAPS-2/EMCCR/P#114/R0 Page 5 of 10
 Where,

D = Distance between North FSTS face to South FSTS face

computed from old history record.
CN = Dimension C of North End- The dimension CN & CS
fitting. are measured distances
from the fuelling machine
side end of bellows
attachment ring to the
CS = Dimension C of South End-
calandria side end of the
fitting.
rolled in liner tubes on
north and south end
fittings.
Refer pre-assembly route
card for any channel.
386 = The 386mm dimensions is the difference between the sum of
205 mm plus 205 mm (distance between bellows attachment
ring fuelling machine side face and end shield tube sheet in
both vaults) and the sum of twice 6mm (nominal gap between
coolant tube and liner tube after the coolant tube joints are
expanded) plus twice 6mm (nominal extrusion of coolant tube
for each coolant tube joint). However this will be established
during procedure qualification.

L = Trimmed length

5.1.2 The square ness of the trimmed tube ends shall be within 0.12 mm. The
45 Deg ID chamfer shall be 1.5mm 0.4 mm. The OD of trimmed ends
shall be debarred. The coolant tube identification shall be indicated with
marker at the numbered end.

5.2 PREPARATION OF GAUGE TUBE :

5.2.1 Select fresh Zr-Nb tube for making gauge tube for marking PT for
trimming.
5.2.2 Mark un-numbered end at approximately 25 mm and trim the tube on
lathe.
5.2.3 Remove burrs on OD; Chamfer ID and end square ness by smooth filing,
check for end square ness.
5.2.4 Place the tube on marking bench and mark the required tube length by
butting the trimmed tube end and the stick micrometer with surface plate
for second end trimming.

NAPS-2/EMCCR/P#114/R0 Page 6 of 10
5.2.5 Trim the second end, deburr OD, chamfer ID and check for end square
ness.
5.2.6 Place the tube on the marking bench, insert the scriber in one end and set
the other end butting with surface plate. Achieve the required length by
adjusting the scriber tool point and fix the scriber firm and rigid. Mark the
dimension on the tube, which is gauge reference tube for PT trimming.
5.2.7 Length of the gauge tube shall be measured using stick micrometer to an
accuracy of 0.1mm & reading shall be recorded on gauge tube for future
reference. Recalibrate & confirm the dimensions, then record.

6.0 COOLANT TUBE TRIMMING :

SEQUENCE OF OPERATION:

6.1 Transport coolant tubes from Central Stores to CCR shop for
trimming/sizing purpose, in its original packing/container.
6.2 Unpack the coolant tube, record the number. Place the Coolant tube on
marking table & clean it using acetone soaked lint free cloth. Inspect
visually for any surface damages scratches, dents, burrs etc on the outer
and inner surfaces at the rolling areas.
6.3 Verify the history dockets, SR, IR and DCR of the coolant tubes. Make
note of designers instruction if any and comply with it.
6.4 Assign lattice location to PT as per approved PT-E/F allotment list.
6.5 Record the Sl. No., DCR No. and enter in check list.
6.5 Measure overall length, ID, OD and bow before trimming to ensure that it
is within limits and record the parameters as per check list.
6.6 Calculate the coolant tube length as per formula shown in 5.1.1. using C n
& Cs values of end fittings of corresponding channel.
6.7 Mark half of the total length to be trimmed at the number end.
6.8 Place the one end marked PT on lathe and on all supports, insert the
sponge roll in bore and trim the number end as per marking and machine
45 ID chamfer to 1.5 mm + 0.4 mm.
6.9 Remove the trimmed PT and place it on the work bench.
6.10 Check end square ness of the trimmed face of tube within 0.12mm by
butting to the angle plate on marking table and mark pressure tube
number and channel number on the tube face with magic ink. Remove
sponge roll from bore and clean.
6.11 Mark the location of trim at un-numbered end as per calculated length with
the help of gauge tube and scribing tool (marking length shall be
increased or decreased by using shim of appropriate thickness).

NAPS-2/EMCCR/P#114/R0 Page 7 of 10
6.12 Trim the PT un-numbered end as per marking.
6.13 Remove PT and place it on the work bench. Deburr, chamfer and polish
the trimmed ends. Check end square ness of the trimmed face of tube
within 0.12mm by butting to the angle plate on marking table. Remove
sponge roll from bore and clean.
6.14 Recheck and ensure the cut dimension of PT as per calculated length.
6.15 Measure the bow of coolant tube at four (4) garter spring position 450 mm
and 1350 mm from center on both side by dial gauge & record in route
card check list. Maximum bow / allowable bow shall not exceed 1.25mm
(2.5 TIR). Mark the position of maximum bow at north vault end of the tube
by needle file.
6.16 Measure and record the following parameter of completed trimmed tube:
Length of tube after trimming within 0.4mm.
Coolant tube OD at both the ends by Pie- tape
Measure and record the wall thickness at both ends.
ID of coolant tube at both ends with bore dial gauge at minimum 2
locations & calculate the average.
Complete the documentation.
6.17 Repack the trimmed PT in polythene cover and close the ends with PVC
caps. Transport the PT to the designated storage area for future use or to
the first end (South end) rolling area, which is applicable.
6.18 Ensure that no damages occur during transportation.
6.19 Mark channel number on numbered end by white masking tape and
preserve the cut-off samples of pressure tube.

NAPS-2/EMCCR/P#114/R0 Page 8 of 10
 Nuclear Power Corporation of India Limited
(A Government of India Enterprise)
Narora Atomic Power Station CL NO. NAPS-
Coolant Channel Replacement Group
2/EMCCR/P#114/CL-14
CHECK LIST FOR COOLANT TUBE TRIMMING
Prepared By Checked By Reviewed By Approved By

M.K.Sharma S.Patra R.D.Bhatt L.K.Jain

SO/D,CCRG SO/G,CCRG MS CS,NAPS

Unit: NAPS # 2 Date:

1. Lattice Location
2. End Fitting Pre-assembly data North South
a) Ref E/F pre-assembly record sheet No

b) E/F No. & Group

c) Orientation

d) Dimension C

e) E/F bore B-1 Dia.

f) Dimension R

3. Dimension D avg of channels (construction data

sheet)
4. Pressure Tube Details N.E. / O.E. N.E / O.E.
(a) Coolant Tube No. DCR No.:
(b) Visual inspection& cleanliness
(c) PT length before trimming
(d) Gauge Tube Length
(e) PT required Length
L = D (Cn + Cs) + 386
(f) Final Trimmed Length
(L+ 0.4 / - 0.4 mm)
(g) Squareness of trimmed ends (specified within 0.12
mm)
(h)Trimmed End ID Chamfer (1.5 X 450 + 0.4/-0.4 mm)
and OD deburr
(i) OD of PT

(j) ID of PT

(k) 2T={OD-ID}

(l) Mark NE/OE at the corresponding ends of PT after

NAPS-2/EMCCR/P#114/R0 Page 9 of 10
 trimming.
(m) Clearance for shop joint (+0.06 mm max) /
Interference (-0.14 mm max)
(n)Clearance for field joint (+0.12 mm max)
(o) Bow measurement (TIR < 2.5 mm)
At 450 Mm From centre

At 1350 Mm From centre

(p) Marking of max. bow (at north end of PT) by needle

file.
5. Remarks, If Any

CONTRACTOR NAPS
EXECUTION QA CCRG QA

Signature:
Date:

REVIEWED BY: SO/G,CCRG

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