Development of Engineering Infrastructure in Pakistan Atomic Energy Commission

National Conference Organized by SASSI “Application of Nuclear Science & Technology in Pakistan”

(July 12-13, 2012)

Waqar M. Butt Member (Engineering), PAEC (member.engg@ gmail.com)

Infrastructure Development Goals and Objectives

To meet the design, manufacturing and testing requirements of

► Operating plants/facilities

► New Plants/ Projects

Objectives

► Life time engineering support for O/M of Plants/ facilities

► Minimize dependence on vendors

► Enhance role in future plants/ facilities

► Offer services to National/International Industry

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Infrastructure Development (Capacity and Capability Building)

Design and Manufacture of Plant Equipment

Testing and Inspection

Specialized Training

Computer, Control and Instrumentation Design & Engineering

Interface with industry

Infrastructure Development Program got boost after international embargo in

mid 70’s

Safe and continued operation of KANUPP after embargo was a major challenge

for PAEC

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Major Infrastructure Facilities

Scientific and Engineering Services (SES)

Heavy Mechanical Complex-3 (HMC-3)

National Centre for Non-Destructive Testing (NCNDT)

Pakistan Welding Institute (PWI)

Informatics complex (ICCC)

HMC-3 NCNDT PWI ICCC

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Design and Manufacture of Plant Equipment

Process equipment design

Manufacture of plant equipment

Replacement equipment support throughout plant design

life and beyond

Major equipment maintenance services

► Ageing management ► Decommissioning

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Applicable Codes and Standards

Codes / Stds. Description

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

AISC American Institute of Steel Construction

AWS American Welding Society

API American Petroleum Institute

BS EN British Standard / European Standard

DIN Deutche Industrial Norman

FEM Federation Europeene De La Manutention

GB Chinese Standards

ISO International Standard Organization

TEMA Tubular Exchanger Manufacturers Association

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Engineering Software In-house capability of using following software

Software Description

ANSYS Design and analysis

Autodesk Inventor Suite 2008 with MDT

3D Modeling and design Software

Catia 3D Modeling and design software

Solid Works 3D Modeling and design software

Pro-E (Wildfire4) 3D Modeling and design software

Auto Plant 2004 Creation of 3D piping models

PV Elite 2008 Comprehensive Software for design of pressure vessels and heat exchangers

STADD Pro 2006 Structural engineering software

Chem CAD 6.0.1 (CC Therm) Software for thermal design of heat exchangers

Fire CAD Design software for Boilers

E-Tank 2000 1.8.0 Software for design of tanks as per API 620, 650 & 653. 6/41

Certification

International Standards Organization ISO 9001: 2008 Certified for Design & Manufacture of Engineering Products for Heavy and Medium Industries

The National Board

of Boiler and

Pressure Vessel

Inspectors

R Repair / Alteration

as per ANSI 23 / NB

Pakistan Nuclear Regulatory

Authority

HMC-3 is the first engineering

organization that has been certified to

produce Nuclear Safety Class-I

equipment and components in Pakistan.

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ASME: Certification

American Society of Mechanical

Engineers

Stamps

A Assembly of Power Boiler

S Power Boiler Design and Fabrication

as per ASME Section-I

PP Power Piping as per ASME B.31.1

U Pressure Vessel as per ASME-VIII Div-I

U2 Pressure Vessel as per ASME-VIII Div-II

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API: Certification

American Petroleum

Institute

Monogram Licensing for

Specifications:

12D Field Welded Steel

Storage Tanks

12F Shop Welded Steel

Storage Tanks

12J Oil & Gas Separators

or / and Oil Gas Water

Separators

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Design & Engineering

Fabrication

Heat Exchanger

Dish Head Forming

Thick Plate Rolling

Pipe and Section Bending

Welding, All Types

Narrow Gap Welding

Plasma Cutting

CNC Machining

Heat Treatment

NDE

Destructive Testing

Hydrostatic

Pneumatic

Vacuum

Quality Assurance & Control

Major Manufacturing Facilities

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Major Manufacturing Facilities

250mm Plate Edge Preparation

Machine

Plasma Cutting Machine (100mm)

250 mm Plate Bending & Rolling

Mill

4m Dia Dish Making Line

Fabrication

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8m CNC Milling & Boring Machine

X, Y, W & Z Stroke:

8.5, 2.0, 1.0 & 1.2 m

respectively.

Positioning Accuracy:

0.015mm/1.0m.

Repeatability Accuracy:

0.01mm.

Machining

Major Manufacturing Facilities

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16m CNC Vertical Boring & Turn Mill

Jobs Size, Maximum:

Diameter 16,000 mm.

Height 6,500 mm.

Weight 320 tons.

Positioning Accuracy:

0.012mm/1.0m.

Repeatability:

0.008mm.

Machining

Major Manufacturing Facilities

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Working Range: 8m in Horizontal & Vertical Planes. Welding: Up to 350mm thick steel plates. Roller supporters: 500 tones

Narrow Gap Welding Machine

Welding

Major Manufacturing Facilities

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Major Equipment Manufactured

Pressure Vessels

Chemical Vessels

Water and Steam Drums

Heat Exchangers

Air Pre-Heaters

Condensers

Heating Furnaces

Vacuum Furnaces

Welding Positioners

Water Treatment Plants

Food irradiation Plants

Desalination Plant Equipment

Chemical Reactors

Boiler Drums

HP Heaters

EOHT, Gantry Cranes (upto 100 tons)

Heavy Steel Structure

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Evaporator for Desalination Plant

Dia = 3,216 mm Length = 16,400 mm Weight = 50 ton Capacity = 1,600 m3/day

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Testing and Inspections

Systematic testing and inspection program

throughout manufacture, construction,

commissioning and operation phases.

Strong NDT/NDE program

Training and re-training of NDT/NDE inspectors and enhancement of

testing facilities.

National center for Non-destructive Testing (NCNDT) of PAEC has

necessary facilities and expertise to meet the inspection & testing

requirements of nuclear plants and offer these services to local

industry.

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Pressure up to 40 MPa & Flow up to 1.08 m3/hour.

Hydrostatic Testing

The Industrial Boroscopy Equipment can undertake normal as well as irradiated jobs. It can work on Tubes of minimum dia 7 mm and length up to 7.5 m.

Boroscopy

Inspection and Testing

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• Size (X- Y- Z travels)

3000 x 1500 x 1500 (mm)

• Loading Capacity

3,637 kg

Coordinate Measuring Machine (CMM) Profile Projector

CMM can be used for testing the machined

and assembled magnets.

Inspection and Testing

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► NDE/ NDT

► Welding technology

► Industrial/Fire safety

Regular Training Courses for

PAEC and local industry.

Specialized Training Program

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NDT Courses for Industry

NDT Appreciation Course for Managers

NDT & Fracture Mechanics

Basic Concept on Acoustic Emmission

Introductory Course on NDT of Concrete

Theoretical Aspects of RT, UT & ET

Radiation Safety

Ultrasonic Thickness & Crack Depth Measurement

Phased Array & Time of Flight Diffraction (TOFD) Techniques

Ultrasonic Defect Detection with Digital/Analog Equipment

Understanding of Ultrasonic Testing in ASME Code Section -V

Interpretation of Radiographs

Ultrasonic Sizing of Defects

Introductory Course on NDT of Concrete

Theoretical Aspects of UT,RT & ET

Eddy Current Testing

Ultrasonic Flaw Detection in Welds

Specialized Training

Courses are also arranged

on industry request.

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Welding Courses for Industry

National Course on

Welding Technology for Engineers

Appreciation Course for Executives

Orientation Course on International Standard

Welding Inspectors Level-I & Level-II

TIG Welding for Welders

Gas Tungsten ARC Welding of Carbon & Alloy Steels

SMAW for Pipe Welders (Mat Carbon Steel)

GTAW Process for TIG Welders (Stainless Steel)

Welding Inspection and Quality Control

Weldability of Metals

Gas metal Arc Welding for Welders

Stainless Steel Pipe Welding for Welders

Welding of Cast Iron for Engineers

Stainless Steel Pipe Welding for GTAW / SMAW Welders

Specialized Courses / Training

Programs are also arranged

on industry request.

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Design and Engineering of Computer, control and Instrumentation

Control System for Process/Chemical Plants

Data acquisition Systems

Electronic Instruments and Software

Training Simulator and testing aids

Control Room modification/up-gradation

Specialized equipment development

Telephone Exchanges

Cargo Scanners

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Full Scope Training Simulators

Simulators for operator training.

Soft Panel based Simulators

Similar simulators for

conventional Power

plants can be

developed

for the industry for

training

purposes.

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• Gamma Rays Cargo Scanner

for vehicle inspection.

Radiation Monitors

• Pedestrian Portal

monitors and Hand & Foot

Contamination monitors.

Gamma Rays Cargo Scanner

•Medium Frequency

Inverters and Automatic Control

Systems up to 250 KW

PCR Machines

• Based upon Polymerase Chain Reaction

technique. Used in medical & biological

research labs for variety of applications

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I & C for Vacuum Induction Furnaces

Telephone Exchanges

• Indigenous development of

telephone exchanges up to

1000 lines including ISDN

services & Executive

telephone sets.

Fermenter

• For batch/continuous

culture & bio-processes

capacity of 1, 10 & 100 liters 27/41

Interface with Industry

Manufacturing services

NDT/NDE Services

Specialized Training Programs

NATIONAL REFINERY

PAKISTAN REFINERY

PAKISTAN STEEL

PEOPLES STEEL MILLS

PPL

OGDC

SNGPL

Engineering Services offered to Industry

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CERN, Switzerland

SESAME

Chinese Vendors

Nuclear Power Plants

MARUBINI, Japan

FUJI ELECTRIC, JAPAN

VOITH, GERMANY

KAPCO

WAPDA

KESC

Welded from 140 mm thick Carbon steel plates.

All joints 100% Ultrasonic tested.

Machining of Top Plate with an angular accuracy of 1 minute.

Final Dimensions: 2986 x 2972 x 2500 mm.

Magnet Supports for CERN

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Back view of YE±4 Shielding Wall in horizontal

position

YE+4 SHIELDING WALL for CERN

Front view of YE±4 Shielding Wall in

horizontal position

Diameter : 13910 mm.

Height : 15745 mm with supports.

Flatness : ±3 mm.

Flatness of each sector : ±2 mm.

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Collaboration in Piping works at CERN

Collaboration in Piping works with ALICE: ~ 96 Man-months.

Work involved welding, installation & pressure testing of

Multilayer pipes of OD 25 mm to 40 mm.

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Vacuum Vessels for CERN

Vacuum Vessels for PETS Dia. 400 x 1360 (L) mm - 2Nos.

Material : A240-304L.

Positioning accuracy of inner plate ± 0.5 mm and parallelism

± 0.3 mm.

The leak tightness value < .10-9 mbar*lit/sec and vacuum

value is 10-8 mbar.

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Turbine Blade Carrier for Power Plant

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Machining of Flange of Main Shaft,

L = 5 m, Weight = 22 T,

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