IGCAR :QAD

Mandate

Quality Assurance Division (QAD) is primarily responsible for catering the Quality Assurance, Inspection, NDT and Quality Audit activities to all the Groups of this Centre. The mandate for QAD is to establish and implement an effective quality management system for the mechanical works of all ongoing works including R&D activities initiated and continued by all Divisions of IGCAR and other DAE units through knowledge sharing, inspections, analysis and research. Inspections and NDT requirements are fulfilled with assurance in conformance to in-house / national / international codes, standards and specifications during procurement fabrication, construction, fabrication and erection for the R&D and other projects carried out at IGCAR and other DAE units.

QA-Projects Section:
- Project Services :
  - To provide seamless QS & Inspection activities for the procurement /manufacturing / Fabrication / construction activities spanning across all groups & facilities of IGCAR
  - Facilitating induction of Research Scholars, Research Associates, Visiting Scientists, Trainee Scientific Officers, Category I and Category II trainees.
  - Application driven developmental works related to QA & Fabrication.
- NDT Services:
  - To provide Robust and Professional NDT services to various Groups/Divisions of IGCAR and other facilities of IGCAR (on request basis).
  - R& D related to technique & procedure development for all NDT methods for various critical component/Service / Structure in both Front & Back end fuel cycle.

Fabrication & Audit Section (FAS)
- Fabrication and Audit Section in QAD will continuously provide Quality Assurance, inspection, testing and audit activities during mechanical construction of FBR developmental projects being undertaken by all groups of IGCAR.
- FAS will constantly endeavor to provide of national & international standard with high degree of technical competence leading to sustained customer satisfaction.

Achievements

Sharp Tools Award for the Best Paper in National Welding Seminar (NWS), 2011 conducted at Bhilai.
Group Achievement Award-2012 for accomplishing the activity on “Design & fabrication of Titanium Electrolytic dissolver for DFRP”
Group Achievement Award-2013 for accomplishing the activity on “Development of In- sodium sensors for PFBR”
Group Achievement Award -2017 for accomplishing the activity on “Fabrication, erection & Commissioning of SFCT at FRTG”.
Group Achievement Award-2019 for accomplishing the activity on “Development of materials for AUSC”.
Venus wire Award for the Best Paper in SS Fabrication practices in IC 2020 conducted at Vadodara.
Quality Circle activities – Won national level & Chennai Level convention- Par Excellence award.

Technology Developed

Quality Assurance and Inspection services during mechanical fabrication, erection and testing of components and systems of sodium cooled FBR developmental projects and Reprocessing plant Projects. Metrological and Optical tests for materials and components for various developmental works of IGCAR.NDT services such as Radiographic testing, Ultrasonic testing, Helium leak testing and Visual testing for various critical components being fabricated for various groups of IGCAR including PFBR, FRFCF, DFRP etc.

Infrastructure/Facilities

2D Digital Height Master Make : Mickrotechnika, Model: M Height 1025,Measuring Range: 0-1025 mm, Resolution 1µmManual and motorized carriage movement, Colour Graphical LCD Display 5.7” diagonal size This height master is being used for height measurement in microns with reference to granite surface plate with advanced features like Contact a surface from above, contact a surface from below, checking groove horizontality(centre & width),Assessing a bore/shaft(centre & diameter),contacting a bore /shaft from above & from below, straightness, roundness flatness etc.

Video Vision Inspection System Make: M/s.Customized Technology, Model – RAPID-I, Measuring range 400X200X150 mm Magnification 11X – 134X. measuring Resolution of 1 µm, Video resolution : 800X600 pixels. Lighting systems : Quadra zone Surface Lighting, Collimated Profile etc. This instrument is being used for 3 dimensional measurement for metrology. It is based on vision inspection method, touch probe is also attached with the system, X.Y,Z –axis movements are controlled by analog joystick. Standard shapes like point, line, circle arc, plane, cylinder etc standard measurements like distance, angle, radius diameter, projection etc. can be measured. Reports can be saved in EXCEL format and measured images can be saved .

Mobile Optical Emission Spectrometer for chemical analysis PMI MASTER PRO Mobile OES This instrument is being used for chemical analysis of metals. This is based on Optical Emission Spectroscopy method. It is Mobile type and can be operated on battery. This system comes with touch probe with spark mode in that light elements like P,S, carbon & boron also can be analysed in addition to other elements in Ferrous base alloys.PMI Master Pro has integral trolley to facilitate movement of instruments onto site.

Portable XRF analyzer XRF handheld Alloy analyzer is utilized for material sorting and chemical analysis. This intrument is working on X-ray Fluorescence Principle.It takes only 20 seconds for analysis except light elements all major elements can be detected using this. This instrument is very useful in grade identifcation. Advantages: Analysis is very fast, very handy, non destructive, skilled operator not required.

Digital Rockwell Hardness Tester Digital Rockwell Hardness Tester Indentation type hardness Testing FIE make,(Digital display) • Load- 60 kg,100kg,150 Kg • Indenter- Diamond Indentor Steel Ball(1/16”) • Scale-(HRA, HRB, HRC) Being utilized for hardness measurement of metallic components.

Metrological Instruments: Basic Measuring Tools.
Linear Scale
Vernier Caliper
Micrometer
Bevel Protractor
Height gauge with surface plate
Slip gauge set
Visual Tools Borescope Fiberscope

	Instrument Name :- N3 Levelling Instrument Make:- WILD Accuracy :- 0.1 mm. ( 100 Micron) Range:- Infinity. Usage:- Levelling / horizontallity		Instrument Name :- N₃ Levelling Instrument Make:- WILD Accuracy :- 0.1 mm. ( 100 Micron) Range:- Infinity. Usage:- Levelling / horizontallity
	Instrument Name :- Digital Plumb Make:- SOKKIA Accuracy :- 1 mm. ( 1000 Micron) Range:- 5 metre. Usage:- Transfer centre point from bottom to Top		Instrument Name :- Tilting Level Make:- BRUNSON Accuracy :- 0.02 mm. ( 20 Micron) Range:- Infinity. Usage:- Levelling / horizontallity at 360°
	Instrument Name :- Jig Transit Make:- BRUNSON Accuracy :- 0.02 mm. ( 20 Micron) Range:- Infinity. Usage:- Establish straight line- Transfer to 360°/ straightness / Verticality.		Instrument Name :- Alignment telescope Make:- BRUNSON Accuracy :- 0.02 mm. ( 20 Micron) Range:- Infinity. Usage:- Axis Alignment.

Model : ASM 182T Make: ADIXEN
Instrument Name :- Helium Mass Sepctrometer
Model : ASM 340 Make: ADIXEN

Make: Dhvani Research, Chennai
Specification:
X – axis: 800 mm, Y – axis: 800 mm , Z – axis: 400 mm
Alpha (Probe rotation): 00 to 3600
Beta (Probe tilting): 1800 (- 900 to +900)
Turn table (Component holding base): 00 to 3600
Acquisition ultrasonic software (acqUT) features function for real-time acquisition of ultrasonic signals, imaging (B-Scan, C-Scan and D-Scan) of these signals, ultrasonic parameter control and motion control.

Model: Omniscan MX – 2, 32:128PR module with dual matrix PAUT probes
Make: Olympus
Application: Ultrasonic testing of weld joints for coarse grained materials Such as austenitic stainless steel welds.

Make: Dhvani Research, Chennai
Pipe Sizes: DN15 to DN100 and length of 1 m to 6 m
Acquisition ultrasonic software features function for acquisition of ultrasonic signals, imaging of these signals and motion control for axial and circumferential ultrasonic testing for pipes.

Make: Olympus Model: Epoch 650
Make: Olympus Model: 6LT
EEC make Advanscan: AS-414

Make: Olympus Make
Length: 12m
Diameter of the probe: 6mm
Olympus make industrial videoscope is wear resistance and rugged one, this instrument is being used for remote visual inspection. Power is provided to the FX by an internally mounted, Lithium-Ion battery which provides over two hours runtime. It’s a kind of portable and compact scope, having video and image capturing facility with .6.5" daylight-viewing LCD monitor. Archiving, sharing and reporting inspection results are made simple with the IPLEX FX.

Digital image correlation (DIC) is an imaging, non-contact, noninvasive technique which computes displacement and strain of an object based on gray scale matching. At QAD, this technique is used for studying the deformation behavior of steels such as stainless steels, carbon steels, Ti-Mg alloys, friction stir welded steels and P91 steels etc., under tensile loading.

Make: Balteau
High voltage range: 5-225kV
Tube Current range: 0.1 – 18 mA
Focal spot size(EN 12543): 1.0 mm & 3.0 mm
Tube head: Metal Ceramic
Anode Cooling type: Water
Duty Cycle: 100%
Steel penetration at max(*): 54 mm

Make: Balteau
High voltage range: 5-160kV
Tube Current range: 0.1 to 18 mA
Focal spot size(EN 12543): 0.4 mm & 1.5 mm
Tube head: Metal Ceramic
Anode Cooling type: Water
Duty Cycle: 100%
Steel penetration at max(*): 35 mm

High voltage range: 5-225kV
Focal spot size(EN 12543): 5 microns/1.5 microns
Tube head: Reflection mode/ Transmission mode
Anode Cooling type: Water based Coolant
Duty Cycle: 100%

Model: 1620
Pixel Size:200 μm
Pixel Matrix:2048 × 2048
Active Area: 409.6 mm × 409.6 mm
Energy: 20 kV - 15 MV S
Speed up to 7.5 fps
Scintillator Direct deposition CsI: Tl or various Gd2O2S:Tb
Technology: Amorphous Silicon active TFT
Applications:
Industrial Non-Destructive Testing, 3D cone beam CT / Metrology and Life and physical science

Laser spot size: 12.5 – 25 – 50 µm
TreFoc Technology: 50 µm
SRb (basic spatial resolution):80 µm
Gray scale resolution: 16-bit
Noise level < 39 dB(A)
Software: DÜRR NDT D-Tect (DICONDE compliant to ASTM 2339)
DÜRR NDT CR-Phantom

Class: DS9 (range 0-4.7 OD) according to EN 14096 Part 2
Light Source: He Ne Laser, (632.8nm)
Sensor: Photomultiplier
Reading System: Flat Reading by Polygon Mirror and Field Flattener Lens Optical Density
Range: Selectable: 0-4.3OD or ,0- 0-4.7 OD A/D Convertor: 12 bits (4096 gray levels)
Sampling Pitch: 50 - 500 µm (at 1 µm steps)
Reading speed: 7 seconds at 2000 resolution

Make: Proceq
Model : Equotip
Rebound type portable hardness tester is capable of measuring the surface hardness of a broad variety of ferrous and non ferrous materials on flat, round surfaces at any measuring direction using hardness scales of HRB, HRC and HV. The specification of the instrument is conformed as per ASTM A956 requirements.

Quality Assurance Division

Mandate

Achievements

Technology Developed

Infrastructure/Facilities