Mandate
- The primary mandate of Central Workshop Division (CWD) is manufacturing of high quality products in accordance with applicable codes and specifications. CWD primarily caters to machining, fabrication, hardfacing and inspection requirements of various groups of IGCAR as well as various other units of DAE at Kalpakkam, viz. MAPS, BHAVINI, BARC-Facilities.
- To cater to all the machining needs including very intricate & high precision parts and assemblies. Centralized management of all the CWD Work Orders apart from Process Planning and coordination for all the manufacturing activities.
- Continuously striving to do technology development in the domain of engineering fabrication / hard facing, precision assembly for the manufacturing of critical reactor components, developmental models, test vessels, storage tanks etc. in accordance with applicable codes and specifications To ensure maximum availability and reliability of Machine tools for manufacturing by following regular standard maintenance practices and to ensure quality and precision dimensional standards using various calibrated measuring instruments.
Achievments
- Large Diameter Steel Vessel for FBTR.
- Control Rod Drive Mechanism [CRDM] Lower Part for FBTR
- Nickel Hydrogen Diffuser for FBTR
- Neutron Detector Holder Assembly for Testing at FBTR ECPS – Replacement for DSRDM
- Reconditioning of Flywheel Housing of Ward Leonard System – FBTR
- Connecting hexagonal piece (SS316L) for IFZ-100 Special sub assembly for FBTR
- Cold Trap for FBTR Secondary sodium Circuit
- Machining of Enriched B4C compression and flexure test specimens for the Poison rod & Absorber rod of FBTR - 40 MWt Core
- Feeder Pipes for Primary Heat Transport system of MAPS-1 / RAPS
- MAPS Turbine blade In-situ weld
- Reclamation of 5th stage Low pressure Turbine Tenons in NAPS-2
- Carbon Steel Shells for MAPS
- Hard facing Stem and Disc of safety relieve valve for KKNP
- Vacuum Chambers for VECC, Kolkatta
- MUSIC - Metrology Under Sodium IGCAR CEA
- Welded specimens for phased array UT - CEA project
- PFBR Transfer Arm Guide and Rail Assembly
- Sodium Duct Sub assemblies for 170m3/hr Annular Linear Induction Pump (ALIP) for PFBR
- Stroke Limiting Device for travel control in CSRDM – PFBR
- Refurbishment of Transfer Pot of PR & PTM-PFBR
- Core Flow Monitoring Mechanism for PFBR
- Nickel Diffuser for Secondary sodium circuit of PFBR
- Electromagnet assemblies for Diverse Safety Rod Drive Mechanism (DSRDM)
- Jet Breaker Components for PFBR
- Cover Gas Hydrogen Meter - Nickel Coil Assemblies for PFBR
- Anti Convection Barrier (ACB) Plug for PFBR
- Guard Pipes and Support Structure for IHX & DHX of PFBR
- Axial Shield Model for PFBR shielding experiments at APSARA for study of neutron transfer through single shield material.
- Continuous Dissolver for Spent Fuel Reprocessing
- Nitrogen Dioxide Generator [NO2], Vent Pots (750 Nos.), Sampling Pots (75 Nos.) for Demonstration Fuel Reprocessing Plant [DFRP]
- Centrifuge for Spent Fuel Reprocessing Plant
- Dissolver Cell Connecting Bed for DFRP
- Pyro Reprocessing Plant
- Feed, Bleed tank, Low level Waste storage tanks for Pyro processing
- Glove box and Pressure chamber for Pyro processing
- Argon storage vessels for Pyro processing plant
- Test Vessel -5 for RDTG
- Diamond Anvil Cell to study the behavior of materials at very high pressures up to 500 GPa and high temperature
- Cold Trap for Sodium Purification Circuits of Test Loop at RDTG
- Thermal Striping Test Vessel For RDTG
- Thermal Shock Test Pot for RDTG
- Tribology Test Vessel for RDTG
- Sodium Test vessel I & II for sodium technology complex
- Expansion tank, Priming vessel and Heater vessel
- Components for Glove Box Sealing Door
- Radioactive Liquid Waste Storage Tanks
- Ball Anchor for Master Slave Manipulator
- U-notched Disc for calibration Blocks
- Wrist Assembly Tape and Rope connector
- Lead cell flanges and blocks
- Special Pot adaptor, Shaft couplings for Neutron Radiography
- Hot cell #5 rear Door
- Thermal mixer for the ultra-supercritical test facility
- Replacement of flexible metal tube in Turbo expander of 28 AUGF – Helium Plant
- Refurbishment of Auxiliary Main Gag Cylinder Housing for Fuel Chopper- KARP
- MUSIC - Metrology Under Sodium IGCAR CEA
- Welded specimens for UT (Phase array)- CEA project
- Residual stress measurement samples by PTA hard facing
- The tenon of turbine blade of MAPS-2 LP rotor rear side third stage is made of AISI 414 material. During regular inspection it was observed that one of the tenons has eroded. It was decided to salvage by repair welding to reduce the reactor down time, accordingly a welding procedure Specification was prepared by MDTD, IGCAR. This novel technique developed by MDTD and CWD IGCAR was executed successfully at MAPS and completed the repair work in a single day which has reduced the reactor down time and resulted in considerable saving in cost.
- Dummy fuel subassemblies were fabricated for core mechanics experiments to validate PFBR core restraint system design and to check the mechanical interlock along with grid plate sleeve. An automatic GTAW system was designed and activated flux developed by the MDTD IGCAR was used for fabrication of Hexagonal sheath. To standardize the technique and meet the code requirement, welding procedure specification (WPS), procedure qualification record (PQR) and welder’s performance qualification (WPQ) were developed. Development of this technique has reduced total work content and increased the productivity considerably.
- Transfer Arm (TA) is the in-vessel handling machine of PFBR used to transfer fresh and spent core subassemblies (SA) within the main vessel. The rail and guide are designed to perform translation movement during operation. The relative motion between these components in the assembly at elevated temperature and sodium environment may lead to wear and self welding. To minimize such problems throughout the operating period of the reactor; these components are designed with hard facing deposit on its mating surfaces. The necessary hard facing technology was developed and executed at CWD.
Expertise
- Central Workshop Division (CWD) is centralized manufacturing facility of IGCAR under Technical Services Group (TSG) of ESG. CWD primarily specializes in machining, welding, hardfacing, fabrication and inspection. CWD caters to the needs of various manufacturing activities towards Prototype Fast Breeder Reactor (PFBR), Fast Breeder Test Reactor (FBTR), Kalpakkam Mini Reactor (KAMINI), R&D projects, reprocessing, post irradiation examination and infrastructure development apart from operation and maintenance requirements.
- CWD maintains the highest quality standards to meet the stringent specifications and requirements under various codes, viz. ASME, ASTM, RCC-MR and ISO. It undertakes manufacturing of uniquely designed nuclear components with intricate geometry, very high precision and technically demanding, which the industries find commercially unviable.
- CWD develops novel manufacturing processes too under technology development and transfer to industries for commercial production.
Infrastructure/Facilities
- Central Workshop is equipped with plant and machinery for machining, fabrication and inspection. CNC machines and metrology tools &equipments were introduced during 1982-1987 along with a Nuclear Clean Room. Further, to Enhance the manufacturing capabilities of CWD many new CNC machines like Vertical Machining Centre, 3-axes Turn Mill Centre, CNC Spark Erosion, Wire Cut EDM, Plasma Cutting machine, Plasma Transferred Arc Welding machine, Automatic TIG Welding machines etc. were commissioned during the period 2005 to 2016. A Nuclear clean Hall of 18m height was constructed recently with High and Low Bays for Inspection and assembly of long slender components of FBRs.
- On the Inspection front, latest state of art Metrology instruments were further augmented in the recent plan periods to ensure the quality of manufacturing in all respects. Some of the machines installed at CWD are 3-axes Coordinate Measuring Machine (CMM), CNC Contour Measuring, CNC Vision Measuring, XRF Analyser, Heavy Duty Electronically controlled Universal Testing machine and Digital Hardness Testing machine.
| Machining | Welding, forming and Fabrication | Inspection |
|---|---|---|
| Lathes (Centre, Horizontal / Vertical Turret) | Plate Rolling Machine | Nikon Measuroscope |
| Milling Machine (Vertical, Univerasal, double column) | NC Pipe Bending Machine | CNC 3 axis Coordinate Measuring Machine |
| Drilling Machines (Radial, Column) | Vertical & Horizontal Band Saw | Profile Projector |
| Horizontal Boring Machine | Double Band Saw | XRF Analyser |
| Slotting, Shaping, Planning | Shearing Machine | CMM with Laser Probes |
| Surface and Cylindrical Grinders | Press Brake | Electronic Universal Testing Machine |
| Tool and Cutter Grinders | Heat Treatment Furnaces | Digital Vernier Height gauge |
| Vertical Honing Machine | Welding Machines - TIG, MIG, PTAW, SMAW | CNC Surface Roughness and Profile Measurement Machine |
| CNC EDM Wire Cut and Spark Erosion | Automatic GTAW Machine | Bend Testing |
| Vertical and Horizontal CNC Machining Centres | PTAW Hard facing Machine | Digital Hardness Testing Machine |
| CNC Milling, CNC Lathe | Spot welding Machine | Video Boroscope |
| CNC Turn-Mill Centre | CNC Abrasive Water Jet Cutting Machine | Digital 3 pin Deep Bore Diameter Measurement |
| CNC Drilling and Tapping | CNC Plasma cutting Machine | CNC Vision Measuring System |
| Machining | Welding, forming and Fabrication | Inspection |
|---|---|---|
| Diameter : 3 mm to 1650 mm | Plate rolling machine : Shells of 400mm to 2500 mm long, 3mm to 25 mm thk | Nikon Measuroscope: 2 dimensional measurements; Accuracy 1 micron, Magnification: 100X |
| Length : 5000 mm (Max) | NC Pipe bending machine: Pipe dia: 100 NB max, Thickness: sch 40 max . Bend angle: 180deg | Coordinate CNC 3 Axisl Measuring machine(CMM): Fully Computerised 3D measurements of dimensions, geometrical features like straightness, parallelism, perpendicularity, symmetricity |
| Load : 4000 kg (Max) | Vertical Band & Horizontal band saw : Cutting of metals of any shape | Contouraograph Measurement of Surface profiles : Measurement of labyrinths,curved blades |
| Surface Finish : 0.4 microns | Shearing machine : 12 mm thk; 3000 mm long | Profile projector: Dimensional measurement of profiles |
| Hardness : 60 HRc | Press brake : Bending of rolled sections | CNC Vision Measuring system: Angularity, Flatness, Squareness, Parallelism, Accuracy 0.01 micron |
| Metals : SS, CS, Nonferrous, Stellite, Colmony, Borated Graphite | Heat treatment furnaces : Annealing , hardening, tempering max temp:1200 C | XRF Analyzer : All ferrous and non ferrous metals |
| Planning | Welding machines : Generators, Welding Rectifiers & Inverter | Universal Testing Machine: Testing Of Weld Specimens And Raw Materials r |
| Spark Erosin : irregular profiles, ultrahigh hard materials, miniature sizes | Plasma cutting machine : Cutting of SS and nonferrous metals Max thk.50 mm | Digital Vernier Height gauge |
High precision CNC Slant Bed Turn Mill Centre
CNC Vertical Machining Centre
CNC abrasive water jet (AWJ) cutting machine
Surface roughness measuring machine
Video Boroscope