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Central Workshop Division

Mandate

Achievments

FBTR & KAMINI

  • 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

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NPCIL


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  • 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

VECC Kolkata

  • Vacuum Chambers for VECC, Kolkatta
  • MUSIC - Metrology Under Sodium IGCAR CEA
  • Welded specimens for phased array UT - CEA project

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PFBR


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  • 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.

Reprocessing Group

  • 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

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Pyro Processing

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  • 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

Infrastructure and R&D Support

  • 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

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PIE

  • 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

Indian AUSC Mission

  • Thermal mixer for the ultra-supercritical test facility

BARCF Kalpakkam

  • Replacement of flexible metal tube in Turbo expander of 28 AUGF – Helium Plant
  • Refurbishment of Auxiliary Main Gag Cylinder Housing for Fuel Chopper- KARP

Miscellaneous

  • MUSIC - Metrology Under Sodium IGCAR CEA
  • Welded specimens for UT (Phase array)- CEA project
  • Residual stress measurement samples by PTA hard facing

Salvaging MAPS-2 Turbine Blade

  • 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.

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Dummy fuel sub assembly Hexagonal sheath fabrication by forming and automatic GTAW process with activated flux (ATIG)


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  • 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.

Manufacturing of Transfer arm Guide and Rail with colmonoy Hard face coating

  • 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.


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Major components manufactured at CWD

Expertise

Infrastructure/Facilities

Equipments
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
Overall Capabilities
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


CWD Machining Facilities

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CWD Fabrication Facilities

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Inspection Facilities

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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