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Nuclear Power Corporation of India Limited

(A Government of India Enterprise)

Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency

Pump for 220 & 540 MWe

Page 1 of 20

Rev. No. : R0

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PP-E-2453 March 2012

1.0 SCOPE

This specification is intended to cover the design, engineering. material,

fabrication, manufacture, inspection, testing, packing and delivery at site,erection and commissioning of the diesel engine driven Horizontal Centrifugal

Water Pumps complete with accessories and auxiliaries mounted on trolley asspecified herein after for Atomic Power Stations. This specification also

includes the Data Sheet-A Format for the data to be filled by the purchaserand Data Sheet-B Format for data to be filled by the Vendor.

2.0 CONTENTS

Sr.

No.

Title Page

No.

1.0 Scope 1

2.0 Contents 1

3.0 Applicable Codes And Standards 1

4.0 General Design Requirements 2

5.0 Special Features 4

6.0 Water Quality 11

7.0 Pump Drive 11

8.0 Inspection And Testing At Manufacturers Works 11

9.0 Tests 15

10.0 Performance Guarantee 17

11.0 Erection And Maintenance Tools 17

12.0 Spare Parts 17

13.0 Special Cleaning, Protection And Painting 18

14.0 Shipment 19

15.0 Data, Drawings to be submitted by the Vendor along with the

Bid

19

16.0 Inspection History Document / Documents To Be Submitted

After Placement Of Order / At Final Stage

19

17.0 Data Sheet-A Format Data to be filled by Purchaser

Vendor along with Bid.

1 to15

18.0 Data Sheet-B consisting of B1,B2 & B3 Format Data to be

filled by Purchaser Vendor along with Bid.

1 to 22

19.0 QAP - Indicative quality plan for pump 23 to 28

3.0 APPLICABLE CODES AND STANDARDS

The design, material, manufacturing and testing of the equipment covered bythis specification shall, unless specifically stated otherwise, conform to the

latest editions as on bid due date of all standards and codes (along with all

addenda), mentioned below and in the data sheets.

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i) Hydraulic Institute Standards, USA.ii) IS: 1520 Specification for Horizontal Centrifugal Pumps for clear

cold, fresh water.

iii) API 610 Centrifugal pumps for refinery services.iv) ASME / ASTM Standards for various tests and materials. Instrumentsociety of America Standards.

v) ASME Boiler and Pressure Vessels Code Section VIII, Div.1 andsect. IX.

vi) ASME and ANSI Power test codesvii) ANSI B 16.5 Standard for Steel pipe flanges and flanged fittings.viii) IS: 5120 Technical Requirement for Rotodynamic Pumps.ix) ANSI B 2.1 Taper pipe threads for instrument taps.x) AWWA Standard Codes for steel pipe flanges and fittings.xi) ASME Section III, Sub-Section ND and NC, if specified in data

sheets.

xii) ISO 1940 - Dynamic Balancing.xiii) PC-E-2454 Technical Specification & Data sheet of Diesel Engines.

4.0 GENERAL DESIGN REQUIREMENTS

(a) The pump shall be of horizontal centrifugal type with impellers arrangedfor proper radial clearances and minimum thrust loads. Details of pump

will be indicated in respective datasheet.

(b) The pumps shall conform to the respective data sheet.

The offered pump model shall be from the existing regular production

range of the bidder.

(c) The pumps shall be free from undue vibrations and shall be capable ofwithstanding the stresses which may be experienced during start up,

operation, shutdown and tests.

(d) Anchor bolts, nuts and seating steel work shall be supplied with the

equipment. Fasteners shall be positively locked to prevent theirloosening during operation due to vibrations or any other reasons.

(e) The equipment shall be designed to permit interchangeability of parts

and ease of access during inspection, maintenance and repair.

(f) The wearing parts shall be so designed that they can be easily replaced.Wearing ring clearances shall be as per API 610.

(g) All pressure containing components including the pump, casing, nozzles

and stuffing box housing, mechanical seal etc. shall be designed,fabricated and tested in accordance with the ASME Boiler and Pressure

Vessel Code as indicated in data sheet.

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(h) All equipments shall be designed, manufactured and packed so that no

damage will result from inland transportation and storage, installation

and operation of the equipment under the climate conditions to which itwill be subjected.

(i) All materials used shall conform to specifications and shall be new in allrespects.

(j) Castings and forgings shall conform to their respective material

specifications and shall be free from flaws and objectionable

imperfections, machined true and in a workmanlike manner.

(k) Proposals for repair or any similar operations involving the plugging,

welding, boring or addition of metal to the original castings or forgings

shall be submitted to the Purchaser and his approval shall be receivedbefore any such work is carried out. Drawings showing the details and

location of such modification shall be submitted to the Purchaser for hisrecords. No weld is allowed for C.I. components.

(l) The separate components of equipment shall be marked with suitable

reference nos. or symbols, which shall also be indicated on the assembly

drawings to aid in their identification and assembly at site.

(m) The bidder shall indicate minimum NPSH required in his offer.

(n) The rotor assembly including impeller, shaft etc shall be statically anddynamically balanced.

(o) Natural frequencies of total pump and diesel engine assembly androtating assembly should not be very close to or should not match with

(i) its own operating frequency (ii) Natural frequency of pump-enginehousing structure or trolley mounted structure. If, during trial

operation, the pump vibrations are found to be high, the equipment will

be liable for rejection. Tenderer shall therefore take care of this aspect

in the design of the equipment to be supplied, considering the pump-engine housing civil structure or the trolley mounted structure, as the

case may be, and prove the above condition by calculations afterplacement of order.

(q) Adequate supports for different parts of the pump shall be given for the

entire pump-engine installation. Suitable clamps, lifting lugs or eye boltsshall be provided at appropriate places for convenient handling of

components.

Pump shall be fully assembled at manufacturers shop and mating parts

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shall be match-marked for ease of assembly at site.

(r) The individual components of equipment shall be marked with suitable

reference numbers or symbols which shall also be indicated on theassembly drawings to aid in their identification and assembly at site.

(s) Trolley mounted pumps shall be supplied with strainer, foot valve in thesuction line and fixed pumps shall have Y-type suction strainer as

specified in the data sheet. Suction strainer required having minimumfree flow area of 3 to 4 times of pipe cross-sectional area. Pressure

drop calculation should be furnished by the CONTRACTOR.

(t) Only hexagonal nuts shall be used for holding the equipment. All boltholes shall be spot faced for washers.

(t) For trolley mounted pumps, complete pump-diesel engine assemblyalong with its accessories, diesel engine control panel, day oil tank,

storage for keeping hose of at least 100 mtr. length shall be mountedon one movable trolley. In addition to general features , the trolley

should have following design features in it :-

i) Double axleii) Tyre of sufficient height to have enough clearance from groundiii) Stay sack or jack to take entire load of trolley during pump

operation.

iv) Towing hookv) Search lightvi) Hand brakevii) Tool box cum lockerviii) Canopy for pump , engine , panel, battery etc.ix) Provision for fixing pump, engine and accessoriesx) Stand for storing hosesxi) Fixed metallic ladder for approach

u) Bidder to give provision for priming arrangement for category C and D

pumps.

5.0 SPECIAL FEATURES

5.1 Design Features

The pumps shall have stable, rising characteristic (H vs. Q) from maximumflow to zero-flow (shut-off head) condition. There shall no inflection point at

any partial load in the head capacity curve. The best efficiency point (BEP)shall occur as near the specified capacity as possible.

Stability of hydraulic performance shall be guaranteed over the entire operating

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range in addition to the duty point. Head and power characteristics over theguaranteed range furnished by CONTRACTOR shall truly represent actual

performance. Pumps of a particular category shall be suitable for operating

over the entire operating range.

The NPSH required shall be less than that available by at least 1.0 meter under

all conditions of pump operation.

Pumps of particular category shall be identical. Components of identical pumpsshall be interchangeable.

All cooling requirements of the pump-engine set shall be self contained i.e.

without requiring any external cooling water supply. No external source ofpower, air supply or cooling water will be provided for this pump-engine set.

The design of the pump set shall be kept simple but rugged for the intended

duty.

The pump-diesel engine sets shall be capable of withstanding maximumexpected reverse rotation arising from full discharge header pressure with fully

open discharge valve. In any case the reverse rotation capability shall not beless than 125% rated speed.

The first critical speed of rotating assembly shall be well away from the

operating speed and in no case less than 130% of the rated speed.

The pump outer casing sections shall be provided with suitable lifting lugs/eyes

to facilitate handling. In addition, suitable provisions shall be made to facilitatesupporting the assembly on the pump floor during lifting operations.

The pump shall be either of split casings or as specified in data sheet.

The pump is expected to remain idle for long periods of time except for testingat intervals.

The equipment shall be designed with regard to ease of maintenance, repair,

cleaning and inspection of parts subject to wear or other deterioration requiringadjustment or repair and shall be accessible and capable of convenient removal

and replacement when required.

De-mineralized (DM) water would be provided, if required for any closed-water-loop air-cooled circuits of pumpset.

5.2 Location

For location of each pump, refer Table-1 (Sheet 1 of 2) specified in data sheet-

A.

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5.3 Materials of Construction

The pumps shall be of standard fitted construction as indicated in respective

data sheet.

The material for the various parts of all the pumps shall conform to thespecifications or equivalent indicated in the data sheet. Compatible materials

shall be used for other components. Material of construction (MOC) notspecified in the data sheet for items like bearing cover, bearing housing, lantern

ring etc. shall be either same or superior to the material of the casing specified

in the data sheet.

The tenderer may quote /offer pumps with other material superior than those

specified under specification / data sheet but which is considered satisfactory byhim for the intended service.

Pump Components

(a) Casing

The casing shall be cast, free from blow holes, sand inclusions and other

detrimental defects.

The casing shall be equipped with replaceable wearing rings on suctionside of impellers. Liquid passage shall be smooth finished or enameled.The casing shall be designed considering maximum suction head plus

shut off head. The casing shall be so proportioned that the velocity of

liquid is gradually reduced and converted into pressure with minimum

of friction and wear. Suitable valved opening shall be provided forventing the high points of the casings and low points for draining.

Insulation cleats shall be provided for high temperature pumps. Drain /vent valves should be of flanged end connection.

(b) Impeller

The impeller shall be of the semi-open or closed type as specified inData sheet and shall be both statically and dynamically balanced to

ensure vibration free operation. The rotor assembly shall be statically

and dynamically balanced. The flexible rotating assembly balancing

shall be done at rated speed and for rigid rotating assembly balancingmay be done at reduced speed. The complete coupling assembly shall

also be dynamically balanced. The impeller shall be properly machined,with liquid passages hand-finished for best radial balance loads.

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The rated impellers shall be atleast 5% smaller in dia. than that can be

accommodated in the casing.

The semi-open type impeller shall be partially balanced hydraulically by

drilling holes through the back shroud into the annular area located on

the top side of the impeller.

Impeller shall be securely fastened to the impeller shaft with keys, taperbushings or locknuts. Impeller shall be positively locked to prevent their

loosening during operation (under forward or reverse torque).

(c) Shaft

The pump shaft shall be made of steel (As stated in Data Sheet) andhaving Brinell hardness number of not less than 200. It shall have

surface finish of 0.75 microns or less. The butting faces of the shaftshall be machined square to the axis and the shaft ends shall be

chamfered on the edge.

(d) Shaft Sleeves

Replaceable shaft sleeves of high surface hardness, clamped in place bythe impeller and free to expand at the other end without stress or

buckling, shall be provided. Shaft sleeves shall be in perfect alignment,

concentric with the axis of rotation and highly polished. The shaftsleeves shall be securely locked to the pump shaft to prevent loosening

in case of reverse rotation. Necessary arrangement for preventing

leakage through the clearance between the shaft and sleeve shall beprovided.

(e) Bearing

The pump bearings may be of anti-friction type. Anti-friction bearings

shall be selected to give 40,000 hours minimum life with continuousoperation at rated operating conditions.

Thrust bearing shall be designed with adequate margin to take the

maximum thrust load generated by the pump with the maximum sizeimpeller that can be fitted.

The bearings shall be properly shielded to prevent leakage of lubricant

or entrance of foreign matter along the shaft. A stainless steel waterdeflector shall be provided to prevent ingress of water into the bearings

from the stuffing box / mechanical seal.

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The rise in bearing grease/oil temperature with continuous running ofthe pump shall be within allowable limits which shall not exceed 20 deg.

C for grease and 30 deg. C. for oil lubricated bearings above ambient.

(f) Mechanical Seals

Mechanical seals, if specified in data sheet, shall be provided.Mechanical seal shall be cartridge type.

(g) Stuffing Box

Packed type stuffing boxes of adequate depth shall be provided, if

specified in data sheet, for minimum leakage and ease of maintenance.Minimum numbers of packing rings shall be 3 + L + 2 for all pumps,

where "L" is the lantern ring. Stuffing boxes shall be of such design that

they can be repacked without removing any part other than the glandand lantern ring. Shaft sleeve under the gland packing shall have

burnished surface with high surface hardness. Stuffing box housing shallfacilitate collection of stuffing box leakage without any spillage. Unless

otherwise specified, gland packing for the pumps shall be made ofGraphite impregnated Teflon.

(h) Wearing Rings

All pumps shall be provided with replaceable wearing rings for the

casing and the impellers, secured in such a manner to prevent turning.

The impeller wearing rings should preferably have a lower hardnessthan the casing wearing rings and differential hardness shall be minimum

50 BHN. Tack welding is not acceptable.

(i) Couplings

The pumps shall be directly coupled to their drives through flexible

membrane type couplings to take care of usual shaft misalignments.Spacer in coupling is required for back pull out designs and wherever

mechanical seal is specified to allow removal of pump internals /mechanical seal without disturbing the pump or its driver. Suitable

guards shall be provided for the couplings to ensure safety during pump

operation. Service factor for coupling shall be 1.5 over engine name

plate rating.

(j) Base Plate

Machined base plates of rigid construction shall be provided toaccommodate both the pump and the drive. The base plates shall be

provided with a drain lip and a tapped drain hole with plug. The baseplate shall be properly drilled for the anchor bolts for mounting on

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concrete slab.

(k) Nozzles & piping

Pump suctions and discharge nozzles shall be provided with flanged

connections, drilled as specified in Data Sheet.

Pump suction and discharge nozzle orientation should match withNPCIL piping typical sketches as enclosed in Annexure-1 & 2 of data

sheet-A, preferably nozzle sizes also to be maintained same as per

drawing.

All piping (i.e. valves, pipes, fittings, etc) carrying DM water in closed

circuit for cooling shall conform to SS 316L.

(l) Accessories Required

The pumps shall be complete with the following accessories.

Constant level oiler for oil lubricated bearings and grease fittings for

grease lubricated bearing. Sight gauges for oil lubricated bearings.

Counter flanges drilled to match the suction and discharge nozzles of

the pumps along with bolts, nuts and gaskets. Matching counter flanges

shall also be supplied for all other flanged connections.

Attachments for support, lifting and handling as necessary.

All the incidental piping with valves required for sealing, lubrication and

cooling of stuffing box packing and / or bearings and vent and drainconnection with valves.

Piping shall be as per Piping Material Specification enclosed in

Annexure-3 of data sheet-A.

(m) Instruments

A pressure gauge shall be provided at the discharge of the pump(As specified in data sheet). This shall include the necessary

tubing, isolating valve and nipple connection to locate the

pressure gauge suitably.

Temperature Indicating Switch (TIS) shall be provided for

measuring mechanical seal cooler flushing liquid outlettemperature and bearing oil bath temperature.

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5.4 Pump and engine shall be provided with suitable lifting lugs for erection andmaintenance. Each pump-engine set shall be supplied with the required

number of foundation bolts, nuts, lock nuts, lock washers, etc.

5.5 Seismic Requirement (If Specified in applicable data sheet)

Pumps are to be designed to withstand seismic loads, as specified in attacheddata sheet. For checking the stresses due to different load combinations ASME

Sec. III NC shall be referred.

Pumps shall be designed to meet:

A. Loads due to maximum internal pressure (equal to design pressure) andsustained mechanical loads. Maximum allowable nozzle loads shall be

those specified in API 610. Level A service limits apply.

B. Loads due to operating basis earthquake (upset condition) as defined byResponse Spectra enclosed together with pressure and sustained loads.

Maximum allowable nozzle loads shall be 2 x API 610 values. Level Bservice limits apply.

C. Loads due to safe shutdown earthquake (emergency condition) asdefined by Response Spectra together with pressure and sustained

loads. Max. allowable nozzle loads shall be 2 x API 610 values. Level

C service limits apply.

Estimated SSE and OBE Response Spectra to be followed for theseismic design will be provided to the successful bidder after placement

of order.

The pump, base-frame, pedestal support assembly and nozzle shall be designedto accept external forces and moments due to piping in accordance with API-

610 and limit the shaft displacement as specified therein. The bidder shallindicate in his offer the maximum acceptable external forces and moments.

Pumps if specified in Data Sheets are to be qualified for SSE and OBE.

The qualification of the pumps shall be as per NPCIL Specification No. PP-P-

1819 titled `Technical Specification for Methods & Procedures for SeismicQualification of Pumps, Panels, Devices, Rotating Equipments, Tanks, Vessels,

Piping and Supports. The specification is largely based on IEEE 382, IEEE

384 and ASME-QME-1. The specification shall be given to successful bidder.

The required response spectra for seismic qualification will be provided later.The supplier shall submit design, analysis and test procedure to Purchaser for

approval.

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6.0 WATER QUALITY

The expected quality of raw water or dematerialized water to be handled by

pumps is given in the respective data/ specification sheets.

7.0 PUMP DRIVE

All pumps are to be driven by diesel engine. The specific requirements for thediesel engine drive for each type of pump shall be as per respective Technical

specification and Data Sheets of Diesel Engine. The bidder however shallfurnish all necessary technical particulars for the diesel engine as called for in

specification and data sheet of diesel engine separately.

The make of diesel engine shall be from NPC approved vendor list.

8.0 INSPECTION AND TESTING AT MANUFACTURES WORKS

8.1 The Supplier shall carry out inspection to establish and maintain quality ofworkmanship in his works and that of his sub-contractors to ensure the

mechanical accuracy of components, compliance with drawings, identity and

acceptability of all materials, parts and equipment. He shall conduct all tests

required to ensure that the equipment and material furnished shall conform tothe requirements of the applicable codes. All test and test procedure proposed

by the manufacturer shall be notified well in advance of the fabrication andmajor shop test of the equipment for the purpose of making general inspections

and for the progress report. The Purchasers representative shall be given full

access to the shop in which the equipment is being manufactured or tested andall test records shall be made available to him. The equipment covered underthis specification shall not be despatched unless the same has been finally

inspected and tested successfully and shipping release issued by the Purchaser.All the instruments used for conducting the specified shop tests shall be

calibrated and calibration certificates furnished from a recognized institution.The calibration shall have been carried out not more than six months prior to

the testing date. Pressures gauges shall be calibrated before and also aftertests.

Final routine and type test for the complete units shall be carried out in the

presence of Purchasers representative.

8.2 All materials used for the fabrication of the pump components shall be of tested

quality. Physical and chemical test certificates for the materials of various

components shall be furnished, for purchaser's approval. Laddle analysis for thecastings shall be sent to the purchaser for his approval. Physical testing of the

bars of casting shall be done in the presence of purchaser and/or hisrepresentative as per approved QAP.

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All material used for manufacture of the equipment covered under this

specification shall be of tested quality. In case the relevant correlating test

certificates are not available, the Supplier shall arrange to carry out thenecessary tests required by the code at his own cost. As a minimum the

components of the pumps shall be subjected to following tests and the test

certificates furnished to the Purchaser accordingly:

(a) Shaft, Impeller, casing : Chemical analysis and physicaltest.

(b) Wearing rings, bushings, sleeves : Chemical analysis, Physical and

hardness.

(c) In addition tests specified in succeeding clauses shall also be conducted.

8.3 Castings

8.3.1 All casting materials shall conform to the relevant material specifications. All

tests as called for in relevant material standards shall be carried out.

8.3.2 Test bars shall be cast for physical tests from the same ladle of metal as the

castings they represent. Four copies of the ladle analysis shall be submitted to

the Purchaser. Physical tests on test bars shall be carried out in the presence ofthe Purchasers representative.

8.3.3 The castings shall be sound, clean and free from porosity, blow holes, hardspots, cold shuts, distortion and other harmful defects. Any projections in

internal surfaces or on external surfaces shall be ground and smoothened for

fine surface finish.

8.3.4 No welding shall be carried out in cast iron castings. In case of other castings,repair of castings by welding is permissible provided the repair process is

approved by Purchaser and the repair is done as per the qualified procedure bya welder qualified by the Purchaser as per ASME Section IX.

8.3.5 Pump components shall be subject to non-destructive tests as specified in the

Data Sheets, and in accordance with relevant Standards.

a) Magnetic

Magnetic castings shall be examined by magnetic particle inspection as

specified in the Data Sheets. The basis for acceptance shall be inaccordance with Data Sheets. The requirements of ASME Section-VIII

Div.I or ASME section III NC , whichever is applicable, mandatoryappendices shall be the minimum requirements.

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b) Non-Magnetic

All non-magnetic castings shall be examined by dye penetration test asspecified in the Data Sheets. The requirements of ASME Section-VIII

Div.I or ASME section III NC , whichever is applicable, mandatory

appendices shall be the minimum requirements.

c) Radiography

100% radiography test shall be conducted on castings if specified in the

Data Sheets. The limit of acceptability shall be in accordance with Data

Sheets. The requirements of ASME Section-VIII Div. I or ASMESection III NC, whichever is applicable, mandatory appendices shall

be the minimum requirements.

d) Dye penetrant test: The entire surface of the impeller castings

(approachable area only) shall be subjected to dye penetrant test as perASTM Specification E-165. Non-machined surface shall be ground

before dye penetrant test. For other castings only machined surfacesshall be tested by dye penetrant test.

8.4 Shafts and Forgings

8.4.1 Shafts

In addition to the physical and chemical tests as per relevant material codes,shafts of 50 mm dia. and above shall be ultrasonically tested in radial direction.Surface of the shaft shall be examined by dye penetrant test to detect surface

defects.

8.4.2 Forgings

8.4.2.1 In addition to physical, visual and chemical tests as per relevant material

standards, all ferromagnetic forgings shall be subject to magnetic particle

testing at the areas of fillet and change of section. The testing is to be carried

out after the rough machining operation (125 micro inches). The testprocedure shall be as per ASME Boiler and pressure vessels code-Section VIII

Div. 1 Appendix VI or ASME section III NC, whichever is applicable. Dyepenetration test shall be carried out for non-magnetic components. Any other

examinations like Ultrasonic or radiographic examination, if specified, shall be

carried out as per data sheets.

8.4.2.2 The prod method will be used with direct current to carry out the magnetic

particle test. The direction of field will be the most suitable one to obtain theclearest indication of any defect. The choice of wet or dry particles will be at

Suppliers discretion. All forgings shall be demagnetised after carrying out the

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test.

8.4.2.3 Any defect that will not machine out during the final machining, will be gouged

out fully, inspected by dye penetrant and/or magnetic particle inspection toensure that the defect is fully removed and repaired using an approved repair

procedure. No weld repair shall be carried out on shafts.

8.5 Fabricated Component

8.5.1 All components which are fabricated from plates or bar stock shall meet the

material specification as per the Standards. The Supplier shall furnish to the

Purchaser mill test report showing the chemical and physical properties of thematerial. In case relevant correlating test certificates are not available, the

supplier shall arrange to carry out necessary tests required as per the code at

his own cost.

8.6 Weldments

8.6.1 All welding shall be performed in accordance with ASME Section IX Code.

8.6.2 The Supplier shall have all welding procedures and welders qualified in

accordance with ASME Section IX Boiler and Pressure Vessel Code, prior to

commencing any welding on the work.

8.6.3 All welding shall be done by qualified welders only.

8.6.4 All the root passes and final passes of the weldments shall be examined by D.P.

test in accordance with ASTM Specification E-165. Dye Penetrant

examination shall be carried out according to the method outlined in ASME forboiler and pressure vessels Section VIII Div. I or ASME section III NC,

whichever is applicable.

8.6.5 Any procedure for the repair of defects in weldments shall be submitted to thePurchaser for his approval prior to any repair being done.

8.7 The pump casing and stuffing box shall be hydrostatically tested in the shop to

a pressure of one & half times the respective standard design pressure. The

testing shall be done with water at ambient temperature. Minimum duration of

pressurisation shall be 30 minutes.

8.8 All other pressure parts including inter-connecting and auxiliary piping will also

be similarly hydrostatically tested.

8.9 Visual Inspection

All pumps shall be offered for PURCHASER'S visual inspection before

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shipment. Pumps shall not be painted before inspection. Pumps shall beassembled with their spares and shown to be interchangeable. Pumps under

each category shall be identical in all respects. After inspection, test certificates

shall be furnished.

9.0 TESTS

9.1 Shop Tests

9.1.1 Prototype Tests

This test shall be carried out if same model and capacity pump is being

manufactured for the first time.

9.1.2 Hydrostatic Tests

Hydrostatic test shall be conducted at 1.5 times the design pressure or 1.5

times shut-off pressure of the pump whichever is higher and the duration of thetest shall not be less than 30 minutes.

9.2 Performance Test

9.2.1 Hydraulic performance test shall be conducted at rated speed with job engine

and all job accessories and auxiliaries to ascertain head, power and efficiency

against capacity. Speed variation shall not exceed 3% of rated speed. Atleast following points on the characteristic curve including shut off, minimum

continuous stable flow, midway between of minimum continuous stable flow

and rated flow, rated point and 120% of rated flow shall be plotted.Performance figures at test speed shall be converted to those at rated speed.

Tolerance for the test shall be as per the data sheet. Acceptable fluctuation oftest readings shall be as per data sheet / standard of Hydraulic Institute USA.

Vibration for all pumps measured on the bearing housing during the hydraulic

performance test shall not exceed 3.3 mm/s RMS over the complete operating

range.

9.2.2 Tests shall be conducted in Suppliers shop in order to ensure freedom fromvibration beyond the specified limits. The rotor assembly including impeller,

shaft etc. shall be statically and dynamically balanced by the Supplier prior to

assembly.

The noise level produced by the rotating equipment shall not exceed that

specified in the Data Sheets.

9.2.3 Diesel engine shall be tested in accordance with governing specification.

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9.2.4 Job-pump-coupling-engine assembly, one from each category pump as

specified in datasheet-A, mounted on job base plate along with its accessories

and auxiliaries shall be continuously run at the rated point for four hours inorder to demonstrate stable performance. Temperature rise (bearing oil/grease,

seal flushing, etc), vibration, etc shall be measured and these shall be within the

specified limits. All other performance parameters should also remain stableduring the test duration.

9.2.5 After the above test, the pump shall be stripped off, to check for its wear and

workmanship. Parts having close clearances shall be checked for any abnormal

rubbing and wear. Wearing clearances shall be measured.

At least one pump from each offered model & capacity of pump should be

tested for NPSH required at minimum four points to cover the entire rangefrom the recommended minimum continuous flow to run out flow / maximum

flow.

9.2.6 The characteristic curves submitted by the CONTRACTOR along with hisTender shall be the basis for the shop performance tests.

9.3 Test at Site

After installation, the pumps offered shall be subjected to field testing at Site at

/ close to its rated temperature for satisfactory mechanical (including thermal)

performance, freedom from vibration & noise, unbalance, proper sealing at thestuffing box, mechanical seals etc. Supplier will cooperate in conducting these

tests. Proper heat dissipating of pump base, bearings, seals etc. should be

demonstrated by CONTRACTOR during test at site. If the equipment does notgive satisfactory mechanical performance for any reason whatsoever and it is

necessary for the manufacturer to make alterations for the purpose of meetingthe guarantees the alteration shall be made and the additional tests required to

show the effects of such alterations shall be performed by the supplier at noexpense to the Purchaser.

All necessary arrangements including piping and instrumentation required for

carrying out the test is in the scope of the CONTRACTOR.

The instruments and apparatus to be used shall be supplied by theCONTRACTOR along with calibration certificates and shall have accuracies as

per the applicable Codes and Standards.

10.0 PERFORMANCE GUARANTEE

Each equipment shall be guaranteed to meet the performance requirementcalled for in the data sheets and technical requirement. The tests shall be

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conducted in accordance with technical specification and rectification of alldefects revealed shall be satisfactorily done. The allowable tolerance on the

guaranteed performance for acceptance shall be as per data specification sheets.

Mechanical running tests shall be conducted at Site as specified above andrectification of all defects shall be satisfactorily done by the Supplier without

any extra cost to the Purchaser.

Guarantee Period

All the equipment covered by this tender shall be guaranteed for a period of 48

months from the date of delivery of last consignment or 12 months from the

date of commissioning whichever is earlier.

11.0 ERECTION AND MAINTENANCE TOOLS

The supplier shall furnish a complete unused set of all special tools, wrenches

etc., with necessary tools boxes as required for erection, maintenance, overhaul

and complete replacement of any equipment being supplied under this

specification for each Project.

12.0 SPARE PARTS12.1 Following minimum Essential Spare parts (or as specified in data sheet / tender

specification) shall be furnished by the supplier for each type of pumps and

drives. The supplier may also recommend spare parts, other than listed below,

if necessary.

For each type of Horizontal Pump

(One set mentioned below means the total quantity of that item required for

one pump)- Impeller (1No)- Shaft sleeves (2 Sets)- Shaft with keys and circlips (1 No.)- Coupling (1 Set)- Casing wearing rings (2 Sets)- Mechanical seal assembly (if specified) (2 Sets)- Stuffing box packing - if specified (2 Sets)- Gaskets (2 Sets)

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- Bearings (2 Sets each type)- Impeller wear ring (2 Sets)- One number of each type and range of instrument (Duplex RTDs/

Temperature Gauges) for GUIDE BEARING /THRUST BEARINGtemperature measurement.

- Temperature Indicating Switch for Lube Oil temperaturemeasurement/seal flushing liquid temperature measurement.

Power supply required for operating instruments shall be derived from batteryof diesel engine for pump.

For each type of Diesel engine - As per applicable Diesel engineSpecification or as specified in data sheet / tender specification.

The Supplier shall indicate item-wise prices of all spare parts recommended by

him for Three (3) years satisfactory operation of the equipment being suppliedby him along with the quantity required against each item.

13.0 SPECIAL CLEANING, PROTECTION AND PAINTING

13.1 All equipment shall be neatly finished in a workmanlike manner. All exposed

metal surfaces shall be smooth and free from burrs. Finished surfaces shall beprotected against corrosion and mechanical damage.

13.2 All carbon steel and cast iron surfaces shall be thoroughly cleaned to remove

mill scales, rust etc. by wire brushing or grit blasting as required. All exterior

surfaces of pumps shall be coated with two coats of Inorganic Zinc Silicate

Primer 75 dft. The exterior surfaces of pump shall further be epoxy painted

with minimum two coats (each coat of 75 dft). Suitable easily removable rustpreventive shall be applied to unpainted metal surfaces to prevent their

corrosion during transportation and storage.

13.3 Before the equipment are packed, they shall be carefully checked to be sure

that all extraneous matters such as rags, tools, rubbish, foreign matter, loose

scale and dirt, welding rod stubs, bolts etc. have been removed. After theinterior is cleaned and dried all openings shall be closed with wooden/metallic

blind flanges, caps etc. to prevent entry of water, dirt, or any other foreignmaterial.

13.4 All parts shall be properly boxed, created or otherwise protected for preventing

any possible damage during transportation. Flanges shall be drilled as per the

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specified standards and all exposed surfaces shall be thoroughly greased beforedespatch. The nozzles shall be protected by fitting suitable caps so that they

are not damaged during transportation.

13.5 Final painting of exterior surfaces of the equipment shall be done as per the

paint and shade suggested by Purchaser.

14.0 SHIPMENT

14.1 The supplier shall be responsible for ensuring that all equipment are carefullyboxed and/or otherwise suitably prepared for shipment so that they will arrive

at Site in a satisfactory condition. Each equipment shall be identified by an

aluminum tag bearing the tag number obtained from the purchaser. No

shipment shall be made unless clear instructions with shipping release areobtained from the Purchaser.

14.2 All small loose pieces, including bolting, tools, gaskets, etc. shall be adequately

crated or boxed for protection during shipment. All pieces shall be marked

with the equipment piece number or mark number.

14.3 Openings of all instruments shall be plugged with suitable plastic caps to

prevent the ingress of dust and moisture.

14.4 No equipment shall be despatched unless the shipping release is issued by the

Purchaser.

15.0 DATA / DRAWINGS TO BE SUBMITTED BY THE VENDOR ALONGWITH THE BID

(a) Any data of Data Sheet-A - which is vendor specific.

(b) All Data, Drawings and Catalogues as called for in Data Sheet-B.

16.0 INSPECTION HISTORY DOCUMENT / DOCUMENTS TO BE

SUBMITTED AFTER PLACEMENT OF ORDER / AT FINAL STAGE

The supplier shall be required to submit the following documents within one

month after despatch of equipment

(a) Final Drawings

(i) Final overall dimensional drawings for the pump engine set ,trolley giving dimensions, loads, weights etc. and details of

items not reflected in construction drawings and foundationdrawing.

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(ii) Cross sectional drawing of pump indicating materials ofconstruction for all parts with standards and grades &

dimensions of all replacement and wear parts.

(iii) Foundation drawings indicating details of pockets for

foundation bolts, grouting allowance, total weight, plinth size

etc.

(iv) Tested Performance Curves.

(b) Bound History dockets five sets each comprising the following

documents.

(i) P.O. and Sub-Order copies.(ii) Approved as built drawings.(iii) Approved Q.APs.(iv) Approved Procedures.(v) Material test certificates.(vi) NDT Reports.(vii) Stress relief Time-Temperature charts.(viii) Welding procedures and Welders Qualification reports.(ix) Hydrostatic Test Certificates.(x) Performance Test Procedure and Performance Test Reports

with curves / other test reports.

(xi) Dimensional Reports.(xii) Radiography films, if any.(xiii) Shipping release copies.(xiv) All Design Concession reports if any.(xv) Guarantee and Compliance Certificate.

(c) Five hard and soft copies / sets of Operation and Maintenance Manuals.

(d) Reproducibles for each of the drawings, and drawings on magnetic

media preferably on CD (Five nos of hard and soft copies)

(e) Five hard and soft copies of Final Approved drawings submitted during

execution of Contract.

(f) Five hard and soft copies of approved Seismic Qualification Reports, if

applicable.

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Data Sheet-A

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Sr. No. Item Description

A. GENERAL DATA

1 Station Refer Table-2

2 Duty Intermittent (Refer note- 4)3 Location Refer Table-1

4 No of Pumps Required Refer Table-1

5 No. of Pumps Working Normally One

6 Parallel operation of pump Not required

7 Seismic Qualification Required by analysis. To be qualified

for SSE and OBE conditions. (ReferTable-1)

8Applicable NPCIL Specification/s

9 Design Standard ASME Sec III Div. I , Sub-section-

ND , B & PV Code Section VIII,Div.1 & API-610 (Refer Table-1)

10 Design Pressure, kg/cm2(g) Refer Table-1

11 Design Temperature, C Refer Table-1

12 Drive Diesel engine driven

B. PUMP DUTY PARAMETERS

1 Rated Capacity, m3/hr Refer Table-1

2 Head at rated capacity, mlc Refer Table-1

3 Suction lift, mlc (abs) - for trailer

mounted pumps only

Suction lift of at least 4.5 mlc for

trailer mounted pumps

4 Static head - for the hot (saturated)water handling pumps only Refer Table-3 of Data Sheet-A

4.1 Pump floor elevation (ForCategory-A and B pumps only)

Refer Table-3 of Data Sheet-A

4.2 Pump suction tank (De-aerator)floor level

Refer Table-3 of Data Sheet-A

5 Friction head of system at ratedcapacity, (mlc)

~10

6 Pump shut-off head (maximum),(mlc)

Vendor to specify.

7 Preferred drive speed, rpm 1500 (Synchronous) at 50 Hz

8 Permissible/ Acceptable Tolerances on Rated Performance Parameters

8.1 Efficiency No negative tolerance

8.2 Flow +2.5% & No negative tolerance

8.3 Head +2.5% & No negative tolerance

9 H-Q characteristic requirement Continuously rising stable

characteristic towards shut offthroughout the Range of Operation

is only acceptable. The powercharacteristic shall be non-

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Data Sheet-A

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overloading with increase in flow.

10 Operation requirement Whenever called upon to operate, itshould operate continuously at any

point between and including

minimum flow and 120% rated flowwithout any problems of cavitation,

vibrations, noise, etc.

C. LIQUID DATA For Raw waterhandling pumps

For Feed water

handling pumps

1. Liquid Handled Raw Water Feed water (De-mineralized

water)

2. Specific Gravity 1 -3. < 500 < 0.2 at 25 0C4. Ph 7.1 to 8.4 9 to 10 at 25 0C5. Total Suspended Solids, ppm 50 to 100 -6. Total Dissolved Solids (max), ppm 500 -7. Chlorides (CaCO3), ppm < 40 -8. Total Hardness 100-300 ppm asCaCO3 -9. Max. Particle Size, mm < 5 -10. Water temperature o C Ambient 160 0C at

saturation

pressure

11. Dissolved OxygenIon

Na

Si

-

< 5 ppb

10 ppb (max.)5 ppb (max.)

20 ppb (max.)

D. PUMPS CONSTRUCTION FEATURES

1 Type of Pump Horizontal Centrifugal Pump2 Type of Casing Back Pull Out

3 Type of Impeller Enclosed

4 Number of Stages Vendor to specify

5

Components to be designed against

Reverse Rotation

Yes

6 Type of pump bearings Anti-friction (Grease / Oil bathlubricated)

7 Type of Coupling Flexible membrane type Spacer

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Data Sheet-A

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Coupling

8 Shaft Sealing Arrangement Refer table-1

9 Axial thrust balancing By thrust bearing / Impeller balanceholes (if required)

10 Nozzle Details

a. Nozzle Connection Type Flanged

b. Flange Drilling Standard ANSI B 16.5, 300#

c. Nozzle Orientation End suction, Top discharge

d. Suction Nozzle Connection pipeSize

Refer Table-1

e. Discharge Nozzle Connection pipe

Size

Refer Table-1

11. Noise level Noise level shall not exceed 85 dBA

measured at distance of 1.86 M fromoutline of equipment

12. Vibrations Value of vibrations shall not exceed

the specification limit.

E. ACCESSORIES AND SERVICES REQD.

1 Common Base Frame Yes. Base Frame shall have

provision for a common drain point(50 NB minimum) which collects all

drains from the pump-set.

2 Foundation Bolts, Nuts, Sleeves,

etc.

Yes

3 Companion Flanges with Nuts,Bolts & Gaskets Yes

4 Cooling/Sealing/ Lubricationsystem with all accessories

completely piped & valved.

All systems should be stand-alone &self-contained.

5 Pump-engine Coupling & Guard Yes

6 Vents with isolation valves Yes

7 Drain connection with valves Yes

8 Bearing temperature gauge with/

without switching contacts

Refer table-1

9 Suction strainer with flushing

provision

Yes only for trailer mounted pumps

10 Suction foot valve Yes only for trailer mounted pumps

11 Suction Pressure / Combinationgauge

Yes

12 Discharge Pressure Gauge Yes, with snubber to dampen

pressure pulsations

13 Priming tank & Accessories Yes only for trailer mounted pumps

14 Priming connection with isolationvalve

Yes

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Data Sheet-A

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15 Lifting Lugs Yes

16 Earthing Cleat Yes

17 Special erection & maintenancetools & tackles

Yes

18

Reducer and Expander to suitsuction and discharge pipe

Yes, if required, it shall consist of

counter flanges with reducer orexpander along with 100 mm straight

pipe piece.

19 Minimum flow cum non return

valve

Yes, on-off type if required.

20.Trolley for mounting engine, pump

and all accessories

Required for trolley mounted pumps

as mentioned in specification clauseno. 4(t).

F. MATERIAL OF CONSTRUCTION1 Casing ASTM A 216 GR WCB

2 Casing Wearing Rings ASTM A 351 CF 3M (Refer note-3)

3 Impeller ASTM A 351 CF8M

4 Impeller Wearing Ring ASTM A 351 CF 3M (Refer note-3)

5 Shaft AISI 410

6 Shaft Sleeves ASTM A 351 CF3M

7 Companion Flange ASTM A 105

8 Base Frame Carbon steel IS:2062 Gr. E 250 BR

9 Shaft Coupling Stainless Steel

10 Suction Strainer ASTM A216 Gr. WCB body with

SS 316L , 1 mm opening size.11 Trailer mounted pump sealing type

11.1 Stuffing Box housing ASTM A216 Gr. WCB

11.2 Gland ASTM A216 Gr. WCB

11.3 Gland Packing Graphite impregnated Teflon

12 Hot water pump sealing type Cartridge type Mechanical Seal.Vendor to specify details

13 Water Deflector AISI 316

Nuts ASTM A193 Gr B714 Fasteners

Bolts ASTM A194 Gr 2H

15 Foot Valve Body ASTM A216 Gr. WCB

16 Foot Valve Internals ASTM A216 Gr. WCB17 Trolley main frame & other parts Main frame of Structural steel

conforming to IS:2062 Gr. E 250

BR and other parts as per

manufacturer standard

G For Drive

1 Diesel engine Refer diesel engine specification anddata sheet

H INSPECTION & TESTING - GENERAL

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Data Sheet-A

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1 Stage Inspection by Purchaser Few inspections as per Sub section

No. J.

2 Material Testing & Identification Yes3 Strip down examination Yes

I INSPECTION & TESTING Non Destructive Examination

1 Radiography Not Required

a Parts to be tested -

b Testing Procedure -

c Acceptance Standard -

2 D.P. Test Required & to be witnessed byNPCIL approved third party

inspection agency. However, the

third party inspection agency is to beappointed by the main bidder.

a Parts to be tested Shaft, Shaft sleeves, Impeller, and

machined surfaces of Casing & other

machined components

b Testing Procedure ASME SEC V

c Acceptance Standard ASME Sec VIII Div I and ASMEsection III NC, whichever is

applicable.

3 Ultrasonic Examination Required & to be witnessed by

NPCIL approved third party

inspection agency. However, thethird party inspection agency is to beappointed by the main bidder.

a Parts to be tested 50 mm dia. & above Shaft (100%)

b Testing Procedure ASME SEC V

c Acceptance Criteria i) 1.6 mm flat bottom hole for D50 mm.

ii)2.0 mm flat bottom hole for 50