Professional Documents
Culture Documents
DOCUMENT TYPE
ENGINEERING SPECIFICATION
NO.
PP-E-2453
TITLE
REV.
NO. &
DATE
DESCRIPTION
OF
REVISION
PREPARED
BY
NAME &
SIGN
CHECKED
BY
NAME &
SIGN
REVIEWED APPROVED
BY
BY
NAME &
NAME &
SIGN
SIGN
NPCIL PROPRIETARY
This document is the property of Nuclear Power Corporation of India Limited (NPCIL). No
exploitation or transfer of any information contained herein is permitted in the absence of an
agreement with NPCIL and neither the document nor any such information may be released
without the written consent of NPCIL
1.0
Page 1 of 20
Rev. No. : R0
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 as
specified herein after for Atomic Power Stations. This specification also
includes the Data Sheet-A Format for the data to be filled by the purchaser
and Data Sheet-B Format for data to be filled by the Vendor.
2.0
CONTENTS
Sr.
No.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
3.0
Title
Page
No.
1
1
1
2
4
11
11
11
15
17
17
17
18
19
19
Scope
Contents
Applicable Codes And Standards
General Design Requirements
Special Features
Water Quality
Pump Drive
Inspection And Testing At Manufacturers Works
Tests
Performance Guarantee
Erection And Maintenance Tools
Spare Parts
Special Cleaning, Protection And Painting
Shipment
Data, Drawings to be submitted by the Vendor along with the
Bid
Inspection History Document / Documents To Be Submitted
19
After Placement Of Order / At Final Stage
Data Sheet-A Format Data to be filled by Purchaser 1 to15
Vendor along with Bid.
Data Sheet-B consisting of B1,B2 & B3 Format Data to be 1 to 22
filled by Purchaser Vendor along with Bid.
QAP - Indicative quality plan for pump
23 to 28
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PP-E-2453
March 2012
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
4.0
Page 2 of 20
Rev. No. : R0
(b)
(c)
The pumps shall be free from undue vibrations and shall be capable of
withstanding 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 their
loosening during operation due to vibrations or any other reasons.
(e)
(f)
The wearing parts shall be so designed that they can be easily replaced.
Wearing ring clearances shall be as per API 610.
(g)
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March 2012
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Rev. No. : R0
(h)
(i)
All materials used shall conform to specifications and shall be new in all
respects.
(j)
(k)
(l)
(m)
(n)
The rotor assembly including impeller, shaft etc shall be statically and
dynamically balanced.
(o)
(q)
Adequate supports for different parts of the pump shall be given for the
entire pump-engine installation. Suitable clamps, lifting lugs or eye bolts
shall 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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March 2012
Page 4 of 20
Rev. No. : R0
(s)
Trolley mounted pumps shall be supplied with strainer, foot valve in the
suction line and fixed pumps shall have Y-type suction strainer as
specified in the data sheet. Suction strainer required having minimum
free 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 bolt
holes shall be spot faced for washers.
(t)
Double axle
Tyre of sufficient height to have enough clearance from ground
Stay sack or jack to take entire load of trolley during pump
operation.
iv) Towing hook
v)
Search light
vi) Hand brake
vii) Tool box cum locker
viii) Canopy for pump , engine , panel, battery etc.
ix) Provision for fixing pump, engine and accessories
x)
Stand for storing hoses
xi) Fixed metallic ladder for approach
u)
5.0
SPECIAL FEATURES
5.1
Design Features
The pumps shall have stable, rising characteristic (H vs. Q) from maximum
flow 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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March 2012
Page 5 of 20
Rev. No. : R0
range in addition to the duty point. Head and power characteristics over the
guaranteed 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 pumps
shall 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 of
power, 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 maximum
expected reverse rotation arising from full discharge header pressure with fully
open discharge valve. In any case the reverse rotation capability shall not be
less 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 facilitate
supporting 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 testing
at intervals.
The equipment shall be designed with regard to ease of maintenance, repair,
cleaning and inspection of parts subject to wear or other deterioration requiring
adjustment 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 closedwater-loop air-cooled circuits of pumpset.
5.2
Location
For location of each pump, refer Table-1 (Sheet 1 of 2) specified in data sheetA.
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March 2012
5.3
Page 6 of 20
Rev. No. : R0
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 the
specifications or equivalent indicated in the data sheet. Compatible materials
shall be used for other components. Material of construction (MOC) not
specified 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 by
him 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 suction
side 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 for
venting 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 in
Data 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 balancing
may 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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March 2012
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Rev. No. : R0
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, taper
bushings 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) and
having Brinell hardness number of not less than 200. It shall have
surface finish of 0.75 microns or less. The butting faces of the shaft
shall 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 by
the 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 shaft
sleeves 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 be
provided.
(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 continuous
operation 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 size
impeller 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 water
deflector shall be provided to prevent ingress of water into the bearings
from the stuffing box / mechanical seal.
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March 2012
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Rev. No. : R0
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 gland
and lantern ring. Shaft sleeve under the gland packing shall have
burnished surface with high surface hardness. Stuffing box housing shall
facilitate collection of stuffing box leakage without any spillage. Unless
otherwise specified, gland packing for the pumps shall be made of
Graphite 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 hardness
than 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 to
accommodate both the pump and the drive. The base plates shall be
provided with a drain lip and a tapped drain hole with plug. The base
plate shall be properly drilled for the anchor bolts for mounting on
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March 2012
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Rev. No. : R0
concrete slab.
(k)
(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 drain
connection 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 outlet
temperature and bearing oil bath temperature.
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March 2012
Page 10 of 20
Rev. No. : R0
5.4
Pump and engine shall be provided with suitable lifting lugs for erection and
maintenance. Each pump-engine set shall be supplied with the required
number of foundation bolts, nuts, lock nuts, lock washers, etc.
5.5
B.
C.
The pump, base-frame, pedestal support assembly and nozzle shall be designed
to accept external forces and moments due to piping in accordance with API610 and limit the shaft displacement as specified therein. The bidder shall
indicate 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-P1819 titled `Technical Specification for Methods & Procedures for Seismic
Qualification 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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March 2012
6.0
Page 11 of 20
Rev. No. : R0
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 the
diesel engine drive for each type of pump shall be as per respective Technical
specification and Data Sheets of Diesel Engine. The bidder however shall
furnish 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
8.1
The Supplier shall carry out inspection to establish and maintain quality of
workmanship 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 to
the requirements of the applicable codes. All test and test procedure proposed
by the manufacturer shall be notified well in advance of the fabrication and
major 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 and
all test records shall be made available to him. The equipment covered under
this 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 after
tests.
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 the
castings 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 his
representative as per approved QAP.
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Rev. No. : R0
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 the
necessary 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)
(b)
(c)
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 of
the Purchasers representative.
8.3.3
The castings shall be sound, clean and free from porosity, blow holes, hard
spots, 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 by
a welder qualified by the Purchaser as per ASME Section IX.
8.3.5
a)
Magnetic
Magnetic castings shall be examined by magnetic particle inspection as
specified in the Data Sheets. The basis for acceptance shall be in
accordance with 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.
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PP-E-2453
March 2012
b)
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Rev. No. : R0
Non-Magnetic
All non-magnetic castings shall be examined by dye penetration test as
specified 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 ASME
Section III NC, whichever is applicable, mandatory appendices shall
be the minimum requirements.
d)
8.4
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
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 the
clearest 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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Rev. No. : R0
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 to
ensure 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 the
material. 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
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
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 for
boiler 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 the
Purchaser 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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Rev. No. : R0
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 the
test 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. At
least 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 of
test 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
9.2.3
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Rev. No. : R0
9.2.4
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 range
from the recommended minimum continuous flow to run out flow / maximum
flow.
9.2.6
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 the
stuffing 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 not
give satisfactory mechanical performance for any reason whatsoever and it is
necessary for the manufacturer to make alterations for the purpose of meeting
the 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 no
expense 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 the
CONTRACTOR 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 requirement
called for in the data sheets and technical requirement. The tests shall be
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Rev. No. : R0
11.0
12.0
SPARE PARTS
12.1
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)
-
Coupling (1 Set)
Gaskets (2 Sets)
(2 Sets)
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Rev. No. : R0
Power supply required for operating instruments shall be derived from battery
of diesel engine for pump.
For each type of Diesel engine As per applicable Diesel
Specification or as specified in data sheet / tender specification.
engine
The Supplier shall indicate item-wise prices of all spare parts recommended by
him for Three (3) years satisfactory operation of the equipment being supplied
by him along with the quantity required against each item.
13.0
13.1
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 rust
preventive 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 the
interior 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 foreign
material.
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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Rev. No. : R0
specified standards and all exposed surfaces shall be thoroughly greased before
despatch. 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 carefully
boxed 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 are
obtained 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
14.4
15.0
16.0
(a)
(b)
Final Drawings
(i)
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March 2012
(b)
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Rev. No. : R0
(ii)
(iii)
(iv)
(c)
Five hard and soft copies / sets of Operation and Maintenance Manuals.
(d)
(e)
Five hard and soft copies of Final Approved drawings submitted during
execution of Contract.
(f)
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PP-E-2453
March 2012
Sr. No.
A.
1
2
3
4
5
6
7
Item
GENERAL DATA
Station
Duty
Location
No of Pumps Required
No. of Pumps Working Normally
Parallel operation of pump
Seismic Qualification
Page 1 of 15
Rev. No. : R0
Description
Refer Table-2
Intermittent (Refer note- 4)
Refer Table-1
Refer Table-1
One
Not required
Required by analysis. To be qualified
for SSE and OBE conditions. (Refer
Table-1)
Design Standard
10
11
12
B.
1
2
3
4
4.1
4.2
5
6
7
8
8.1
8.2
8.3
9
_________________________________________________________________________________________
PP-E-2453
March 2012
Sr. No.
10
Operation requirement
Description
overloading with increase in flow.
C.
LIQUID DATA
1.
Liquid Handled
2.
Specific Gravity
Conductivity, S/cm
< 500
< 0.2 at 25 0C
4.
Ph
7.1 to 8.4
9 to 10 at 25 0C
5.
50 to 100
6.
500
7.
8.
Total Hardness
9.
100-300 ppm as
CaCO3
<5
10.
Water temperature o C
Ambient
11.
5
6
Rev. No. : R0
3.
D.
1
2
3
4
Item
Page 2 of 15
< 40
160 0C at
saturation
pressure
< 5 ppb
10 ppb (max.)
5 ppb (max.)
20 ppb (max.)
Dissolved Oxygen
Ion
Na
Si
PUMPS CONSTRUCTION FEATURES
Type of Pump
Horizontal Centrifugal Pump
Type of Casing
Back Pull Out
Type of Impeller
Enclosed
Number of Stages
Vendor to specify
Components to be designed against Yes
Reverse Rotation
Type of pump bearings
Anti-friction (Grease / Oil bath
lubricated)
Type of Coupling
Flexible membrane type Spacer
_________________________________________________________________________________________
PP-E-2453
March 2012
Sr. No.
Item
8
9
10
a.
b.
c.
d.
Nozzle Details
Nozzle Connection Type
Flange Drilling Standard
Nozzle Orientation
Suction Nozzle Connection pipe
Size
Discharge Nozzle Connection pipe
Size
Noise level
e.
11.
12.
E.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Page 3 of 15
Rev. No. : R0
Description
Coupling
Refer table-1
By thrust bearing / Impeller balance
holes (if required)
Flanged
ANSI B 16.5, 300#
End suction, Top discharge
Refer Table-1
Refer Table-1
_________________________________________________________________________________________
PP-E-2453
March 2012
Sr. No.
15
16
17
Item
Lifting Lugs
Earthing Cleat
Special erection & maintenance
tools & tackles
18
Reducer and Expander to suit
suction and discharge pipe
Page 4 of 15
Rev. No. : R0
Description
Yes
Yes
Yes
Yes, if required, it shall consist of
counter flanges with reducer or
expander along with 100 mm straight
pipe piece.
Yes, on-off type if required.
19
20.
F.
1
2
3
4
5
6
7
8
9
10
11
11.1
11.2
11.3
12
13
14
15
16
17
G
1
H
_________________________________________________________________________________________
PP-E-2453
March 2012
Page 5 of 15
Rev. No. : R0
Sr. No.
1
Item
Stage Inspection by Purchaser
2
3
I
1
a
b
c
2
b
c
a
b
c
a
b
c
Description
Few inspections as per Sub section
No. J.
Yes
Yes
_________________________________________________________________________________________
PP-E-2453
March 2012
Sr. No.
Page 6 of 15
Rev. No. : R0
Item
Description
section III NC, whichever is
applicable.
Required & to be witnessed by
I. G. C. Test
NPCIL approved third party
inspection agency. However, the
third party inspection agency is to be
appointed by the main bidder.
Parts to be tested (100%)
Impeller and other austenitic SS
parts as per ASTM A 262 Practice E
INSPECTION & TESTING Performance & Other Tests Required
(CHP)
Casing, Stuffing box, Assembled
Hydrostatic test - Parts to be tested
pump & other pressure retaining
(100%)
parts
1.5 Times Design Pressure or twice
Hydrostatic test pressure,
the normal operating pressure
kg/cm2(g)
whichever is higher.
Static & Dynamic Balancing
Impeller, Shaft, coupling as well as
(100%)
complete rotating assembly as per
std. ISO 1940 gr. 6.3 or better
All the pumps shall be tested at six
points between shut-off to 120% of
rated capacity with diesel engine.
Shop Performance tests (100%)
Head (H), Power (P) Efficiency ()
vs Capacity (Q) to be plotted for
rated speed.
On one pump to establish NPSH
Required at five points between and
NPSH Required test
including minimum flow to 120%
rated flow.
Test/ Acceptance Standard
As indicated in the specification.
Vibration Acceptance Standards
As indicated in the specification.
Strip Down Test
Required
Field performance test (CHP)
As indicated in the specification.
Root Mean Square value of Velocity of Vibrations shall not exceed the
value indicated in the specification.
Mandatory spares for pump for each site: To be supplied as indicated in the
specification.
Notes
CHP: Customer Hold Point.
Drive rating to be selected as per the diesel engine specification
Differential hardness of 50 BHN shall be maintained between the matching wearing
_________________________________________________________________________________________
PP-E-2453
March 2012
Sr. No.
parts.
Item
Page 7 of 15
Rev. No. : R0
Description
_________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-A
Rev. No. : R0
Parameter
Category-A
3
1.
25
2.
100
3.
Design Standard
4.
5.
6.
7.
Location of pump
8.
9.
Design Temperature, C
Category-B
Category-C
Category-D
50
44
83
100
115
115
ASME Sec III Div. ASME Sec III Div. B & PV Code
I , Sub-section- NC I , Sub-section- NC Section VIII, Div.1 B & PV Code
& API-610
& API-610
& API-610
Section VIII, Div.1
& API-610
Not required
By analysis required By analysis required Not Required
as per ASME Sec as per ASME Sec
III Div. I , Sub- III Div. I , Subsection- NC & API- section- NC & API610
610
5
Pedestal mounted
centre line
supported
Indoor
2
Pedestal mounted
centre line
supported
12 *
3*
Indoor
Outdoor
Outdoor
20
20
20
20
165
165
50
50
_______________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-A
Rev. No. : R0
Parameter
Category-A
Category-B
Category-C
Category-D
10.
80
100
100
100
11.
50
80
80
80
12.
Cartridge
Mechanical seals
with seal cooler &
magnetic filter
Cartridge
Mechanical seals
with seal cooler &
magnetic filter
13.
Shall be self
contained i.e.
without requiring
external cooling
water supply
Shall be self
contained i.e.
without requiring
external cooling
water supply
Required
Required
14.
Required
Required
Not Required
Not Required
15.
Liquid handled
Feed water
Feed water
Raw water
Raw water
16.
Pump drive
17.
5.0
5.0
_______________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Station
Requirement of
centrifugal pumps
Remark
Category
Quantity
1*
2. Madras Atomic
Power Station-1&2
1*
3. Narora Atomic
Power Station-1&2
2*
2*
5. Kaiga Generating
Station-1&2
2*
6. Rajasthan Atomic
Power Station-3&4
2*
1. Rajasthan Atomic
Power Station-2
4. Kakrapar Atomic
Power Station-1&2
_________________________________________________________________________________________
PP-E-2453
March 2012
8.
9.
Station
Requirement of
centrifugal pumps
10. Total
Quantity
required
Remark
2*
1*
2*
Category-A
Category-B
Category-C
12*
Category-D
3*
(*) For category- C & D pumps, the quantities required to be procured shall be finalized by
Operation Directorate.
ABBERVIATIONS :- SG- Steam Generator, SBO- Station Black Out, BDBA Beyond Design
Basis Accident, EFWST- Emergency Feed Water Storage Tank.
Pump
_________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-A
Page 12 of 15
Rev. No. : R0
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-A
Page 13 of 15
Rev. No. : R0
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-A
Page 14 of 15
Rev. No. : R0
A
Piping Material specification for typical scheme as shown in Annexure-1 of data-sheet-A is as follows :i)
Pipe size 15, 25, 50, 80 NB, seamless conforming to SA-106-Gr-B, Sch.-80 (Sch-40 for suction).
ii) Elbow LR, 15, 25, 50, 80 NB, Sch.-80, seamless conforming to SA-234-Gr-WPB, BW ANSI 16.9.
iii) Tee (EQ/UNE) 15, 50, 80 ,100 NB, Sch.-80, seamless conforming to SA-234-Gr-WPB, BW ANSI 16.9.
iv) Flange, 80 and 50 NB, WNRF, 600 #, BW ends (150# for suction) conforming to SA-105, ANSI 16.5.
v) Cap threaded 25 NB, 3000 # conforming to SA-105, Seal Welded, ANSI 16.11.
vi) Branch connections - Couplings A-105, SW, ANSI 16.11.
vii) Gasket - Spiral wound SS with graphite filling.
viii) Bolts conforming to SA-193-Gr- B-7 and Nuts conforming to SA-194-Gr-2H.
ix) Gate Valve 15, 25, 50, 80 NB, 600 # ANSI 16.34.
x)
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-A
Page 15 of 15
Rev. No. : R0
Unit
Diesel engine
floor
elevation
De-aerator
floor
elevation
De-aerator
normal
water level
KAPS-1
111.5 m
116 m
119.9 m
KAPS-2
111.5 m
116 m
119.9 m
RAPS-2
360.1 m
(1181.4ft)
372.46 m
(1222ft)
374.59 m
(1229ft)
TAPS-3
111.5 m
124* m
126.6* m
TAPS-4
111.5 m
124* m
126.6* m
NAPS-1
100.5 m
116 m
118.8 m
NAPS-2
100.5 m
116 m
118.8 m
(m- meter)
*in TAPS 3&4 the diesel pump takes suction from EFWST and not from de-aerator tank, hence elevations given in the table are related to EFWST.
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
DESIGN DATA
Page 1 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
DESIGN DATA
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
1.29
Page 2 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
DESIGN DATA
1.30
1.31
1.32
1.33
1.34
1.35
1.36
1.37
1.38
1.39
1.40
1.41
1.42
1.43
1.44
Page 3 of 28
Rev. No. : R0
Bidders Data
Length of
a) Drive end bearing assembly, mm
b) Mechanical seal cartridge, mm
c) Distance between shaft ends required for easy removal of
back pull-out assembly, mm
Length of spacer in spacer coupling, mm
KW rating of the coupling
Combined pump & driver critical speed, rpm
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
1.45
1.46
1.47
1.48
1.49
1.50
DESIGN DATA
Page 4 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
1.51
1.52
1.53
1.54
1.55
1.56
1.57
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
DESIGN DATA
Page 5 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
DESIGN DATA
Page 6 of 28
Rev. No. : R0
Bidders Data
b) Discharge
c) Drain
d) Vent
Nozzle location / orientation
a) Suction
b) Discharge
Maximum finished diameter of the pump shaft, mm
Axial hydraulic balance is achieved by
Mech. seal offered
a) Type
b) Make & Model No.
c) API Plan No.
d) Type of cooling arrangement for seal cooler
Radial bearing
a) Type
b) Make & Model No.
c) Type of lubrication arrangement
d) Type of cooling arrangement for bearing oil bath
Thrust bearing offered
a) Type
b) Make & Model No.
c) Type of lubrication arrangement
d) Type of cooling arrangement for bearing oil bath
Location of thrust bearing
Coupling offered
a) Type
b) Make & Model No.
c) Non-Sparking coupling guard offered? (Yes /No)
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
DESIGN DATA
2.16
2.17
2.18
2.19
2.20
2.21
3.0
Page 7 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
DESIGN DATA
6.0
6.1
6.2
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
4.0
5.0
Page 8 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
DESIGN DATA
Page 9 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
DESIGN DATA
Page 10 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
1.29
DESIGN DATA
Page 11 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
DESIGN DATA
1.30
1.31
1.32
1.33
1.34
1.35
1.36
1.37
1.38
1.39
1.40
1.41
1.42
1.43
1.44
Page 12 of 28
Rev. No. : R0
Bidders Data
Length of
a) Drive end bearing assembly, mm
b) Distance between shaft ends required for easy removal
of back pull-out assembly, mm
Length of spacer in spacer coupling, mm
KW rating of the coupling
Combined pump & driver critical speed, rpm
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
1.45
1.46
1.47
1.48
1.49
1.50
1.51
DESIGN DATA
Page 13 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
1.52
1.53
1.54
1.55
1.56
1.57
DESIGN DATA
Rev. No. : R0
Bidders Data
driver?
Frequency of maintenance required for the offered design of
the pump.
Ease and speed of maintainability
Positive locking arrangement provided for all threaded
fasteners
Are the pump bearings, seal, threaded components, etc.
designed for the maximum reverse rotation speed possible in
the pump?
Is any Anti-reverse rotation device provided in the pump or its
driver?
Is warming up arrangement required for pump start up /
operation at 160 0C
1.58
2.0
2.1
2.2
2.3
2.4
2.5
2.6
CONSTRUCTION FEATURES
Number of impellers
Type of impeller
Impeller diameter (mm)
Maximum diameter impeller that can be fitted (mm)
Method of fastening impeller to shaft
Pump Casing
a) Type of casing
b) Hydrotest pressure, kg/cm2 g
Nozzles size (NB), ANSI Drilling Std. & Rating
a) Suction
b) Discharge
c) Drain
2.7
Page 14 of 28
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
DESIGN DATA
Page 15 of 28
Rev. No. : R0
Bidders Data
d) Vent
Nozzle location / orientation
a) Suction
b) Discharge
Maximum finished diameter of the pump shaft, mm
Axial hydraulic balance is achieved by
Gland packing offered
a) Type
b) Make & Model No.
c) No. of packing rings
Radial bearing
a) Type
b) Make & Model No.
c) Type of lubrication arrangement
d) Type of cooling arrangement for bearing oil bath
Thrust bearing offered
a) Type
b) Make & Model No.
c) Type of lubrication arrangement
d) Type of cooling arrangement for bearing oil bath
Location of thrust bearing
Coupling offered
a) Type
b) Make & Model No.
c) Non-Sparking coupling guard offered? (Yes /No)
a) Features provided in pump design which enhance
reliability described?
b) Features provided in pump-set design for heat
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
2.17
2.18
2.19
2.20
2.21
3.0
3.1
DESIGN DATA
Page 16 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
DESIGN DATA
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
6.0
6.1
6.2
6.3
3.14
4.0
5.0
Page 17 of 28
Rev. No. : R0
Bidders Data
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
DESIGN DATA
Page 18 of 28
Rev. No. : R0
Bidders Data
specification
a) Seismic Qualification as specified
b) Critical Speed & Transverse deflection of rotor
c) Natural frequencies of the pump set
d) Natural frequencies of the mounting structure
a) Whether the analysis will be done by Consultants or
in-house expertise exists with the Contractor. Please
state.
b) The educational qualification and experience of
persons performing the analysis. (Give details)
d) Give details of similar work done by Contractor in the
past
e) State Software/hardware facilities to be used for
analysis
Painting - Inorganic Zinc Silicate Primer as specified
Painting Epoxy Finish coat as specified
Anchor bolts, nuts & seating steel work
Common base frame for pump-prime mover unit
Instruments included in scope as specified?
Casing drain provided with isolation valve?
Counter flanges along with bolts, nuts & gaskets included in
scope of supply for all nozzles of pump?
Lifting lugs, eye bolts, etc provided?
Insulation cleats provided?
Special tools and tackles
Mandatory Spares
Recommended Spares
Tests at site offered as specified?
_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Page 19 of 28
Rev. No. : R0
General arrangements drawings for the complete pump and drive assembly
along with trolley , showing overall dimensions and locations of the various
connections, supports and foundation arrangement of the pump assembly.
2.2
Cross-sectional drawing indicating the assembly of the pumps and their major
parts, along with material specification.
2.3
2.4
Description of the standard shop inspection and quality control procedure of the
manufacturer. Description of the pump performance test rig at the shop.
2.5
2.6
________________________________________________________________________________________
PP-E-2453
March 2012
Description
Page 20 of 28
Rev. No. : R0
(a)
(b)
(c)
(d)
Instruction manuals
(e)
(f)
(g)
Manufacturing, Inspection
and Test Procedures.
Quality Assurance and
Inspection Plan.
(h)
______
________ weeks
(i)
_______
__________ weeks
(j)
________________________________________________________________________________________
PP-E-2453
March 2012
(k)
2.7
Page 21 of 28
Rev. No. : R0
_______ weeks
2.8
Proof of Ability
2.8.1
Bidder shall give details of previous experience with design, manufacture and
supply of similar pumps. He shall provide a detailed list of customers, power
plants with type and number of similar equipment supplied. The details shall
include design capacity, total developed head, efficiency and operating
experience as on date.
Experience of type and extent of seismic analysis carried out by the bidder earlier on similar
equipment. Attach a brief write up on the methodology of seismic analysis
proposed by him for these equipment.
2.9
Schedule of Deviations
2.10
If the proposal has got any deviation from the technical specification, the
tendering conditions and the general condition of contract, tenderers shall
tabulate those deviations here and sign below. More sheets should be attached
if required. In absence of this it will be presumed that the offer is strictly in
accordance with this specification.
Manufacturing and Delivery Schedule
Time in weeks from the
Date of Issue
of
Purchase Order/ LOI
2.10.1
2.10.2
2.10.3
Start manufacture.
Complete manufacture.
2.10.4
2.10.5
Complete shipment.
________________________________________________________________________________________
PP-E-2453
March 2012
2.10.6
Arrival at site.
3.0
4.0
Page 22 of 28
Rev. No. : R0
Months
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PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B (Indicative QAP)
Page 23 of 28
Rev. No. : R0
W WITNESSED BY
R REVIEWED BY
2 VENDOR QC
The characteristic of a component, process or operation whose failure neither materially reduces the usability of the product in operation, nor does it affect the aesthetic
aspects.
MAJOR -
The characteristic of a component, process or operation whose failure may cause operation failure which can not be readily corrected at site or cause substandard
performance, increased erection and maintenance cost, reduced life or seriously affect aesthetics.
CRITICAL
The characteristic of a component, process or operation whose failure will surely cause operation failure or intermittent troubles which is difficult to rectify at site or render
the unit unfit for use or cause safety hazard.
NOTE: THIS TYPICAL QA PLAN IS ENCLOSED WITH TENDER SPECIFICATION FOR BIDDERS REFERENCE AND TO GIVE THEM AN IDEA OF INTENDED SCOPE OF QS
ACTIVITIES TO BE UNDERTAKEN DURING EXECUTION OF THIS CONTRACT. IT IS TO BE NOTED THAT THIS IS NOT A COPY OF FINAL QA PLAN. THE FINAL QA
PLAN IS TO BE PREPARED BY SUCCESSFUL BIDDER AND GOT APPROVED PRIOR TO EXECUTION OF CONTRACT.
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B (Indicative QAP)
Rev. No. : R0
1.
COMPONENT
AND
OPERATION
CHARACTE
RISTICS
CLAS
S
TYPE OF
CHECK
QUANTUM OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE
NORM
FORMAT OF
RECORD
AGENCY
REMARKS
Casting
Casing
including
nozzles,
Impeller, Wear
rings, Stuffing
Box
Pouring
Major
Witness
100%
Applicable
spec.
As per
applicable spec.
& procedure
Inspection
Report
1,2
Chemical
compositio
n
Heat
Treatment
Major
Chemical
Applicable
spec.
As per
applicable spec.
Test Report
Major
Procedure
/Report review
100%
HT Chart
Mech.
Properties
Major
Physical Test
Test Report
--
Dimensions
Major
Dimensional
Inspection
Report
Inspection
Report
Inspection
Report
Surface
Finish
LPE
Applicable
Spec.,
Approved
Procedure
Major
Visual Insp.
100%
Major
NDE
100%
As per
Applicable
Spec.,
Approved
Procedure
Applicable
spec.
Applicable
spec.
Manufacturers
Drawing
Manufacturers
Drawing
Approved
Procedure
Approved
Procedure
2,1
Castings to be
procured from
foundry approved
by NPCIL
Furnace should
have valid
calibration from
an NABL
approved
agency
1
For Impeller,
machined
surfaces of
Casing & other
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B (Indicative QAP)
SL.
No
2.
COMPONENT
AND
OPERATION
Forgings/Bar
Stock
Shaft, Shaft
Sleeves, etc
CHARACTE
RISTICS
CLAS
S
TYPE OF
CHECK
QUANTUM OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE
NORM
Rev. No. : R0
FORMAT OF
RECORD
AGENCY
MPE
Major
NDE
100%
Chemical
Compositio
n
Heat
Treatment
Major
Chemical
Approved
Specification
Major
Procedure/Re
port review
100%
Approved
Specification
Mech.
Properties
Major
Physical
Approved
Specification
LPE
Major
NDE
Approved
Procedure
U.T. (For
shaft dia.
> 50 mm)
Dimensions
Major
NDE
Major
Dimensional
As per
Approved
Specification
As per
Approved
Specification &
Approved
Procedure
As per
Approved
Specification &
Approved
Procedure
Manufacturers
Drawing
Manufacturers
Drawing
REMARKS
Inspection
Report
2,1
Test
Certificate
HT Chart
Test
Certificate
Inspection
Report
Inspection
Report
Inspection
Report
machined
casting surfaces
only
For Casing only
Furnace should
have valid
calibration from
an NABL
approved
agency
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B (Indicative QAP)
SL.
No
COMPONENT
AND
OPERATION
CHARACTE
RISTICS
3.
IGC Test
4.
Fasteners
Metallurgic
al
Dimensions
5.
After
Machining
CLAS
S
TYPE OF
CHECK
QUANTUM OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE
NORM
Rev. No. : R0
FORMAT OF
RECORD
AGENCY
P
Critic
al
Major
Corrosion
resistance
Dimensional
100%
Random
Sample Per
Size & Heat
Mechanical
& Chemical
Major
Mechanical
and Chemical
Dimensions
Major
Measurements
100%
LPE/MPE
Major
NDE
100%
REMARKS
ASTM A 262
Practice E
Manufacturers
Drawing
Approved
Specification /
Drawing
Approved
Drawing
ASTM A 262
Practice E
Manufacturers
Drawing
Approved
Specification/
Drawing
Approved
Drawing
Test Report
Inspection
Report
Test
Certificate
Inspection
Report
Approved
Procedure
Approved
Specification
Approved
Procedure
As per
Approved
Specification,
ISO 1940 Gr.
6.3 or better
As per
Approved
Procedure
Inspection
Report
Test Report
2,1
1,2
Test Report
For Shaft,
Impeller, Rotor
Assembly,
Coupling
Assembly
For Casing, St.
Box housing,
Assembled
pump, etc
As per
Approved
Drawing &
Procedures
Test Report,
Inspection
Report
6.
Balancing
Static &
Dynamic
Balancing
Major
Unbalance
100%
7.
Hydraulic Test
Hydrostatic
Test
Major
Integrity
100%
Approved
Procedure
8.
Support
Structures
(Pump & Drive
support
Dimension,
Orientation
,
Workmans
hip &
Major
Visual and
dimensional,
NDE
100%
Approved
Drawing &
Procedures
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B (Indicative QAP)
SL.
No
COMPONENT
AND
OPERATION
9.
Performance
10.
NPSH TEST
11.
Running Test
12.
Disassembly
Test (Strip
test)
13.
Prime Mover
14.
Painting/Packi
ng/Documenta
tion
CHARACTE
RISTICS
CLAS
S
TYPE OF
CHECK
QUANTUM OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE
NORM
Rev. No. : R0
FORMAT OF
RECORD
AGENCY
P
Finish,
LPE/MPE,
Cleanliness
Capacity Vs
Head
Capacity Vs
Efficiency
Capacity Vs
Power
NPSH-R
REMARKS
Critic
al
Hydraulic
100%
Approved
Procedure
As per
Approved
Procedures
Test Report
NPCIL CHP
Critic
al
Hydraulic
One Pump of
each type
Approved
Procedure
Test Report
NPCIL CHP
Temperatu
re Rise,
Vibration,
Noise Level
Appearanc
e
(Rubbing,
Wear, Tear
&
Breakage)
Routine
Test
Type Test
Critic
al
Measurements
One Pump of
each type
Approved
Procedure
As per
Approved
Procedures
As per
Approved
Procedures
Test Report
NPCIL CHP
Major
Visual
As per
Approved
Procedures
Test Report
Major
Performance
Test Report
Major
Performance
1 No./Type
As per
Approved
Procedures
Test Report
Review of
Documents
Major
Visual /Review
100%
As per
Approved Spec.
& Procedure
Inspection
Report &
History
Docket
100%
Approved
Procedure
100%
Approved
Procedure
Approved
Spec. &
Procedure
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B (Indicative QAP)
Page 28 of 28
Rev. No. : R0
NOTES:1) ALL INSPECTION REPORTS, TEST CERTIFICATES, TEST REPORTS SHALL BE REVIEWED BY PRIME VENDOR BEFORE SUBMITTING
THE SAME FOR REVIEW BY NPCIL / NPCIL APPROVED THIRD PARTY INSPECTION AGENCY.
2) WHENEVER WITNESSING BY CUSTOMER IS SPECIFIED ONLY AS 1 , VENDORS REPRESENTATIVE SHALL ALSO WITNESS THE TEST.
3) IN ABSENCE OF CO-RELATED TEST CERTIFICATES, CHECK TEST FOR BOTH MECHANICAL AND CHEMICAL SHALL BE CARRIED OUT
FROM NPCIL APPROVED LAB. SAMPLE FOR CHECK TEST SHALL BE DRAWN BY PURCHASER.
4) DETAILED QAP TO BE PREPARED BY VENDOR SHALL COVER ALL REQUIREMENTS AS SPECIFIED IN THIS PROCUREMENT
SPECIFICATION.
5) SPARES WILL ALSO BE SUBJECTED TO SAME TESTS AND EXAMINATIONS AS REQUIRED FOR CORRESPONDING PARTS IN MAIN
EQUIPMENT.
6) QAP FOR SUCTION STRAINER, SEAL COOLERS SHALL BE PREPARED BY VENDOR AND SUBMITTED FOR APPROVAL OF PURCHASER
AND TO INDICATE CHPs.
7) ALL THE MEASURING INSTRUMENTS (MECHANICAL & ELECTRICAL) SHALL HAVE APPROPRIATE CALIBRATION TRACEABLE TO
NATIONAL STD.
8) ALL NDT PROCEDURES (UT, MPT, LPT) SHALL BE APPROVED BY NPC PRIOR TO CARRYING OUT ANY NDT ACTIVITIES.
9) NPC APPROVED CHEMICALS ONLY SHALL BE USED FOR DPT.
10) NDT ARE TO BE CARRIED OUT ONLY BY ISNT OR ANSI LEVEL 2 QUALIFIED PERSONNELS.
11) FOR HEAT TREATMENT, THE FURNACE AND ALLTHE MEASURING INSTRUMENTS I.E RECORDER, THERMOCOUPLES AND
INDICATORS SHOULD BE APPROPRIATELY CALIBRATED AND THOSE ARE ALSO SUBJECTED TO REVIEW BEFORE HEAT TREATMENT
IS UNDERTAKEN.
12) MECHANICAL TESTING / CHEMICAL ANALYSIS ARE TO BE CARRIED OUT AT NPC APPROVED LABORATORIES.
13) THE REPRESENTATIVE OF CONTRACTOR AUTHORISED TO WITNESS THE TEST SHALL HAVE REQUIRED EXPERIENCE AND
KNOWLEDGE OF ACTIVITIES BEING INSPECTED. HE SHALL BE EMPLOYEE OF CONTRACTOR ONLY.
14) WPS, PQR & WELD REPAIR PROCEDURE SHALL BE GOT APPROVED FROM NPCIL. WELD REPAIR ON ANY PART SHALL ONLY BE
DONE WITH THE PRIOR APPROVAL OF THE PURCHASER.
15) APPROVAL OF NPCIL SHALL BE OBTAINED BEFORE ANY ITEMS / SERVICES ARE SUB-ORDERED.
________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012