You are on page 1of 66

REVISION CONTROL SHEET

DOCUMENT TYPE

ENGINEERING SPECIFICATION

NO.

PP-E-2453

TITLE

TECHNICAL SPECIFICATION FOR DIESEL ENGINE


OPERATED
HORIZONTAL
CENTRIFUGAL
EMERGENCY PUMP FOR 220 & 540 MWe

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

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

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

APPLICABLE CODES AND STANDARDS


The design, material, manufacturing and testing of the equipment covered by
this 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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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

i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
4.0

Page 2 of 20
Rev. No. : R0

Hydraulic Institute Standards, USA.


IS: 1520 Specification for Horizontal Centrifugal Pumps for clear
cold, fresh water.
API 610 Centrifugal pumps for refinery services.
ASME / ASTM Standards for various tests and materials. Instrument
society of America Standards.
ASME Boiler and Pressure Vessels Code Section VIII, Div.1 and
sect. IX.
ASME and ANSI Power test codes
ANSI B 16.5 Standard for Steel pipe flanges and flanged fittings.
IS: 5120 Technical Requirement for Rotodynamic Pumps.
ANSI B 2.1 Taper pipe threads for instrument taps.
AWWA Standard Codes for steel pipe flanges and fittings.
ASME Section III, Sub-Section ND and NC, if specified in data
sheets.
ISO 1940 - Dynamic Balancing.
PC-E-2454 Technical Specification & Data sheet of Diesel Engines.

GENERAL DESIGN REQUIREMENTS


(a)

The pump shall be of horizontal centrifugal type with impellers arranged


for 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 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)

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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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 3 of 20
Rev. No. : R0

(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 it
will be subjected.

(i)

All materials used shall conform to specifications and shall be new in all
respects.

(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 received
before any such work is carried out. Drawings showing the details and
location of such modification shall be submitted to the Purchaser for his
records. 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 and
dynamically balanced.

(o)

Natural frequencies of total pump and diesel engine assembly and


rotating assembly should not be very close to or should not match with
(i) its own operating frequency (ii) Natural frequency of pump-engine
housing 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 pumpengine housing civil structure or the trolley mounted structure, as the
case may be, and prove the above condition by calculations after
placement 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 bolts
shall be provided at appropriate places for convenient handling of
components.
Pump shall be fully assembled at manufacturers shop and mating parts

_________________________________________________________________________________________
PP-E-2453
March 2012

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 4 of 20
Rev. No. : R0

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 the
assembly drawings to aid in their identification and assembly at site.

(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)

For trolley mounted pumps, complete pump-diesel engine assembly


along with its accessories, diesel engine control panel, day oil tank,
storage for keeping hose of at least 100 mtr. length shall be mounted
on one movable trolley. In addition to general features , the trolley
should have following design features in it :i)
ii)
iii)

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)

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 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

_________________________________________________________________________________________
PP-E-2453
March 2012

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 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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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

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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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 7 of 20
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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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 8 of 20
Rev. No. : R0

The rise in bearing grease/oil temperature with continuous running of


the 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 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

_________________________________________________________________________________________
PP-E-2453
March 2012

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 9 of 20
Rev. No. : R0

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 with
NPCIL 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 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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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 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

Seismic Requirement (If Specified in applicable data sheet)


Pumps are to be designed to withstand seismic loads, as specified in attached
data 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) and


sustained 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 by


Response Spectra enclosed together with pressure and sustained loads.
Maximum allowable nozzle loads shall be 2 x API 610 values. Level B
service limits apply.

C.

Loads due to safe shutdown earthquake (emergency condition) as


defined 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 the
seismic design will be provided to the successful bidder after placement
of order.

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.
_________________________________________________________________________________________
PP-E-2453
March 2012

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

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

INSPECTION AND TESTING AT MANUFACTURES WORKS

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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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 12 of 20
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)

Shaft, Impeller, casing

Chemical analysis and physical


test.

(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 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

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 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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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

b)

Page 13 of 20
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)

Dye penetrant test: The entire surface of the impeller castings


(approachable area only) shall be subjected to dye penetrant test as per
ASTM Specification E-165. Non-machined surface shall be ground
before dye penetrant test. For other castings only machined surfaces
shall 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 test
procedure shall be as per ASME Boiler and pressure vessels code-Section VIII
Div. 1 Appendix VI or ASME section III NC, whichever is applicable. Dye
penetration 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 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

_________________________________________________________________________________________
PP-E-2453
March 2012

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 14 of 20
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

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 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

_________________________________________________________________________________________
PP-E-2453
March 2012

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 15 of 20
Rev. No. : R0

shipment. Pumps shall not be painted before inspection. Pumps shall be


assembled 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 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

Tests shall be conducted in Suppliers shop in order to ensure freedom from


vibration 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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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 16 of 20
Rev. No. : R0

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 in
order 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 stable
during 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 range
from the recommended minimum continuous flow to run out flow / maximum
flow.

9.2.6

The characteristic curves submitted by the CONTRACTOR along with his


Tender 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 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

_________________________________________________________________________________________
PP-E-2453
March 2012

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 17 of 20
Rev. No. : R0

conducted in accordance with technical specification and rectification of all


defects 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 and
rectification 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 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)
-

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

Gaskets (2 Sets)

(2 Sets)

_________________________________________________________________________________________
PP-E-2453
March 2012

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 18 of 20
Rev. No. : R0

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 BEARING
temperature measurement.

Temperature Indicating Switch for Lube Oil temperature


measurement/seal flushing liquid temperature measurement.

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

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 be
protected 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 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

_________________________________________________________________________________________
PP-E-2453
March 2012

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 19 of 20
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

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 ALONG


WITH THE BID

16.0

(a)

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

(b)

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

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 foundation
drawing.

_________________________________________________________________________________________
PP-E-2453
March 2012

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

(b)

Page 20 of 20
Rev. No. : R0

(ii)

Cross sectional drawing of pump indicating materials of


construction 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.

Bound History dockets five sets each comprising the following


documents.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
(xv)

P.O. and Sub-Order copies.


Approved as built drawings.
Approved Q.APs.
Approved Procedures.
Material test certificates.
NDT Reports.
Stress relief Time-Temperature charts.
Welding procedures and Welders Qualification reports.
Hydrostatic Test Certificates.
Performance Test Procedure and Performance Test Reports
with curves / other test reports.
Dimensional Reports.
Radiography films, if any.
Shipping release copies.
All Design Concession reports if any.
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.

_________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

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)

Applicable NPCIL Specification/s

Design Standard

10
11
12

Design Pressure, kg/cm2(g)


Design Temperature, C
Drive

B.
1
2
3

PUMP DUTY PARAMETERS


Rated Capacity, m3/hr
Refer Table-1
Head at rated capacity, mlc
Refer Table-1
Suction lift, mlc (abs) - for trailer
Suction lift of at least 4.5 mlc for
mounted pumps only
trailer mounted pumps
Static head - for the hot (saturated) Refer Table-3 of Data Sheet-A
water handling pumps only
Pump
floor
elevation
(For Refer Table-3 of Data Sheet-A
Category-A and B pumps only)
Pump suction tank (De-aerator)
Refer Table-3 of Data Sheet-A
floor level
Friction head of system at rated
~10
capacity, (mlc)
Pump shut-off head (maximum),
Vendor to specify.
(mlc)
Preferred drive speed, rpm
1500 (Synchronous) at 50 Hz
Permissible/ Acceptable Tolerances on Rated Performance Parameters
Efficiency
No negative tolerance
Flow
+2.5% & No negative tolerance
Head
+2.5% & No negative tolerance
H-Q characteristic requirement
Continuously
rising
stable
characteristic towards shut off
throughout the Range of Operation
is only acceptable. The power
characteristic
shall
be
non-

4
4.1
4.2
5
6
7
8
8.1
8.2
8.3
9

ASME Sec III Div. I , Sub-sectionND , B & PV Code Section VIII,


Div.1 & API-610 (Refer Table-1)
Refer Table-1
Refer Table-1
Diesel engine driven

_________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

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.

Total Suspended Solids, ppm

50 to 100

6.

Total Dissolved Solids (max), ppm

500

7.

Chlorides (CaCO3), ppm

8.

Total Hardness

9.

Max. Particle Size, mm

100-300 ppm as
CaCO3
<5

10.

Water temperature o C

Ambient

11.

5
6

Rev. No. : R0

Whenever called upon to operate, it


should operate continuously at any
point
between and including
minimum flow and 120% rated flow
without any problems of cavitation,
vibrations, noise, etc.
For Raw water
For Feed water
handling pumps
handling pumps
Raw Water
Feed water (Demineralized
water)
1
-

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

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
Data Sheet-A

Sr. No.

Item

8
9

Shaft Sealing Arrangement


Axial thrust balancing

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

Noise level shall not exceed 85 dBA


measured at distance of 1.86 M from
outline of equipment
Vibrations
Value of vibrations shall not exceed
the specification limit.
ACCESSORIES AND SERVICES REQD.
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.
Foundation Bolts, Nuts, Sleeves,
Yes
etc.
Companion Flanges with Nuts,
Yes
Bolts & Gaskets
Cooling/Sealing/ Lubrication
All systems should be stand-alone &
system with all accessories
self-contained.
completely piped & valved.
Pump-engine Coupling & Guard
Yes
Vents with isolation valves
Yes
Drain connection with valves
Yes
Bearing temperature gauge with/
Refer table-1
without switching contacts
Suction strainer with flushing
Yes only for trailer mounted pumps
provision
Suction foot valve
Yes only for trailer mounted pumps
Suction Pressure / Combination
Yes
gauge
Discharge Pressure Gauge
Yes, with snubber to dampen
pressure pulsations
Priming tank & Accessories
Yes only for trailer mounted pumps
Priming connection with isolation
Yes
valve

_________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

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

Minimum flow cum non return


valve

20.

Required for trolley mounted pumps


as mentioned in specification clause
no. 4(t).
MATERIAL OF CONSTRUCTION
Casing
ASTM A 216 GR WCB
Casing Wearing Rings
ASTM A 351 CF 3M (Refer note-3)
Impeller
ASTM A 351 CF8M
Impeller Wearing Ring
ASTM A 351 CF 3M (Refer note-3)
Shaft
AISI 410
Shaft Sleeves
ASTM A 351 CF3M
Companion Flange
ASTM A 105
Base Frame
Carbon steel IS:2062 Gr. E 250 BR
Shaft Coupling
Stainless Steel
Suction Strainer
ASTM A216 Gr. WCB body with
SS 316L , 1 mm opening size.
Trailer mounted pump sealing type
Stuffing Box housing
ASTM A216 Gr. WCB
Gland
ASTM A216 Gr. WCB
Gland Packing
Graphite impregnated Teflon
Hot water pump sealing type
Cartridge type Mechanical Seal.
Vendor to specify details
Water Deflector
AISI 316
Fasteners
Nuts
ASTM A193 Gr B7
Bolts
ASTM A194 Gr 2H
Foot Valve Body
ASTM A216 Gr. WCB
Foot Valve Internals
ASTM A216 Gr. WCB
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
For Drive
Diesel engine
Refer diesel engine specification and
data sheet
INSPECTION & TESTING - GENERAL

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

Trolley for mounting engine, pump


and all accessories

_________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

Page 5 of 15
Rev. No. : R0

Sr. No.
1

Item
Stage Inspection by Purchaser

2
3

Material Testing & Identification


Strip down examination

I
1
a
b
c
2

INSPECTION & TESTING Non Destructive Examination


Not Required
Radiography
Parts to be tested
Testing Procedure
Acceptance Standard
Required & to be witnessed by
D.P. 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
Shaft, Shaft sleeves, Impeller, and
machined surfaces of Casing & other
machined components
Testing Procedure
ASME SEC V
Acceptance Standard
ASME Sec VIII Div I and ASME
section III NC, whichever is
applicable.
Required & to be witnessed by
Ultrasonic Examination
NPCIL approved third party
inspection agency. However, the
third party inspection agency is to be
appointed by the main bidder.
Parts to be tested
50 mm dia. & above Shaft (100%)
Testing Procedure
ASME SEC V
Acceptance Criteria
i) 1.6 mm flat bottom hole for D
50 mm.
ii) 2.0 mm flat bottom hole for 50 <
D 80 mm.
iii) 2.5 mm flat bottom hole for 80 <
D 150 mm.
D-Range of pump shaft diameter
Required & to be witnessed by
M.P. 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
Pump Casing
Testing Procedure
ASME SEC V
Acceptance Standard
ASME Sec VIII Div I and ASME

b
c

a
b
c

a
b
c

Description
Few inspections as per Sub section
No. J.
Yes
Yes

_________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

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

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
Data Sheet-A

Sr. No.
parts.

Item

Page 7 of 15
Rev. No. : R0

Description

Normally pump-engine set is not in service. It is kept in isolated condition. It is required


to be operated only during emergency condition. However, the pump-engine will be
tested at regular intervals at partial/full load. Though the mode of operation is
intermittent, it is always kept poised to start in emergency service and operate
continuously. As the pump-engine is expected to remain idle for long periods of time,
bidder shall indicate over hauling/ maintenance requirements to keep the pump-engine
always available in good working condition.
Bidder to submit Data sheet B1, B2 & B3 enclosed in Technical specification for
horizontal centrifugal pump indicated in the specification.
Recommended API 610 makes of pump: KSB, Pune; Kirloskar Ebara make of KBL,
Pune; BPCL, Allahabad; Flowserve, Coimbatore. (Only API 610 model is acceptable)
Natural frequencies of the total pump-diesel engine assembly and rotating assembly
should not be very close to or should not match with its own operating frequency or the
natural frequency of the structure on which the pump-set is mounted.
Pump vendor shall recommend the fixing arrangement of the pump-engine set in the
trolley in order to meet the specified vibration limits.

_________________________________________________________________________________________
PP-E-2453
March 2012

Nuclear Power Corporation of India Limited

(A Government of India Enterprise)


Page 8 of 15

Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-A

Rev. No. : R0

Table-1: For the horizontal centrifugal pump (Sheet 1 of 2)


S. No.

Parameter

Category-A
3

1.

Rated Capacity (m /hr)

25

2.

Rated head (MLC)

100

3.

Design Standard

4.

SSE & OBE qualification

5.

Quantity required (Refer Table-2)

6.

Type of pump installation

7.

Location of pump

8.

Design Pressure, kg/cm2(g)

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*

Mounted on Mobile Mounted on Mobile


Trolley
Trolley

Indoor

Outdoor

Outdoor

20

20

20

20

165

165

50

50

_______________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

Nuclear Power Corporation of India Limited

(A Government of India Enterprise)


Page 9 of 15

Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-A

Rev. No. : R0

Table-1: For the horizontal centrifugal pump (Sheet 2 of 2)


S. No.

Parameter

Category-A

Category-B

Category-C

Category-D

10.

Suction Nozzle Connection pipe Size (NB)

80

100

100

100

11.

Discharge Nozzle Connection pipe Size (NB)

50

80

80

80

12.

Shaft sealing arrangement

Cartridge
Mechanical seals
with seal cooler &
magnetic filter

Cartridge
Mechanical seals
with seal cooler &
magnetic filter

Stuffing box &


gland packing

Stuffing box &


gland packing

13.

All cooling requirements of the pump-engine


set

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.

Bearing oil temperature gauge

Required

Required

Not Required

Not Required

15.

Liquid handled

Feed water

Feed water

Raw water

Raw water

16.

Pump drive

Diesel engine driven

Diesel engine driven

Diesel engine driven

Diesel engine driven

17.

Suction lift (mlc)

5.0

5.0

_______________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

Nuclear Power Corporation of India Limited


(A Government of India Enterprise)
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump
Page 10 of 15
for 220 & 540 MWe
Rev. No. : R0
Data Sheet-A

Table-2: Station wise break up for horizontal centrifugal


pump (Sheet 1 of 2)
Sl.
No.

Station

Requirement of
centrifugal pumps

Remark

Category

Quantity

It will be used to transfer feed


water from deaerator to SGs
during SBO.

1*

It will be used to transfer raw


water to Calandria / SGs during
BDBA/ SBO.

2. Madras Atomic
Power Station-1&2

1*

It will be used to transfer raw


water to Calandria / SGs during
BDBA/ SBO.

3. Narora Atomic
Power Station-1&2

It will be used to transfer feed


water from deaerator to SGs
during SBO.

2*

It will be used to transfer raw


water to Calandria / SGs during
BDBA/ SBO.

It will be used to transfer feed


water from deaerator to SGs
during SBO.

2*

It will be used to transfer raw


water to Calandria / SGs during
BDBA/ SBO.

5. Kaiga Generating
Station-1&2

2*

It will be used to transfer raw


water to Calandria / SGs during
BDBA/ SBO.

6. Rajasthan Atomic
Power Station-3&4

2*

It will be used to transfer raw


water to Calandria / SGs during
BDBA/ SBO.

1. Rajasthan Atomic
Power Station-2

4. Kakrapar Atomic
Power Station-1&2

_________________________________________________________________________________________
PP-E-2453
March 2012

Nuclear Power Corporation of India Limited


(A Government of India Enterprise)
Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump
Page 11 of 15
for 220 & 540 MWe
Rev. No. : R0
Data Sheet-A

Table-2: Station wise break up for horizontal centrifugal


pump (Sheet 2 of 2)
Sl.
No.
7.

8.

9.

Station

Requirement of
centrifugal pumps

Kaiga Generating Station-3&4

Tarapur Atomic Power Station3&4

Rajasthan Atomic Power


Station-5&6

10. Total
Quantity
required

Remark

2*

It will be used to transfer raw


water to Calandria / SGs
during BDBA/ SBO.

It will be used to transfer


feed water from EFWST /
deaerator to SGs during
SBO.

1*

It will be used to transfer raw


water to Calandria / SGs
during BDBA/ SBO.

2*

It will be used to transfer raw


water to Calandria / SGs
during BDBA/ SBO.

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.

Preferred make of components:


Sl.No Item

Make (only API 610 models acceptable)

KSB, Pune; Kirloskar Ebara make of KBL, Pune; BPCL,


Allahabad; Flowserve.

Pump

_________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

Page 12 of 15
Rev. No. : R0

Annexure-1of Data Sheet-A

________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

Page 13 of 15
Rev. No. : R0

Annexure-2 of Data Sheet-A

________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

Piping Material Specifications

Page 14 of 15
Rev. No. : R0

Annexure-3 of Data Sheet-

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)

All pump internal piping shall be of Stainless steel conforming to 304L/316L.

________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-A

Page 15 of 15
Rev. No. : R0

TABLE-3 of Data Sheet-A


ELEVATIONS OF FIXED PUMP (CATEGORY-A & B) , DEAREATOR WATER LEVEL & FLOOR LEVEL AS SHOWN IN ANNEXURE-1 OF DATA SHEET-A FOR
VARIOUS STATIONS

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

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
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

Pump Category for Category A or B pumps


(Indicate either Category A or B)
Pump designation
Manufacturers Name
Manufacturer's Model number
No. of pumps offered
Type of pump
No. of Stages
Shaft Orientation
Design Pressure, kg/cm2g
a) Pressure parts handling the pumped fluid
b) Other Pressure parts
Design Temperature, 0C
a) Pressure parts handling the pumped fluid
b) Other Pressure parts
Design Code for
a) Pressure parts handling the pumped fluid
b) Other Pressure parts
Capacity of each pump, m3/hr
a) At Rated flow
b) at 120 % Rated flow
Total dynamic head, MLC
a) at Rated Flow
b) at Minimum continuous flow
c) at 120 % Rated flow
Shut off head, MLC
Head rise from Rated point to shutoff, %
Fluid temperature at rated point, 0C

_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
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

Fluid specific gravity at rated point


Pump eff. at Rated flow %
NPSH required, MLC
d) at Rated flow
e) at Minimum continuous flow
f) at 120 % Rated flow
Capacity at Best Eff. Point (BEP), m3/hr
Specific speed at BEP (US units)
Suction specific speed at BEP (US units)
KW required at
a) Rated flow
b) min. cont. flow
c) 120 % Rated flow
Driver
a) Rating, KW
b) Make
c) Model No
Rated Speed, rpm
Recommended minimum continuous flow, m3/hr.
Maximum flow that the pump can handle continuously without
any problem of NPSH or excessive vibration, m3/hr
Capability of pump to operate continuously at any point between
and including minimum flow and 120 % rated flow, without any
problem of NPSH or excessive vibration
Direction of rotation of pump when viewed from driven end
Reverse rotation speed, rpm
(a) At Max. possible reverse flow
(b) For which pump is designed

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

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
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1

DESIGN DATA

1.30
1.31

Noise level at 1.0 M from the outline of equipment, dBA


Will the pump rotor / deflection be designed to avoid touching
any stationary part under the most adverse operating condition?
Radial clearance at wear ring as per API 610 (as new/max. before
replacement), mm/mm
Maximum thrust load in pump with max. size impeller that can be
fitted in the casing, kgf
a) at design internal clearances
b) at twice design int. clearances
Maximum thrust load in pump at twice design internal
clearances when pump is rotating in the reverse direction, kgf
Maximum thrust load carrying capability of the thrust bearing,
kgf
Ratio of max. thrust load possible / thrust load capability of the
thrust bearing
Maximum temperature rise of lubrication oil, 0C
Rated life of anti-friction bearings (not more than 10% failure),
hrs
Max. leak rate through the mech. seal, cc/hr
MTBF of Mechanical seal, hrs

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

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
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

a) 1st critical speed at 2 x design clearances


b) 2nd critical speed at 2 x design clearances
Pump rotor wet critical speed, rpm
a) 1st critical speed at 2 x design clearances
b) 2nd critical speed at 2 x design clearances
Driver rotor critical speed, rpm
a) First critical speed
b) Second critical speed
RMS value of velocity on bearing housing of pump & driver,
mm/s
a) At Rated flow
b) At Minimum flow
c) At 120% Rated flow
Vibration levels recommended by contractor (RMS velocity in
mm/s) as
a) Normal Condition
b) Alarm Condition
c) Trip Condition
Lifetime for which the pump & driver unit is designed, years
Closed loop cooling water for the complete pump set
a) Quality
b) Total Hold-up Volume required / Pump set, litres
c) Design Pressure, kg/cm2 g
d) Inlet temperature / outlet temperature at most adverse
condition, 0C / 0C
i) Mechanical seal coolers
ii) Mech. seal cooling jacket (if applicable)
iii) Bearing jacket (if applicable)

_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
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

iv) Pump pedestal (if applicable)


v) Diesel Engine
vi) Any other service (please state)
Is the direction of rotation of the pump matched to that of its
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, mechanical 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
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

_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
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

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
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1

DESIGN DATA

2.16

a) Features provided in pump design which enhance reliability


described?
b) Features provided in pump design for heat dissipation
without requiring any external cooling source described?
Weights
a) Total (dry) weight of pump, kg
b) Total weight of the drive coupling, kg
c) Total weight of prime mover, kg
d) Total weight of the base plate, kg
e) Total weight of complete assembly (dry), kg
f) Total shipping weight of complete assembly (dry), kg
g) Total weight of pump back pull out assembly, kg
h) Total (wet) weight of pump, kg
i) Total weight of complete assembly (wet), kg
Overall Dimensions of complete assembly
a)
Length, mm
b)
Width, mm
c)
Height, mm
Dimensions of the base plate
a)
Length, mm
b)
Width, mm
c)
Height, mm
Height of suction nozzle centre line above bottom of base plate,
mm
Height of discharge nozzle flange face above bottom of base plate,
mm
MATERIAL OF
CONSTRUCTION

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

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
Data Sheet-B-1 (For category A and B pumps only, to be filled by bidder)
B-1

DESIGN DATA

6.0

(Indicate the complete standard to which it conforms)


Casing including Suction & Discharge Nozzles
Mech. Seal housing
Impeller
Casing wear rings
Impeller wear rings
Shaft
Shaft sleeve
Base plate
Gaskets
Fasteners
Companion Flanges
Drive Coupling
Suction Strainer
a) Body
b) Strainer Element
Other functionally important components
TESTS AND INSPECTION
Will all the tests and inspection as detailed in tender be done?
NOZZLE LOADS
The TENDERER shall confirm that the maximum allowable loads
on the pump nozzles shall be twice those specified in API 610
EQUIPMENT AND SERVICES OFFERED

6.1
6.2

Please state whether the following equipment / services as


specified are offered or not. (Yes / No)
Pump as per specifications
Prime mover as specified

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

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
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

Qualification by analysis of equipment covered under this


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)
c) Give details of similar work done by Contractor in the past
d) 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

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
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

Pump Category for Category C or D pumps


(Indicate either Category C or D)
Pump designation
Manufacturers Name
Manufacturer's Model number
No. of pumps offered
Type of pump
No. of Stages
Shaft Orientation
Design Pressure, kg/cm2g
Pressure parts handling the pumped fluid
Other Pressure parts
Design Temperature, 0C
a) Pressure parts handling the pumped fluid
b) Other Pressure parts
Design Code for
a) Pressure parts handling the pumped fluid
b) Other Pressure parts
Capacity of each pump, m3/hr
a) At Rated flow
b) at 120 % Rated flow
Total dynamic head, MLC
a) at Rated Flow
b) at Minimum continuous flow
c) at 120 % Rated flow
Shut off head, MLC
Head rise from Rated point to shutoff, %
Fluid temperature at rated point, 0C

_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
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

Fluid specific gravity at rated point


Pump eff. at Rated flow %
NPSH required, MLC
a) at Rated flow
b) at Minimum continuous flow
c) at 120 % Rated flow
Capacity at Best Eff. Point (BEP), m3/hr
Specific speed at BEP (US units)
Suction specific speed at BEP (US units)
KW required at
a) Rated flow
b) min. cont. flow
c) 120 % Rated flow
Driver
a) Rating, KW
b) Make
c) Model No
Rated Speed, rpm
Recommended minimum continuous flow, m3/hr.
Maximum flow that the pump can handle continuously
without any problem of NPSH or excessive vibration, m3/hr
Capability of pump to operate continuously at any point
between and including minimum flow and 120 % rated flow,
without any problem of NPSH or excessive vibration
Direction of rotation of pump when viewed from driven end
Reverse rotation speed, rpm
a) At Max. possible reverse flow
b) For which pump is designed

_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-B-2 (For category C and D pumps only, to be filled by bidder)
B-2

DESIGN DATA

1.30
1.31

Noise level at 1.0 M from the outline of equipment, dBA


Will the pump rotor / deflection be designed to avoid touching
any stationary part under the most adverse operating
condition?
Radial clearance at wear ring as per API 610 (as new/max.
before replacement), mm/mm
Maximum thrust load in pump with max. size impeller that can
be fitted in the casing, kgf
a) at design internal clearances
b) at twice design int. clearances
Maximum thrust load in pump at twice design internal
clearances when pump is rotating in the reverse direction, kgf
Maximum thrust load carrying capability of the thrust bearing,
kgf
Ratio of max. thrust load possible / thrust load capability of
the thrust bearing
Maximum temperature rise of lubrication oil, 0C
Rated life of anti-friction bearings (not more than 10%
failure), hrs
Max. leak rate through the gland seal, cc/hr
MTBF of gland seal, hrs

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

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
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

a) 1st critical speed at 2 x design clearances


b) 2nd critical speed at 2 x design clearances
Pump rotor wet critical speed, rpm
a) 1st critical speed at 2 x design clearances
b) 2nd critical speed at 2 x design clearances
Driver rotor critical speed, rpm
a) First critical speed
b) Second critical speed
RMS value of velocity on bearing housing of pump & driver,
mm/s
a) At Rated flow
b) At Minimum flow
c) At 120% Rated flow
Vibration levels recommended by contractor (RMS velocity in
mm/s) as
a) Normal Condition
b) Alarm Condition
c) Trip Condition
Lifetime for which the pump & driver unit is designed, years
Closed loop cooling water for the complete pump set
a) Quality
b) Total Hold-up Volume required / Pump set, litres
c) Design Pressure, kg/cm2 g
d) Inlet temperature / outlet temperature at most
adverse condition, 0C / 0C
i.
Diesel Engine
ii.
Any other service (please state)
Is the direction of rotation of the pump matched to that of its

_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
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

Confirm suitable provision for priming of pump is provided.

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

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
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

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
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

dissipation without requiring any external cooling


source described?
Weights
a) Total (dry) weight of pump, kg
b) Total weight of the drive coupling, kg
c) Total weight of prime mover, kg
d) Total weight of the base frame & plate, kg
e) Total weight of complete assembly (dry), kg
f) Total shipping weight of complete assembly (dry), kg
g) Total weight of pump back pull out assembly, kg
h) Total (wet) weight of pump, kg
i) Total weight of complete assembly (wet), kg
Overall Dimensions of complete assembly
a) Length, mm
b) Width, mm
c) Height, mm
Dimensions of the base plate
a) Length, mm
b) Width, mm
c) Height, mm
Height of suction nozzle centre line above bottom of base
plate, mm
Height of discharge nozzle flange face above bottom of base
plate, mm
MATERIAL OF
CONSTRUCTION
(Indicate the complete standard to which it conforms)
Casing including Suction & Discharge Nozzles

_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
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

Gland packing housing


Impeller
Casing wear rings
Impeller wear rings
Shaft
Shaft sleeve
Base plate
Gaskets
Fasteners
Companion Flanges
Drive Coupling
Suction Strainer
a) Body
b) Strainer Element
Other functionally important components
TESTS AND INSPECTION
Will all the tests and inspection as detailed in tender be done?
NOZZLE LOADS
The TENDERER shall confirm that the maximum allowable
loads on the pump nozzles shall be twice those specified in API
610
EQUIPMENT AND SERVICES OFFERED

6.1
6.2
6.3

Please state whether the following equipment / services as


specified are offered or not. (Yes / No)
Pump as per specifications
Prime mover as specified
Qualification by analysis of equipment covered under this

3.14
4.0
5.0

Page 17 of 28
Rev. No. : R0

Bidders Data

_________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
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

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
Data Sheet-B-3 (To be filled by bidder)

Page 19 of 28
Rev. No. : R0

FOR PUMP CATEGORY A,B,C & D


Probabilistic Safety Analysis Input Data : Following data to be submitted
a
b
c
d

Mean time between failures (MTBF) :


Test Frequency
:
Impact of ageing on performance
:
No. of cycles of operation in life time:

Drawings, Curves and Information required with Proposal


The following information shall be submitted with the proposal separately for all type
of Pumps.
2.1

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

Performance curves showing the total pump head, efficiency, power


consumption and NPSH requirement against capacity for the range of zero to
120% of design capacity. Further, these curves shall include the head
capacity characteristics for the largest impeller size that can be fitted inside the
pump casing.

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

Descriptive and illustrative literature, covering the pump construction and


materials.

2.6

Drawings, Data, Instruction Manual, Test Reports etc., Schedule of


Submission
The supplier shall submit various certified drawings and data for review of the
Purchaser and afterwards for final distribution in quantities and in accordance
with the procedure set up in Tendering and Contract conditions, according to
the following schedule in respect of each project.

________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-B-3 (To be filled by bidder)

Description

Page 20 of 28
Rev. No. : R0

Submission for Approval


after the date of
issue of LOI/Purchase Order

(a)

Foundation drawing of all pumps


and equipments furnished under this
specification showing load data
and anchor bolt locations.

(b)

General arrangements drawing


of all pump & equipment offered
indicating principal dimension
and locations of the various
connections, supports etc.

_______ ________ weeks

(c)

Detailed cross sectional


drawing of all the pumps
showing construction details,
material and specification of the
various connection, supports etc..

________ _______ weeks

(d)

Instruction manuals

________ ________ weeks

(e)

Reports of various shop and


material test, performance
test etc.

________ ________ weeks

(f)

Seismic design analysis report ________ ________ weeks


(only for the safety related
pumps, IF SPECIFIED)

(g)

Manufacturing, Inspection
and Test Procedures.
Quality Assurance and
Inspection Plan.

(h)

______

________ weeks

________ _________ weeks


_______ __________ weeks

(i)

Operation & Maintenance


Instruction Manuals for all
the Pumps & Motors.

_______

__________ weeks

(j)

Inspection history document

________ _________ weeks

________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-B-3 (To be filled by bidder)

(k)

2.7

Design calculation of the Equipment ________

Page 21 of 28
Rev. No. : R0

_______ weeks

Time Required by the Supplier


The contractor shall state the period required for the preparation of his
drawings and the time he has allowed for approval of the drawings by the
Purchaser in the delivery period specified.

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

Submission of drawings and documents for approval.

2.10.2
2.10.3

Start manufacture.
Complete manufacture.

2.10.4

Testing at manufacturers works

2.10.5

Complete shipment.

________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-B-3 (To be filled by bidder)

2.10.6

Arrival at site.

3.0

Guarantee period offered

4.0

Quality Assurance Plan (QAP)

Page 22 of 28
Rev. No. : R0

Months

An indicative sample QAP is enclosed in the specification for reference. The


bidder shall enclose along with the bid their quality assurance manual. The
bidder shall also submit detailed quality assurance and inspection plan along
with the bid describing in detail all stages of material control, manufacturing,
inspection and testing as per enclosed tentative QAP.

________________________________________________________________________________________
PP-E-2453
March 2012

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
Data Sheet-B (Indicative QAP)

Page 23 of 28
Rev. No. : R0

SAMPLE QUALITY ASSURANCE PLAN FOR CENTRIFUGAL PUMPS

1. SCOPE AND PURPOSE:


The purpose of this sample Quality Assurance Plan is to describe general practices and sequences of activities (such as inspection, testing, control,
etc..) to be performed during the manufacture of the equipment. This is a sample QAP and should be tailored by suitable modifications keeping in
mind the tender specification requirements, codes, standards and vendor/sub-vendor good practices.
2. ABBREVIATIONS AND DEFINITIONS:
P PERFORMED BY

W WITNESSED BY

R REVIEWED BY

1 NPC / NPC APPROVED THIRD PARTY INSPECTION AGENCY

2 VENDOR QC

3 EXTERNAL LABORATORY OR SUB VENDOR.

WHEREVER CHP IS MENTIONED, IT IS A CUSTOMER HOLD POINT.


CLASS OF CHECK:
MINOR -

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

Nuclear Power Corporation of India Limited

(A Government of India Enterprise)


Page 24 of 28

Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe
Data Sheet-B (Indicative QAP)

Rev. No. : R0

SAMPLE QUALITY ASSURANCE PLAN FOR CENTRIFUGAL PUMPS


SL.
No

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

One per heat

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

One Per Heat &


Heat Treatment
lot
100%

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

Nuclear Power Corporation of India Limited

(A Government of India Enterprise)


Page 25 of 28

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

One Per Heat

Approved
Specification

Major

Procedure/Re
port review

100%

Approved
Specification

Mech.
Properties

Major

Physical

Approved
Specification

LPE

Major

NDE

One Per Heat &


Heat Treatment
lot
100%

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

100% (On semifinished parts)


100%

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

For Shaft, Shaft


Sleeves & other
machined
surfaces of
forgings only

________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

Nuclear Power Corporation of India Limited

(A Government of India Enterprise)


Page 26 of 28

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

For Shaft, Shaft


Sleeves,
machined
surfaces of
Casing & other
machined
surfaces only

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

For all Austenitic


SS parts

________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

Nuclear Power Corporation of India Limited

(A Government of India Enterprise)


Page 27 of 28

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

Refer QAP for


Prime Mover

________________________________________________________________________________________________________________________________________________________
PP-E-2453
March 2012

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
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

You might also like