Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal

Emergency Pump for 220 & 540 MWe Page 1 of 20 Rev. No. : R0

1.0

SCOPE This specification is intended to cover the design, engineering. material, fabrication, manufacture, inspection, testing, packing and delivery at site, erection and commissioning of the diesel engine driven Horizontal Centrifugal Water Pumps complete with accessories and auxiliaries mounted on trolley 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 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

3.0

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.

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Page 2 of 20 Rev. No. : R0

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

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. 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. 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. The equipment shall be designed to permit interchangeability of parts and ease of access during inspection, maintenance and repair. The wearing parts shall be so designed that they can be easily replaced. Wearing ring clearances shall be as per API 610. 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.

(b)

(d)

(e)

(f)

(g)

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Page 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. All materials used shall conform to specifications and shall be new in all respects. 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. 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. 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. The bidder shall indicate minimum NPSH required in his offer. The rotor assembly including impeller, shaft etc shall be statically and dynamically balanced. 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. 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

(i)

(j)

(k)

(l)

(m)

(n)
(o)

(q)

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Page 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. 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. Only hexagonal nuts shall be used for holding the equipment. All bolt holes shall be spot faced for washers. 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.

(s)

(t)

(t)

5.0 5.1

SPECIAL FEATURES Design Features The pumps shall have stable, rising characteristic (H vs. Q) from maximum flow to zero-flow (shut-off head) condition. There shall no inflection point at any partial load in the head capacity curve. The best efficiency point (BEP) shall occur as near the specified capacity as possible. Stability of hydraulic performance shall be guaranteed over the entire operating

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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.
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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Page 6 of 20 Rev. No. : R0

5.3

Materials of Construction The pumps shall be of standard fitted construction as indicated in respective data sheet. The material for the various parts of all the pumps shall conform to the specifications or equivalent indicated in the data sheet. Compatible materials shall be used for other components. Material of construction (MOC) not specified in the data sheet for items like bearing cover, bearing housing, lantern ring etc. shall be either same or superior to the material of the casing specified in the data sheet. The tenderer may quote /offer pumps with other material superior than those specified under specification / data sheet but which is considered satisfactory by him for the intended service.

Pump Components (a) Casing The casing shall be cast, free from blow holes, sand inclusions and other detrimental defects. The casing shall be equipped with replaceable wearing rings on suction side of impellers. Liquid passage shall be smooth finished or enameled. The casing shall be designed considering maximum suction head plus shut off head. The casing shall be so proportioned that the velocity of liquid is gradually reduced and converted into pressure with minimum of friction and wear. Suitable valved opening shall be provided for venting the high points of the casings and low points for draining. Insulation cleats shall be provided for high temperature pumps. Drain / vent valves should be of flanged end connection.

(b)

Impeller The impeller shall be of the semi-open or closed type as specified in Data sheet and shall be both statically and dynamically balanced to ensure vibration free operation. The rotor assembly shall be statically and dynamically balanced. The flexible rotating assembly balancing shall be done at rated speed and for rigid rotating assembly balancing may be done at reduced speed. The complete coupling assembly shall also be dynamically balanced. The impeller shall be properly machined, with liquid passages hand-finished for best radial balance loads.

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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.

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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
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concrete slab.

(k)

Nozzles & piping Pump suctions and discharge nozzles shall be provided with flanged connections, drilled as specified in Data Sheet. Pump suction and discharge nozzle orientation should match 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.

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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. 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. 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. 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.

5.5

B.

C.

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6.0

WATER QUALITY The expected quality of raw water or dematerialized water to be handled by pumps is given in the respective data/ specification sheets.

7.0

PUMP DRIVE All pumps are to be driven by diesel engine. The specific requirements for the diesel engine drive for each type of pump shall be as per respective Technical specification and Data Sheets of Diesel Engine. The bidder however shall furnish all necessary technical particulars for the diesel engine as called for in specification and data sheet of diesel engine separately. The make of diesel engine shall be from NPC approved vendor list.

8.0 8.1

INSPECTION AND TESTING AT MANUFACTURES WORKS The Supplier shall carry out inspection to establish and maintain quality of workmanship in his works and that of his sub-contractors to ensure the mechanical accuracy of components, compliance with drawings, identity and acceptability of all materials, parts and equipment. He shall conduct all tests required to ensure that the equipment and material furnished shall conform to the requirements of the applicable codes. All test and test procedure proposed by the manufacturer shall be notified well in advance of the fabrication and major shop test of the equipment for the purpose of making general inspections and for the progress report. The Purchasers representative shall be given full access to the shop in which the equipment is being manufactured or tested and all test records shall be made available to him. The equipment covered under this specification shall not be despatched unless the same has been finally inspected and tested successfully and shipping release issued by the Purchaser. All the instruments used for conducting the specified shop tests shall be calibrated and calibration certificates furnished from a recognized institution. The calibration shall have been carried out not more than six months prior to the testing date. Pressures gauges shall be calibrated before and also after tests. Final routine and type test for the complete units shall be carried out in the presence of Purchasers representative.

8.2

All materials used for the fabrication of the pump components shall be of tested quality. Physical and chemical test certificates for the materials of various components shall be furnished, for purchaser's approval. Laddle analysis for the castings shall be sent to the purchaser for his approval. Physical testing of the bars of casting shall be done in the presence of purchaser and/or his representative as per approved QAP.

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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. Chemical analysis, Physical and hardness.

(b)

Wearing rings, bushings, sleeves :

(c) 8.3 8.3.1

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

Castings All casting materials shall conform to the relevant material specifications. All tests as called for in relevant material standards shall be carried out. 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. 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. 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. Pump components shall be subject to non-destructive tests as specified in the Data Sheets, and in accordance with relevant Standards.

8.3.2

8.3.3

8.3.4

8.3.5

a)

Magnetic Magnetic castings shall be examined by magnetic particle inspection as specified in the Data Sheets. The basis for acceptance shall be in accordance with Data Sheets. The requirements of ASME Section-VIII Div.I or ASME section III NC , whichever is applicable, mandatory appendices shall be the minimum requirements.

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b)

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 8.4.1

Shafts and Forgings 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 8.4.2.1

Forgings 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. 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

8.4.2.2

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test. 8.4.2.3 Any defect that will not machine out during the final machining, will be gouged out fully, inspected by dye penetrant and/or magnetic particle inspection 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 8.5.1

Fabricated Component 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. Weldments All welding shall be performed in accordance with ASME Section IX Code. 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. All welding shall be done by qualified welders only. 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. Any procedure for the repair of defects in weldments shall be submitted to the Purchaser for his approval prior to any repair being done. 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. All other pressure parts including inter-connecting and auxiliary piping will also be similarly hydrostatically tested. Visual Inspection All pumps shall be offered for PURCHASER'S visual inspection before

8.6 8.6.1 8.6.2

8.6.3 8.6.4

8.6.5

8.7

8.8

8.9

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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 9.1 9.1.1

TESTS Shop Tests 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 9.2.1

Performance Test 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. 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.

9.2.2

9.2.3

Diesel engine shall be tested in accordance with governing specification.

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9.2.4

Job-pump-coupling-engine assembly, one from each category pump as specified in datasheet-A, mounted on job base plate along with its accessories and auxiliaries shall be continuously run at the rated point for four hours 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. 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.

9.3

10.0

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

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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 12.1

SPARE PARTS Following minimum Essential Spare parts (or as specified in data sheet / tender specification) shall be furnished by the supplier for each type of pumps and drives. The supplier may also recommend spare parts, other than listed below, if necessary. For each type of Horizontal Pump (One set mentioned below means the total quantity of that item required for one pump) Impeller (1No) -

Shaft sleeves (2 Sets) Shaft with keys and circlips (1 No.)

Coupling (1 Set) Casing wearing rings (2 Sets) Mechanical seal assembly (if specified) (2 Sets) Stuffing box packing - if specified (2 Sets)

Gaskets (2 Sets)

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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 13.1

SPECIAL CLEANING, PROTECTION AND PAINTING 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. 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. 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. All parts shall be properly boxed, created or otherwise protected for preventing any possible damage during transportation. Flanges shall be drilled as per the

13.2

13.3

13.4

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Page 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. SHIPMENT 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. 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. Openings of all instruments shall be plugged with suitable plastic caps to prevent the ingress of dust and moisture. No equipment shall be despatched unless the shipping release is issued by the Purchaser. DATA / DRAWINGS TO BE SUBMITTED BY THE VENDOR ALONG WITH THE BID (a) (b) 16.0 Any data of Data Sheet-A - which is vendor specific. All Data, Drawings and Catalogues as called for in Data Sheet-B.

14.0 14.1

14.2

14.3

14.4

15.0

INSPECTION HISTORY DOCUMENT / DOCUMENTS TO BE SUBMITTED AFTER PLACEMENT OF ORDER / AT FINAL STAGE The supplier shall be required to submit the following documents within one month after despatch of equipment (a) Final Drawings (i) Final overall dimensional drawings for the pump engine set , trolley giving dimensions, loads, weights etc. and details of items not reflected in construction drawings and foundation drawing.

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Page 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. Foundation drawings indicating details of pockets for foundation bolts, grouting allowance, total weight, plinth size etc. Tested Performance Curves.

(iii)

(iv) (b)

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) (d)

Five hard and soft copies / sets of Operation and Maintenance Manuals. Reproducibles for each of the drawings, and drawings on magnetic media preferably on CD (Five nos of hard and soft copies) Five hard and soft copies of Final Approved drawings submitted during execution of Contract. Five hard and soft copies of approved Seismic Qualification Reports, if applicable.

(e)

(f)

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-A

Page 1 of 15 Rev. No. : R0

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

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)

8 9

Applicable NPCIL Specification/s Design Standard Design Pressure, kg/cm2(g) Design Temperature, C Drive 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

10 11 12 B. 1 2 3 4 4.1 4.2 5 6 7 8 8.1 8.2 8.3 9

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-

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-A

Page 2 of 15 Rev. No. : R0

Sr. No.

Item

Description overloading with increase in flow. 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 < 500 < 0.2 at 25 0C 9 to 10 at 25 0C 160 0C at saturation pressure < 5 ppb 10 ppb (max.) 5 ppb (max.) 20 ppb (max.)

10

Operation requirement

C. 1.

LIQUID DATA Liquid Handled

2. 3. 4. 5. 6. 7. 8. 9. 10.

Specific Gravity

Ph Total Suspended Solids, ppm Total Dissolved Solids (max), ppm Chlorides (CaCO3), ppm Total Hardness Max. Particle Size, mm Water temperature o C

7.1 to 8.4 50 to 100 500 < 40 100-300 ppm as CaCO3 <5 Ambient

11.

D. 1 2 3 4 5 6 7

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

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-A

Page 3 of 15 Rev. No. : R0

Sr. No. 8 9 10 a. b. c. d. e. 11.

Item Shaft Sealing Arrangement Axial thrust balancing Nozzle Details Nozzle Connection Type Flange Drilling Standard Nozzle Orientation Suction Nozzle Connection pipe Size Discharge Nozzle Connection pipe Size Noise level

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

12. E. 1

2 3 4

5 6 7 8 9 10 11 12 13 14

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

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-A

Page 4 of 15 Rev. No. : R0

Sr. No. 15 16 17 18

Item Lifting Lugs Earthing Cleat Special erection & maintenance tools & tackles Reducer and Expander to suit suction and discharge pipe

Description Yes Yes Yes Yes, if required, it shall consist of counter flanges with reducer or expander along with 100 mm straight pipe piece. Yes, on-off type if required.

19 20.

Minimum flow cum non return valve Trolley for mounting engine, pump and all accessories

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

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

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-A

Page 5 of 15 Rev. No. : R0

Sr. No. 1 2 3 I 1 a b c 2

Item Stage Inspection by Purchaser Material Testing & Identification Strip down examination

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

b c

a b c

a b c

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 iii) 2.5 mm flat bottom hole for 80 < D 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

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-A

Page 6 of 15 Rev. No. : R0

Sr. No.

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 2 kg/cm (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%) 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.

Item

K 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
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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-A

Page 7 of 15 Rev. No. : R0

Sr. No. parts.

Item

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.

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump 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 Category 1. Rajasthan Atomic Power Station-2 A Quantity 1 It will be used to transfer feed water from deaerator to SGs during SBO. It will be used to transfer raw water to Calandria / SGs during BDBA/ SBO. 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. 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. It will be used to transfer raw water to Calandria / SGs during BDBA/ SBO. It will be used to transfer raw water to Calandria / SGs during BDBA/ SBO. It will be used to transfer raw water to Calandria / SGs during BDBA/ SBO. Remark

1*

2. Madras Atomic Power Station-1&2

1*

3. Narora Atomic Power Station-1&2

2*

4. Kakrapar Atomic Power Station-1&2

2*

5. Kaiga Generating Station-1&2

2*

6. Rajasthan Atomic Power Station-3&4

2*

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump 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. Station
Kaiga Generating Station-3&4

Requirement of centrifugal pumps C 2*

Remark
It will be used to transfer raw water to Calandria / SGs during BDBA/ SBO.

8.

Tarapur Atomic Power Station3&4

It will be used to transfer feed water from EFWST / deaerator to SGs during SBO.
It will be used to transfer raw water to Calandria / SGs during BDBA/ SBO. It will be used to transfer raw water to Calandria / SGs during BDBA/ SBO.

1*

9.

Rajasthan Atomic Power Station-5&6 Category-A Category-B Category-C Category-D

2*

10. Total Quantity required

5 2 12* 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 1 Pump Make (only API 610 models acceptable) KSB, Pune; Kirloskar Ebara make of KBL, Pune; BPCL, Allahabad; Flowserve.

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe 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. Cross-sectional drawing indicating the assembly of the pumps and their major parts, along with material specification. 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. Description of the standard shop inspection and quality control procedure of the manufacturer. Description of the pump performance test rig at the shop. Descriptive and illustrative literature, covering the pump construction and materials. 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.

2.2

2.3

2.4

2.5

2.6

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-B-3 (To be filled by bidder) Page 20 of 28 Rev. No. : R0

Description

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. General arrangements drawing of all pump & equipment offered indicating principal dimension and locations of the various connections, supports etc. Detailed cross sectional drawing of all the pumps showing construction details, material and specification of the various connection, supports etc.. Instruction manuals Reports of various shop and material test, performance test etc.

______

________ weeks

(b)

_______ ________ weeks

(c)

________ _______ weeks

(d) (e)

________ ________ weeks ________ ________ weeks

(f)

Seismic design analysis report ________ ________ weeks (only for the safety related pumps, IF SPECIFIED)

(g) (h)

Manufacturing, Inspection and Test Procedures. Quality Assurance and Inspection Plan. Operation & Maintenance Instruction Manuals for all the Pumps & Motors. Inspection history document

________ _________ weeks _______ __________ weeks

(i)

_______

__________ weeks

(j)

________ _________ weeks

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-B-3 (To be filled by bidder) Page 21 of 28 Rev. No. : R0

(k)

Design calculation of the Equipment ________

_______ weeks

2.7

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 2.8.1

Proof of Ability 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 If the proposal has got any deviation from the technical specification, the tendering conditions and the general condition of contract, tenderers shall tabulate those deviations here and sign below. More sheets should be attached if required. In absence of this it will be presumed that the offer is strictly in accordance with this specification. Manufacturing and Delivery Schedule Time in weeks from the Date of Issue of Purchase Order/ LOI 2.10.1 2.10.2 2.10.3 2.10.4 2.10.5 Submission of drawings and documents for approval. Start manufacture. Complete manufacture. Testing at manufacturers works Complete shipment.

2.10

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Nuclear Power Corporation of India Limited (A Government of India Enterprise) Technical Specification on Diesel engine operated Horizontal Centrifugal Emergency Pump for 220 & 540 MWe Data Sheet-B-3 (To be filled by bidder) Page 22 of 28 Rev. No. : R0

2.10.6 3.0

Arrival at site. Guarantee period offered Months

4.0

Quality Assurance Plan (QAP) 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.

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