TECHNICAL SPECIFICATION FOR

CANNED MOTOR CENTRIFUGAL PUMP UNIT

CONTENTS

SECTION A: TECHNICAL SPECIFICATION FOR PUMP

Clause

no.

Item Page

no.

1 SCOPE OF SUPPLY 1

2 APPLICABLE CODES, PUBLICATIONS AND STANDARDS 1

3 DESIGN & CONSTRUCTION REQUIREMENTS 3

4 MATERIALS AND WORKMANSHIP 8

5 EXAMINATION- INSPECTION & TESTING 9

6 PUMP PERFORMANCE TESTS 12

7 EXAMINATION OF PRODUCT 13

8 SPARE PARTS 13

9 MAINTENANCE TOOLS 13

10 GUARANTEE 13

11 PREPRATION FOR SHIPMENT 13

12 INFORMATION REQUIRED WITH BID 14

13 INFORMATION REQUIRED AFTER THE PLACEMENT OF ORDER 15

14 SUB-CONTRACT 15

15 HISTORY DOCKET REQUIREMENTS 16

16 DELIVERY 16

ANNEXURE-1: SALIENT TECHNICAL DATASHEET OF PUMP 17

ANNEXURE-2 : RESPONSE SPECTRA AND DAMPING COEFFICIENT

FOR SEISMIC DESIGN OF PUMP-MOTOR UNIT 19

ANNEXURE-3 : TECHNICAL DATASHEET TO BE FILLED BY VENDOR

(FOR PUMP)

20

SECTION B: GENERAL REQUIREMENTS FOR MOTORS

1 SCOPE 24

2 APPLICABLE STANDARDS 24

3 OPERATING CONDITIONS 24

4 DESIGN REQUIREMENTS 25

5 PERFORMANCE REQUIREMENTS 28

6 PAINTING AND FINISH 29

7 INSPECTION & TESTING 29

8 GURANTEE 30

9 INSTRUCTION MANUALS 30

10 DATA TO BE FURNISHED WITH TENDER 30

ANNEXURE-4: SALEINT REQUIREMENT FOR MOTOR 31

ANNEXURE-5: MOTOR DATASHEET TO BE FILLED BY MOTOR

MANUFACTURER AND SUBMITTED THROUGH PUMP

MANUFACTURER

33

1

SECTION A: TECHNICAL SPECIFICATION FOR PUMP

1. SCOPE OF SUPPLY

1.1 This specification establishes the technical requirements for a Canned Motor Centrifugal

Pump unit. The scope of supply includes design, materials of construction of various

parts, manufacture, inspection and testing, packing, and delivery at Reactor Group

stores, BARC along with final documents & guarantee certificate of Canned Motor

Centrifugal pump.

1.2 Quantity : 1 no.

1.3 It is not the intent to specify completely herein all details of design and construction of

the equipment. However, the equipment shall conform, in all respects, to high standards

of engineering design and workmanship and be capable of performing continuous

operation up to vendor's guarantee in a manner acceptable to the purchaser who

will interpret the meaning of specifications and shall have the right to reject any work or

materials which, in his judgment, are not in full accordance therewith.

1.4 Canned Motor Centrifugal Pump Unit supplied under this specification shall include but

not be limited to the following to make the equipment complete.

o Canned Motor Pump unit

o Counter fittings along with spool piece to match with tube size

o Foundation bolts, nuts, base frame,

o Recommended spare parts and maintenance tools

1.5 Only manufacturers of Canned Motor Centrifugal Pumps and having previous

experience in design & manufacturing for high pressure (above 160 bar) &

temperature (above 300 °C) shall quote. The manufacturer shall also have

experience of design, testing & qualification of pump as per the requirement of

ASME Section III.

1.6 The general requirement of motor is mentioned in SECTION B.

2. APPLICABLE CODES, PUBLICATIONS AND STANDARDS

2.1 The pump along with its drive motor and their accessories shall comply with the latest

edition of applicable codes/standards. The following publications shall be applicable to

the extent specified herein. In the event of any conflict between the requirements of

this specification and the publication given below, the requirements of this specification

shall govern.

2.2 American Society of Mechanical Engineers (ASME) Boiler and Pressure vessels codes

2

ASME Section III,

Division 1, Subsection

NC

Rules for construction of nuclear facility components

(Class 2 components)

ASME Section II Material Specification Part-A, Part-B, Part-C & Part-D

ASME Section V Non Destructive Examination

ASME Section IX Welding & Brazing qualification

ASME PTC 8.2 Performance Test Code for Centrifugal Pumps.

ASME SA-388 Specification for ultrasonic testing of heavy steel

forgings.

2.3 American National Standard Institute (ANSI)

ANSI B-16.5 Steel Pipe Flanges & Flanged Fittings

ANSI B-16.25 Butt welding ends

ANSI/HI ANSI-Hydraulic Institute Pump Standard

ANSI B1.1 Unified Inch Screw Threads

ANSI B1.13M Metric Screw thread: M profile

2.4 American Society for Testing & Materials (ASTM)

ASTM E-446 Standard reference radiograph for steel castings up to 2

inch thickness.

ASTM E - 71 Industrial Radiographic Standards for steel castings.

ASTM E - 94 Radiographic testing

ASTM E - 142 Method for controlling quality of radiographic testing

ASTM A-262 Standard practice for checking IGC on Austenitic S.S

ASTM E-165 Liquid Penetrant Inspection Method

ASTM A-193 Alloy Steel and Stainless Steel Bolting Materials for

High-Temperature Service.

ASTM A-194 Carbon and Alloy Steel Nuts for Bolts for High-

Pressure and High-Temperature Service.

ASTM A-351 Austenitic Steel Castings for High-Temperature

Services.

ASTM A-216 Specification for steel castings, carbon, suitable for

fusion welding for high temperature service

ASTM A-380 Standard recommended practice for cleaning and

descaling stainless steel parts, equipment and system

ASTM A-182 Specification for forged or rolled alloy steel pipe

flanges, forged fittings and valves and parts for high

temperature service

ASTM A-388 Standard practice for ultrasonic examination of heavy

steel forgings.

ASTM A-745 Standard practice for ultrasonic examination of

austenitic steel forgings.

3

2.5 American Petroleum Institute (API)

API 685 Seal less Centrifugal Pumps for Petroleum, Heavy Duty

Chemicals and Gas Industry service

2.6 Bureau of Indian Standard (BIS)

BIS - 4218 ISO - Metric screw threads.

BIS -325 Specification for three phase induction motors

BIS-13947 : Part-I Degree of protection by enclosures for low voltage

switchgear and control gear

2.7 International Organization for Standardization (ISO)

ISO- 2372 Mechanical vibration of machines with operating speed

from 600 to 12000 RPM.

ISO-1940 Mechanical vibration-Balance quality requirements for

rotors in a constant (rigid) state.

ISO-10816-7 Mechanical vibration: Evaluation of mechanical

vibration by measurement of non rotating part.

Rotodynamic pumps for industrial applications,

including measurements on rotating shafts.

2.8 Institute of Electrical and Electronics Engineer (IEEE)

IEEE-344 Recommended practice for seismic qualification of

class 1E equipment for nuclear power generating

stations.

IEEE-252 Test procedure for polyphase induction motors having

liquid in the magnetic gap

3. DESIGN & CONSTRUCTION REQUIREMENTS

3.1 Application: The pump will be used for recirculation of Demineralized Water in the

High pressure & High temperature Prototype Experimental Loop. The operation of loop

can be continuous over the several months or intermittent (as and when required) based

on the experimentation needs. The various components of Pump and Experimental loop

are mainly Stainless Steel 316L. Experimental Loop requires pump to develop high

head at lower flow condition at duty point.

4

3.2 The vendor may use multiple impellers in series (multi stage pump) in order to meet the

high duty point head requirement at low duty point flow condition.

3.3 Design temperature and pressure of the pump is 360 °C and 220 bar(g) respectively.

Other salient technical requirements for pump are mentioned in Annexure-1.

3.4 The mechanical design of pump shall be as per ASME Section III, Division 1,

Subsection NC.

3.5 The pumps shall be horizontal, centrifugal with end suction and vertical upward

discharge and electrically driven type. Nominal speed of Pump shall be 2900 rpm.

3.6 The design and construction of pump-motor unit shall be suitable to take care of all

aspects like balancing, misalignment, vibration, starting torque requirement etc. The

design and construction shall be approved by the purchaser. Design report including

stress analysis with all loading conditions & load combinations shall be submitted to

purchaser for approval. The bid shall clearly indicate that they agree to comply with

the requirement of supply of Design report including stress analysis with all load

combination for the approval of purchaser after the placement of purchase order.

3.7 NPSH available for pump is greater than 10 m for duty point condition.

3.8 The drawings giving overall dimensions of the complete pump-motor assembly

with foundation and base plate details must be submitted by the bidder for pump-

Motor unit along with the quotation/bid to facilitate the technical evaluation.

3.9 The Pump-Motor unit will be located in an area where ambient temperature will be

between 10 to 50 oC. The units shall be suitable for the above service conditions.

3.10 The Pump-Motor unit shall be designed with regard to ease of maintenance, inspection

and repair. The design shall be such that any maintenance required can be performed by

persons with the skills that are normally available in power plants. The design of the

pump and motor shall be such that maintenance is not normally required more

frequently than once in every three years and preferably not more frequently than once

in every five years.

3.11 All pump components, with the exception of bearings and parts specifically designed for

easy replacement, shall be suitable for a minimum of 20 years continuous duty

operation.

3.12 The pump drive motor shall follow the requirements given in the specification for

motors, which are enclosed herein (Section-B). Supply voltage should be 3 phase 415 V.

3.13 Instruments

The pump-motor unit shall be provided with at least but not limited to following

instruments for safe and satisfactory operation of the pump-motor unit

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A) Bearing wear monitor indicator is to be provided to monitor the bearing condition.

This shall give signal for replacement of bearing before excessive damage.

B)Thermostat on stator winding for protection against overheating.

3.14 External Nozzles forces & moments

The pump shall withstand and be capable of satisfactory operation when subjected to the

forces and moments mentioned in API 685 corresponding to suction and discharge size

of the pump volute. To minimize the misalignment of the pump and the driver shaft due

to piping load effects, the pump and its base plate shall be constructed with sufficient

structural stiffness to limit the displacement of the pump shaft at the driven end of the

shaft. The pump supports shall be capable of accommodating the external loads without

sustaining any significant displacements that would cause unacceptable misalignment of

rotating parts.

3.15 Seismic Design Criteria

The pump-motor unit as well as the supporting structure shall be designed to endure

the loads generated due to Design Basis Earthquake (DBE) along with other loads viz.

load during design, normal operation, hydrodynamic load and other applicable loads etc.

as per the requirements of ASME Section-III, Division-1, Subsection-NC and NF. The

nozzle loads due to connected piping shall also be considered while performing Finite

Element analysis.

The seismic qualification for structural integrity of pressure boundary and support

structure shall be assessed by performing detailed finite element analysis. To qualify

for DBE, the response spectrum analysis shall be performed for determining the seismic

response in various elements of pump-motor unit (including flywheel) subjected to

simultaneous action of three components of earthquake. The design basis earthquake

load shall be considered in level-C of service loading.

The combined stresses in individual components / elements such as pump casing, base

frame, mounting bolts of pump casing to base frame, flange connecting bolts etc. shall

be within the allowable stresses for design, service level-A, service level-C loading of

ASME Section-III, Division-1, Subsection-NC and NF. The response spectra and

damping values for seismic design are attached as Annexure-2.

The pump-motor unit shall be qualified for seismic by analysis

3.16 Pump operation

3.16.1 The rating of the motor shall be suitable to drive the pump for the entire range of flow

up to 120% of duty point flow while operating with high pressure and temperature DM

water specific gravity 1.0.

3.16.2 Performance

The pump should have a continuously dropping characteristic such that the head

decreases with increasing capacity. It shall be stable when operating alone or in parallel

with other similar pumps. The rise of total head from rated flow to shut off head at rated

speed shall be as high as possible. The upper limit shall be specified by manufacturer

and shall be compatible with design pressure.

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3.16.3 The Operating conditions and Design conditions for pump-motor unit is given in the

Annexure-1.

3.17 Detailed requirement

3.17.1 The pump-motor unit shall be suitable for indoor installation/operation.

3.17.2 The impeller shall be securely keyed to the shaft. Means shall be provided to prevent

loosening of impeller during operation including rotation in reverse direction.

3.17.3 The impeller shall be of non-overloading type. The impeller shall be fully

enclosed/semi enclosed type and constructed as single piece casting. Fabricated

impeller is not acceptable.

3.17.4 The pump casing shall be of robust construction. All liquid passages in the casing shall

be finished smooth.

3.17.5 Casing and its nozzles shall withstand usual moments and thrust. The maximum value

of moments and forces in all directions that the casing can withstand shall be indicated.

However, the values shall not be less than that mentioned in API 685 Clause

corresponding to suction and discharge nozzle size.

3.17.6 Suitable base plate shall be provided for pump-motor unit. Suitable holes shall be

provided for grouting and they shall be so located that the base can be grouted in place

without disturbing the pump-motor unit.

3.17.7 The size of tube where pump is connected is of 3/4 inch. outside diameter with 0.109

inch. thickness. Along with Counter fitting, the vendor shall provide suitable spool piece

to connect the Pump with the tube. If flanged type counter connection, then it shall be

Weld neck type with relevant ASTM standard. only. The arrangement and material of

the counter fittings and spool piece shall be approved by the purchaser.

3.17.8 The bearings shall be lubricated with pumped liquid (Water) itself i.e. no external

lubrication shall be required. It shall permit easy removal and replacement. Provision for

continuous venting shall be made to avoid dry running of bearing. The rated life of the

bearings shall be guaranteed to be not less than 30,000 hours of operation. The vendor

shall also furnish the relevant details regarding the bearings used in the pump-motor

and indicate the expected life.

3.17.9 Mating components of same materials of construction shall have adequate

hardness difference and the replaceable component shall preferably have lower

hardness than the non replaceable component.

3.17.10 The shaft shall be finished smooth and surface finish shall be indicated.

3.17.11 All the surfaces coming in contact with the liquid pumped shall be made smooth.

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3.17.12 All welds and weld repairs subjected to hydrostatic pressure shall be made in

accordance with ASME section- III, Divison 1, Subsection NC

3.17.13 Examination of the cast pressure retaining materials shall be carried out as per

the requirements of ASME Section III, Division 1, NC-2570. However, additional

examination as mentioned in Clause no. 5 shall also be carried out.

3.17.14 Shaft

Design shall be such that the fatigue strength of the shaft is not reduced by notches and

surface finish shall be 3.2 micron Ra or better.

3.17.15 Balance and vibration

The first critical speed of the complete rotating assembly shall be not less than 130%

of rated speed. The unit shall be mechanically and hydraulically balanced so that

the maximum value of vibration of the pump-motor unit, while the unit is operating

at rated conditions, shall be well within zone B of the applicable class of

machine as per ISO 10816-7. Pressure pulsation or vibrations in the pumped fluid

shall not cause excessive or undue vibrations of the connected piping and equipment.

Dynamic balancing of the rotating assembly shall be carried out as per approved

procedure. The rotating part pump-motor unit shall confirm to balance quality grade

G2.5 as per ISO 1940. The procedure shall conform to ISO-1940, "Balance quality of

rotating rigid bodies."

3.17.16 Pump-Motor unit Base

The pump-motor unit base shall be of sturdy construction to withstand the weight

of the complete pump-motor unit, vibration loads, earth quake load as well as normal

piping loads. The final foundation details shall be worked out by the vendor in

consultation with the purchaser.

3.17.17 Draining and venting

Vent and drain connections shall be provided and arranged so that all spaces

normally filled with the pumped liquid can be completely drained before the pump is

opened for maintenance and similarly while filling, no air pockets are left.

3.17.18 Auxiliary connections and piping

All nozzles for auxiliary connections e.g. drain & vent shall be welded to the pump

body, the details of which shall be subject to purchaser's approval. All tapping

connections shall be brought out to accessible locations and shall be terminated with

S.S. 316L gate valve. The free end of each valve shall have NPT threads and closed

with a threaded S.S. plug.

3.17.19 Threaded fasteners

Threads on screws, studs, bolts and nuts shall conform to metric system. All fasteners

shall be provided with corrosion resistant positive locking devices, to prevent

loosening. Frictional locking device shall not be used. Threads on all screws, studs,

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bolts and nuts shall confirm to ANSI B1.1 or ANSI B 1.13M standard.

3.17.20 Surface condition and finish

All fluid passages shall have a good surface finish. The internal and external surface of

cast pressure bearing components and welds shall have a surface finish of 10 microns

RMS or better.

The local surface discontinuities which results because of defects which are acceptable

under Inspection/testing clause (Clause no. 5) are acceptable notwithstanding the above

surface finish requirements.

3.17.21 Cleaning

Cleaning of parts shall be carried out in accordance with ASTM A380. All inside

surfaces shall be degreased and then flushed with clean water. The de-greasing agent

and water used for cleaning shall not contain more than 25 ppm sulphur and halogen.

Surfaces shall be visibly clean and there shall be no discoloration or evidence of oil,

grease, dirt etc.

3.17.22 Handling

Pump-motor unit shall be provided with suitable lifting lugs or eye bolts for handling.

3.17.23 Identification

The pump-motor unit shall be provided with a corrosion resistant identification tag.

This tag shall be attached to the pump by corrosion resistant tagging wires.

4. MATERIALS AND WORKMANSHIP

4.1 The material of construction of different parts of pumps shall be as per following

Casing ASTM A-182 Grade F CF3M (SS 316L)

(Preferred) or

/ASTM A-351 Grade CF3M (SS 316L)

Impeller ASTM A-351 Grade CF3M (SS 316L)

Shaft ASTM A-182 Grade F CF3M (SS 316L)

Stator and Rotor CAN ASTM B 575 (N10276) Hastelloy C276

Auxiliary piping Stainless steel compatible with pump MOC

Counter fitting along with spool piece Stainless steel 316L

Base Plate IS 2062

4.2 The cobalt content in all wetted parts (In contact with circulating Fluid) shall be less than

0.1 % by weight.

4.3 Materials and standard parts which are not specifically described herein and which are

necessary for the fulfillment of this specification shall be of good quality and in

accordance with the best practice, adequate to ensure satisfactory operation, service life

and ease of maintenance in accordance with the provision of this specification.

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4.4 Other material of construction of other wetted parts shall be Stainless Steel or other

corrosion resistant material for high pressure and temperature service.

4.5 Bolting materials shall not gall.

4.6 The materials of construction as indicated in this specification are the minimum

acceptable. The vendor may offer equivalent or better materials provided each material is

approved by the purchaser.

4.7 Materials shall be tested/inspected in accordance with Inspection & testing mentioned in

this specification and the relevant ASTM material specification and shall meet all the

requirements stated therein.

4.8 Heat treatment of castings, forgings and other parts shall be carried out as per

requirements of materials specifications using calibrated furnace.

5. EXAMINATION- INSPECTION & TESTING

5.1 General

The vendor shall be responsible for and shall provide and perform the examination,

inspection and testing in accordance with the requirements of ASME Section III, Sub-

section NC, ASME Section V and test mentioned in relevant ASTM standard which are

specified herein.

All products shall be carefully examined during manufacture and after completion to

determine their conformance with this specification with respect to material,

workmanship, finishing, marking and dimensions and to assess their conformance with

other requirements stated or reasonably implied and not covered by specific test.

The vendor shall submit a detailed QAP for the approval of the purchaser before

commencement of manufacture.

Examination, inspection and testing shall be conducted in a manner satisfactory to and

shall be subject to approval by purchaser. Inspection and test reports shall be submitted by

the contractor to the purchaser for approval.

The purchaser or his authorized representative shall have access to the contractor's

premises at all reasonable times to the extent necessary to assess compliance with the

provisions of this specification. The purchaser shall also have the right to conduct at his

own expense any additional inspection or testing.

All the inspection/testing specified herein unless otherwise specified shall be witnessed by

the purchaser/his authorized representative. The calibration certificate shall be provided

before the inspection visits. Purchaser/ Inspector may witness the calibration of important

instruments

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5.2 Inspection or test failure

In the event of the equipment or any part thereof failing to meet the examination or

test requirements specified herein, the contractor shall furnish the detailed mapping

of the defects/ failures and all relevant details to the purchaser. The contractor shall

obtain written permission from purchaser before repair and subsequent use of such

equipment or part. If the repairs, including re-design, are likely to affect the result of

tests or work previously completed, appropriate re-examination and re-testing shall

be conducted and resubmitted to Purchaser for approval. Permission from the purchaser

is required to perform weld repairs on castings.

A report shall be made on casting repairs describing the extent and location of repairs to

each casting.

5.3 Material Examination

All materials designated to be in conformance with an ASTM standard shall be tested

as required by such standard and NC-2000 of ASME Section III, Division 1. For

pressure retaining parts, NABL accredited laboratory calibrated instrument shall be used

for the material testing and the same shall be witnessed by purchaser or his authorized

representative. For other materials, Proof in the form of certified test report or mill

certificates with proper correlation that the required tests have been carried out at the

source will be acceptable but if these are not available, these tests will be performed by

vendor. All casting materials (which are in contact with process fluid) shall be checked

for Inter Granular Corrosion test as per ASTM A-262 practice A/B. For IGCT carried

out as per ASTM-A-262-practice B, the corrosion rate shall not exceed 50 mpy.

5.4 Visual Examination

It will be confirmed visuallly that all castings, forging and/or other raw materials are free

of flaws, cracks, blow, holes or other defects. Visual examination shall be performed for

external appearance of pump motor unit and internals shall be checked after dismantling.

5.5 Liquid penetrant examination

5.5.1 Liquid penetrant examination shall be performed as per ASME Section V. Procedure

shall be subject to Purchaser's approval. Following parts shall be subjected to Liquid

penetration examination.

a) All accessible surfaces of pressure retaining parts

b) First and last passes of all welds

c) Impeller

d) Shaft

e) Weld repair areas, if any

f) Machined parts in contact with pumped fluid

g) Weld edge preparations

h) Surface prior to and after hard facing

i) Bolts

j) Stator spacing rings, rotor bars, short circuit rings, retaining rings and brazed

joints in the motor.

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Acceptance standards for shaft, shaft sleeve, castings, forgings, hard facing surfaces, for

weldment, for bolts and for weld edge preparation shall be as per requirements of ASME

Section III NC.

5.6 Radiographic examination

5.6.1 Radiographic examination in accordance with the approved procedure shall be performed

on the following components :

i) All castings components which are pressure retaining.

ii) Longitudinal weld of stator and rotor cans

iii) All butt welds and weld repairs (if any), subjected to hydrostatic pressure.

Radiographic technique shall be as per relevant ASTM standard or ASME Section V

standard. Acceptance standard shall meet severity level 2 as per ASME Section III ,

Subsection NC.

5.7 Ultrasonic Examination

Ultrasonic examination in accordance with the standard procedure shall be performed on

i) Shaft of pump-motor unit.

ii) Pressure retaining components (which are subject to hydrostatic pressure) which are

forged.

iii) Body of the Motor.

The examination shall be performed after heat treatment. It shall be examined in

accordance with ASTM A-388 (specification for ultrasonic examination of heavy

forgings). The Acceptance criteria shall be as per ASME SECTION III Subsection NC.

5.8 Ferrite control

Delta ferrite determination shall be carried out on casing, impeller, other pressure

retaining Stainless Steel parts and also on stainless steel welding materials. Minimum

delta ferrite shall be 5%.

5.9 Dimensional Examination

Dimensional examination shall be carried out on all dimensions indicated on various

approved drawings. The measured dimensions shall be within specified tolerances.

5.10 Hydrostatic test

All pressure retaining components shall be subjected to hydrostatic pressure of at least

346 bar (g) (Which is near to1.25 time the design pressure multiplied with allowable

stress ratio at room temperature to the design temperature). The test shall be conducted

in accordance with NC-6200 of ASME Section III latest edition. Hydrostatic test pressure

shall be kept constant for a period of 10 minutes. No leakage or permanent

distortion shall be allowed. Any permanent distortion or seepage of water shall be the

cause of rejection of the units. Hydrostatic test shall be carried out using clear water.

5.11 Helium leak test

After hydro test, helium leak test shall be performed on complete pump-motor assembly,

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at a differential pressure of 1.03 kg/cm2 with minimum 50% helium. Helium leak test of

pressure retaining parts is to be carried out by vacuum method only. This will be

followed by Pressure/Sniffer probe technique to locate the leaks, if leakage rate exceed

the acceptance limits during Vacuum method.

Prior to the test, the components shall be thoroughly dried at 150 °C for 2 hrs. while

being purged with a flow of dry air. The pump-motor unit shall be enclosed in vinyl

sheet. Vacuum will be pulled inside the pump and helium shall be injected in the vinyl

sheet. The maximum leak rate of helium to the pump inside shall not exceed 10-6

std.

cc/sec for weld joint. For Gasket/O-ring joints maximum leak rate preferably shall not

exceed 10-5

std. cc/sec, However, nevertheless leak rate more than 10-4

std. cc/sec is not

acceptable for Gasket/O-ring.

6. PUMP PERFORMANCE TESTS

6.1 General

The pump-motor unit manufactured shall be subjected to the general performance test

and rated performance test as specified below. The pump running tests shall be

performed at rated voltage and frequency. The pump-motor unit shall not be modified

for testing. The performance requirements as specified in the following sections of this

specification are for tests performed at rated voltage and frequency.

The performance tests and acceptance criteria shall be made in accordance with the

ANSI/HI pump standard or equivalent. The performance tests shall be witnessed by the

purchaser/ his authorized representative.

The performance tests shall be carried out using clear water at near room temperature.

6.2 General pump performance test

Measurement shall be made to determine the characteristics of the units over the

entire range of flow from zero to maximum permissible flow (which shall not be less than

120% of duty point flow). A sufficient number of points shall be obtained on the

characteristic curve to enable an accurate plot to be made. The characteristics to be

determined and submitted as test curves are: Developed head, Required NPSH, Pump

power, Shaft torque and Efficiency vs. flow. Water temperature and pump RPM shall

also be noted and submitted. The test results shall be extrapolated for actual condition.

6.3 Rated performance test The pump-motor unit shall be operated at rated voltage, frequency and flow for 24 hours.

The measurements shall include voltage, starting current and running current, frequency,

power input, winding temperature, rpm, capacity, head, water temperature, vibration,

noise, gasket leakage if any, overall efficiency of the unit etc. During this test, various

measurements taken during general performance test as stated in above clause shall be

made and recorded once in 2 hours. The observed values must match with required

values.

After the rated performance test, pump assembly shall be disassembled and after

checking all components for any failure/ damage the pump shall be assembled back. In

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case of any part or component requires replacement/modification, re-testing (for 8.0 hrs

at rated conditions) and re-examination shall be carried out. After reassembly, pump shall

be checked for satisfactory operation for 10-15 minutes.

6.4 Vibration test

The vibration test shall be carried out as per relevant industrial standard and shall confirm

to Zone B as per the ISO-10816-7 standard.

6.5 Dynamic Balance test

Dynamic balance test of pump-motor assembly is to be carried out as per ISO-1940. The

rotating parts of pump-motor unit shall confirm to balance quality grade G2.5.

7. EXAMINATION OF PRODUCT

The pump and motor unit shall be carefully examined during manufacture and after

completion to determine their conformance with this specification with respect to

materials and their testing and workmanship, finish, marking and dimensions and to

assess their conformance with other requirements stated or reasonably implied and

not covered by specific tests.

8. SPARE PARTS

The supplier shall recommend a list of spares along with unit price that are required for

10 years operation to be stocked for maintenance purposes. The purchaser has right to

purchase/not to purchase any or all spares and unit price of spare shall remain same.

9. MAINTENANCE TOOLS

The bidder shall supply one set of maintenance tools required for installation and regular

maintenance of pump-motor unit at no extra cost.

10. GUARANTEE

The pump-motor unit shall be guaranteed for a period of 18 months after

installation or 36 months from the date of shipment whichever is earlier, against any

malfunctioning, defects in design, materials or workmanship. If within the expiry of

this guarantee period the equipment fails to operate satisfactorily at its rated conditions

or the subject goods or any part thereof are found defective in design, workmanship or

materials, the supplier shall be responsible to arrange repairs/ replacement (at

Purchaser's premises) at his own cost. The guarantee period for the replaced parts or

repair work shall be the same as above.

11. PREPRATION FOR SHIPMENT

The units shall be prepared for shipment and prolonged storage as stated below:

The interior of the pump-motor unit shall be thoroughly cleaned and dried. All external,

internal, machined and unfinished surfaces susceptible to corrosion shall be protected

against corrosion with a liberal coating of an approved easily removable rust preventive

compound. The compound shall be such that it will not chemically react with the

material and shall be stable up to an ambient temperature of 50 °C. It shall remain on the

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surfaces at temperatures encountered during the long periods of shipment and storage.

It shall not be washable with water but shall be easily and thoroughly removable with a

non-corrosive solvent. All machined surfaces shall be protected against mechanical

damage. Paints or chemicals used for marking, preserving or testing shall be halogen and

sulfur free.

All openings shall be adequately sealed to prevent ingress of corrosive water vapor.

Suitable desiccant or rust-inhibitor shall be kept inside, if necessary, prior to sealing.

Flanged openings shall be closed with plywood blank flange held in place with bolts and

sealed with a blank gasket of natural rubber or equivalent.

Threaded openings shall be closed with suitable threaded plugs or caps (for

internally or externally threaded openings respectively) using a good quality thread

tape. No thread sealant shall be used.

All components shall be tropical packed, suitably boxed, crated and protected from

damage and moisture in transit to site. The crates shall be suitably lined with water

proof material to prevent ingress of moisture. Equipment shall be prepared for a

period in transit exceeding two weeks.

The construction and lining of the boxes shall provide protection for its components.

The packaging shall provide adequate cushioning, blocking and bracing to protect

against shocks and prevent internal movement of the unit. Adequate skidding,

hoisting and tie down provisions shall be provided to facilitate easy handling and

safe movement.

Delivery of the pump-motor unit or any part must not take place until the purchaser has

been notified and a written shipping release of the material is obtained.

12. INFORMATION REQUIRED WITH BID FOR PUMP

Two copies of quotation complete in every respect

should be forwarded along with

detailed catalogues, specifications, data sheets etc. Quotations not giving complete

information, as asked below, will be liable to rejection.

Following information shall be provided by the bidders along with the quotation.

12.1 Sectional drawings of the pump-motor unit showing overall dimensions, materials

of construction and details of suction/ discharge connections, motor, support details

etc.

12.2 Base plate and foundation details

12.3 Required NPSH of the pumps.

12.4 Performance curves: Delivered head, NPSHR, Pump power, Shaft torque, Efficiency Vs.

flow at the rated speed (RPM).

15

12.5 Guaranteed Head and capacity of the unit.

12.6 Rated maximum operating temperature

12.7 Completed Pump and motor data sheet (Annexure-3 of Section A and Annexure-5 of

Section B). Offer without these filled data sheets shall not be considered for the

evaluation.

12.8 A recommended spare parts list complete with unit prices and recommended

quantities of each spare part required for at least ten years of trouble free service.

12.9 List of previous supply order where similar size, type & quality of high pressure &

temperature pumps have been supplied (indicate the P.O. number & total price).

12.10 Guaranteed life of the pump-motor unit.

12.11 Design, test pressure & Overall efficiency of the pump-motor unit.

12.12 Complete list of deviations from this specification, if any.

12.13 QAP including details of stage-wise inspection to be followed during manufacture.

13. INFORMATION REQUIRED AFTER THE PLACEMENT OF ORDER 13.1 Detailed shop drawings of the pump- motor unit indicating material of construction and

dimensions, shall be submitted for purchaser's approval.

13.2 Design report including stress analysis with all load combination shall be submitted for

purchaser’s approval prior to commencement of fabrication/manufacture.

13.3 Inertia of the Pump-Motor Unit

13.4 Part list for the pump ordered.

13.5 Detailed Quality Assurance Plan for purchaser’s approval.

13.6 Detailed inspection/test procedures as per the specification shall be submitted to the

purchaser for approval prior to start of manufacture of pump-motor units.

13.7 Material test certificates, tests and inspection reports shall be submitted.

13.8 Instruction manual containing installation, operation and maintenance instructions, part

list and dimensional drawings shall be submitted.

14. SUB-CONTRACT

The vendor shall not sub-contract any or all of the work without the written consent from

16

the purchaser. The vendor shall be responsible to the purchaser for all works under this

contract including the works of the sub-contractors, as allowed by the purchaser. Sub-

contracting shall not affect the delivery schedule under any circumstances.

15. HISTORY DOCKET REQUIREMENTS

Two copies of History docket shall be submitted along with CD containing Scanned copy of

the same. The docket shall contain following quality assurance records & documents.

• Purchase order with technical specification

• All Official correspondence

• All Design and pump performance documents

• Approved and as built drawings

• Approved QAP

• Certified material test report

• Heat treatment records

• All NDT documents including approved procedures

• Hydrostatic test reports

• Performance test reports

• Guarantee certificate

• Instruction and maintenance manual

• Any other relevant documents

16. DELIVERY

The delivery of all the pump-motor units shall be within Nine (9) months after placement

of purchase order.

17

ANNEXURE-1: SALIENT TECHNICAL DATASHEET OF PUMP

General

Type Centrifugal Canned motor type

( Leak proof centrifugal)

Configuration Single Volute, Horizontal end suction, vertical

discharge

Quantity 1 no.

Material of construction of wetted part

• Stainless Steel 316L with relevant ASTM standard

(as mentioned in Clause 4) .

• Cobalt content in all wetted parts (In contact with

circulating Fluid) shall be less than 0.1 % by

weight.

Applicable Code • Design, fabrication & testing: ASME Section III,

Division 1, Subsection: NC

• Performance test: ANSI/HI or equivalent standard

Suction & Discharge line tube size

(Matching connection with pump is in

scope of Vendor)

3/4 inch. outside diameter with 0.109 inch. thickness

Location Indoor

Pump prime mover Induction motor as per specification mentioned in

Section B

Operating Condition

Operation Continuous

Fluid Handled Demineralized Water

Design Temperature 360 oC

Design Pressure 220 bar(g)

Operating temperature

Max.: 340 °C

Normal: 220°C - 325 °C

Min.:25 °C

Operating suction pressure

Max. : 190 bar(g)

Normal: 80 bar (g) - 188 bar (g)

Min.: 1 bar(g)

Duty point Capacity 2.0 m3/hr

Duty point Head 185 mWC

NPSH available at duty point condition > 10 mWC

Fluid Density (To be taken For

calculation of hydraulic power

requirement)

1000 kg/m3

Performance Head decreases with increasing capacity for entire

range of flow.

Design condition

18

External nozzles forces and moments As mentioned in Clause 3.14

Seismic Design criteria As mentioned in Clause 3.15

Rated speed About 2900 RPM.

Balance quality grade G2.5 as per ISO 1940.

Vibration

Within zone B of the applicable class of

machine as per ISO 10816-7 for Category I pump

or better

First Critical speed Shall not be less than 130 % of the Rated speed.

Motor rating

Shall be suitable to drive the pump at least up to

120% of the duty point flow for water with density

1000 kg/m3.

Inspection & Testing

• Material test (Clause 5.3)

• Liquid penetrant examination (Clause 5.5)

• Radiographic examination (Clause 5.6)

• Ultrasonic test (Clause 5.7)

• Hydrostatic test (Clause 5.10)

• Helium leak test (Clause 5.11)

Performance test

• General pump performance test (Clause 6.2)

• Rated pump performance test (Clause 6.3)

• Vibration test (Clause 6.4 )

• Dynamic balance test (Clause 6.5)

19

ANNEXURE-2:RESPONSE SPECTRA AND DAMPING

COEFFICIENT FOR SEISMIC DESIGN OF PUMP-MOTOR UNIT

Frequency

(Hz)

Acceleration

(g)

Frequency

(Hz)

Acceleration

(g)

Frequency

(Hz)

Acceleration

(g)

0.5 0.2 1.14286 0.345 2.3529 0.614

0.52632 0.205 1.17647 0.357 2.5 0.635

0.55556 0.215 1.21212 0.364 2.6667 0.657

0.58824 0.22 1.25 0.375 2.8571 0.678

0.625 0.225 1.29032 0.385 3.0769 0.696

0.66667 0.235 1.33333 0.396 3.3333 0.714

0.71429 0.245 1.37931 0.407 3.6364 0.732

0.76923 0.255 1.42857 0.421 4 0.75

0.83333 0.264 1.48148 0.435 4.4444 0.765

0.90909 0.28 1.53846 0.455 5 0.77

0.93023 0.285 1.6 0.471 5.7143 0.765

0.95238 0.292 1.66667 0.485 6.667 0.75

0.97561 0.295 1.73913 0.507 8 0.715

1 0.303 1.81818 0.52 10 0.642

1.02564 0.31 1.90476 0.539 13.333 0.55

1.05263 0.32 2 0.557 20 0.442

1.08108 0.33 2.1053 0.575 40 0.32

1.11111 0.34 2.2222 0.594 100 0.2

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0 10 20 30 40 50

Acc

el.

(g

)

Freq (Hz)

Design spectra at 3% damping

20

ANNEXURE-3: TECHNICAL DATASHEET TO BE FILLED BY

VENDOR (FOR PUMP) GENERAL

Manufacturer of Canned motor

pump-motor unit (Yes / No)

Experience in design &

manufacturing for high pressure

(above 160 bar) & temperature

(above 300 °C) (Yes/ No)

(If Yes, Provide PO reference)

Experience of design, testing &

qualification of pump as per ASME

Section III. (Yes / No)

(If Yes, Provide PO reference)

Make

Model no.

Service

Type

No. of stages

Suitable for

Location(Indoor/Outdoor)

Suction & Discharge Nozzle size

Quantity

Applicable code/standard

Pump prime mover

Guarantee

Delivery time

OPERATING CONDITION

Suitable for Operation

(Continuous/ Intermittent)

Fluid handled

Specific gravity of fluid

considered for estimating the

motor power requirement at duty

point condition

Duty point Capacity

Duty point Head

Pump Efficiency at duty point

Shaft torque at duty point

Pump power at duty point

NPSH Required at duty point

flow and Rated speed

RATED CONDITION

Rated flow

Rated head

21

Rated Efficiency (BEP

Efficiency)

Rated shaft torque

Pump power at rated condition

Max. Allowable operating

temperature at suction.

Rated speed (RPM)

Synchronized speed (RPM)

DESIGN PARAMETERS

Performance (Characteristics

Curve to be attached)

Maximum permissible flow for

continuous pump operation (run-

out flow)

Pump power at run-out condition

Max. Pump rating

Shut off head

Max. permissible duration for

pump operation at shut off head

Minimum permissible flow for

continuous pump operation

First critical speed (RPM)

Specific speed

Suction Specific speed

Impeller type

Nos. of Impeller stages

Design pressure

Design temperature

Casting quality factor considered

for pump casing design

Hydrostatic test pressure

Rotating Mass moment of

inertia of Pump-Motor unit

Overall size of Pump- motor unit

Minimum required Foundation

size for installing one pump-

motor assembly

External nozzles forces and

moments considered

Seismic Design criteria

considered

Impeller dia.

Impeller radial clearance

22

Max. diameter of impeller, the

casing can accommodate and

rated condition for the same

impeller

Shaft dia.

Weight of total pump-motor unit

External (Jacket) cooling water

requirement, if any (Category of

Water/Flow/Inlet pressure/

Pressure drop/ Inlet temperature/

Heat to be removed etc.)

Bearing (Type and Lubrication)

Direction of Rotation

Balance Quality Grade of the

rotors.

Vibration of the unit while

operation

MATERIALS OF CONSTRUCTION ( With relevant ASTM standard, as applicable)

Casing

Impeller

Shaft

Stator and Rotor CAN

Auxillary piping

Counter fitting

Spool piece for matching the tube

size with Suction & discharge

nozzle size of pump

Base Plate

Bearing

Bearing sleeve

Gasket

O' Ring

Stator body

All bolts & nuts

Other material of construction of

wetted part

Cobalt content in all wetted parts

(In contact with circulating Fluid)

shall be less than 0.1 % by

weight. (Yes/ No)

INSPECTION AND TESTING (Mention the different components & relevant standard

for which the tests are to be carried out).

Material test

Liquid penetrant Examination

Radiographic examination

23

Ultrasonic examination

Hydrostatic test

Helium leak test

Confirm that all the above tests

are to be carried out as per Clause

no. 5 (Yes / No)

Agree for Witnessing of

inspection/ testing by the

purchaser (Yes / No)

PERFORMANCE TEST (Mention the relevant standard)

General pump performance test

Rated performance test

Vibration test on all pumps

Dynamic balance test on all

pumps

Confirm that all the above tests

are to be carried out as per Clause

no. 6 (Yes / No)

Agree for Witnessing of

inspection/ testing by the

purchaser (Yes / No)

MOTOR ( Please also fill Annexure-5 for of motor)

Type

Make

Max. Rating

Motor efficiency at duty point

condition

Motor efficiency at rated

condition

OTHER

Recommended spares (Please attach the list along with unit price)

Regular maintenance tool to be

provided with Pump-Motor

unit

(Please attach the list)

Whether pump offered meet all

the requirement mentioned in

this specification (Yes/ No)

• If no then attach the

deviation list

END OF SECTION A

24

SECTION B: GENERAL REQUIREMENTS FOR MOTORS

1. SCOPE

This specification covers the general requirements for design, manufacture, inspection, testing

and supply of squirrel cage induction motors having a rated capacity to suit Pump as specified

in the section A and requirement specified in this section B. This specification is meant only

for the guidance to the supplier and it is not the intent to cover all aspects of design and

manufacture. The salient requirements of motor are stated in the Annexure-4 of the motor

specification.

2. APPLICABLE STANDARDS

The motors shall conform to the latest editions of the following standards unless specified

otherwise in this specification.

2.1 Bureau of Indian Standard (BIS)

BIS-325 Specification for Three-Phase Induction Motors

BIS-14578 Three phase induction motors for use in nuclear power

plants- Specification

BIS-12615 Energy efficient induction motors- Three phase squirrel

cage

BIS-12075 Mechanical vibration of rotating electrical machines with

shaft heights 56 mm and higher measurement, evaluation

and limits of vibration severity

BIS-15881 Three phase cage induction motor specifically designed

for IGBT converter supply specification

In case of conflicts, requirement specified in this specification shall govern.

3. OPERATING CONDITIONS

3.1 Motors shall be suitable for continuous operation under the following conditions

Ambient temperature at the location of

motor

10 to 50 °C

Site altitude Less than 1000 metres

Relative Humidity 90% at 40 °C

Rated voltage and its variation 415 V ± 10%

Rated frequency and its variation 50 Hz ± 5 %

Number of Phases 3

Sustained Combined variation of frequency

and voltage (arithmatic addition)

10 %

Unbalance in supply voltage 3 %

Permissible harmonics in the supply voltage 5 %

Method of power supply system grounding Effectively grounded system

Temperature rise of motor winding under Less than that mentioned for Class B

25

normal operating conditions of voltage and

frequency (By winding resistance method)

Temperature rise of motor winding under

extreme conditions of voltage and frequency

(By winding resistance method)

Less than that mentioned for Class F

Seismic requirement As mentioned in Clause 3.15 of Section

A.

Radiation withstand capacity of motor At least 100 Mega rad

4. DESIGN REQUIREMENTS

4.1 General

4.1.1 The salient technical requirement of Motor is mentioned in Annexure-4.

4.1.2 Motors shall be designed, manufactured and equipped with accessories in accordance

with this specification and the applicable standards. Materials and components not

specifically stated in this specification and which are necessary for meeting the

requirements of this specification shall be included in the scope of supply.

4.1.3 The design and workmanship shall be in accordance with the best engineering practices

to ensure satisfactory performance and service life as specified herein.

4.1.4 The intent of this specification is that the contractor supplying the equipment shall

provide motors which shall be suitable for properly starting and operating the

equipments under operating and environmental conditions as specified in the

specification.

4.1.5 The motors shall be preferably of the squirrel cage induction type and shall be

manufactured, tested and shall perform in accordance with the latest revision of BIS-325

or equivalent.

4.1.6 Design and manufacture of the motors shall be coordinated with the requirements of

the driven equipment. The motor manufacturer shall cooperate fully with the purchaser

and the manufacturer of the driven equipment by furnishing the following

information necessary for proper assembly and operation of the unit as a whole.

i) A fully dimensioned outline drawing of the motor and its terminal box arrangement.

ii) The relevant motor characteristics viz. speed/torque and speed/current etc.

iii) The maximum permissible temperature under stalled rotor conditions for cold and

hot motor, when started on full rated voltage.

iv) Information required like rated speed, number of starts/restarts, operating duty, load

on bearings, mounting, instrumentation, Weight etc.

v) All details that are required by the agency performing seismic analysis of motor and

the driven equipment as a single unit.

4.1.7 The vendor shall make available to the motor manufacturer a copy of this

specification and shall be responsible to the purchaser for coordinating with the

motor manufacturer for the supply of the required motor and accessories and for the

26

satisfactory operation of the complete unit.

4.1.8 Motor shall have the kW rating based on continuously driving the connected equipment

under all specified operating conditions. The vendor may indicate the various de-rating

factors considered, if any for the motors.

4.1.9 Minimum efficiency of motors shall be as per relevant Indian Standard (IS).

4.1.10 Motor if powered through electronic Pulse Width Modulated or any similar variable

speed drives shall be suitably designed to take in to account harmonics and voltage

surges generated by such drives. Suitability of the motor for operation with such drives

shall be confirmed.

4.2 Enclosures

Motors shall be provided with explosion proof enclosure providing degree of protection

not less than IP 66.

4.3 Rotor

The rotor design shall provide a rigid cage construction with bars firmly wedged in

bar slots and solidly bonded to the end rings. The end ring assembly shall be such

that it is free to move with the expansion of the bars without distortion and

withstand mechanical stresses for the type of duty specified. The motor cage shall be

designed to operate satisfactorily under respective starting and load cycles.

In case the supplier prefers other type of rotor construction due to technical reasons, the

same shall be intimated to the purchaser for approval.

The ability of the cage construction to provide satisfactory operation under

respective starting cycles, and load cycling shall be a matter of close attention

during design and manufacture and this feature of the motor design shall be fully

described in the tender.

The motor shall be capable of operating on full speed requirement imposed by the

driven equipment in the forward and reverse direction. The rotor bars shall not be

insulated in the portion between the slot walls and the bars. The vendor shall furnish the

details of construction provided to meet starting and load cycle duty.

4.4 Frame

The motor frame may be of rigid fabricated steel or casting. Specific mention of the

material offered shall be made in the offer indicating the complete details of the material.

4.5 Direction of Rotation

The direction of rotation shall refer to the non-drive end of the machine. All motors shall

be designed for operation in either direction of rotation. Motors shall have the specified

direction of rotation as determined by the phase sequence on the terminal markings,

marked by an arrow on the stator frame or on the name plate.

27

4.6 Insulation

Motor shall be provided with Class C insulation except when stated otherwise. However

the temperature rise of windings should be limited to those for Class-B for normal

operation.

Motor winding shall be given special tropical, fungicidal and `power house'

treatment for protection against tropical weather condition, fungus growth and

moisture, oil, abrasive and conducting dust and sulphur fumes in combination with

weak acid or alkali fumes respectively that are likely to be encountered in and

around the plant area.

Any joint in motor insulation such as at coil connections or between slot and

end-winding sections, shall have protection equivalent to that of the slot sections of

the coils.

The insulation system should have high di-electric strength, high mechanical strength and

long life.

The temperature rise of the motor insulation shall not exceed the limits specified by BIS

325 for an ambient temperature of 50 °C.

4.7 Terminal boxes

The terminal box shall be fabricated from sheet steel plates with a steel plate cover for

the fault rating specified for 600V system. The stator leads shall be brought into the

terminal box as insulated cable through a suitable barrier and terminated in clamp or

compression type terminals.

The terminal box shall be suitable for top entry of cables and shall be provided with

suitable gasket on the covers to make it moisture proof. However, the terminal box

shall be hermetically sealed. Gasket of neoprene or approved equivalent shall be

provided at cover joints and also between the box and the motor frame. The terminal

box shall be provided with cable box/gland of adequate size of equipment rating. The

exact number and size of cable would be intimated to successful supplier. The size of

terminal box should have ample space to cater for bending radius of cables as per

regulations. Terminal boxes should be totally water proof and protection should be

equal to or better than IP 66.

4.8 Bearing and Bearing housing

Self lubricated bearings shall be used. The rated life of the bearings shall be guaranteed to

be not less than 30,000 hours of operation. Motor manufacturer shall obtain from the

driven equipment manufacturer all necessary details required for selection of bearings

and in consultation with bearing vendor, select suitable bearings. Operating temperature

of bearing under all conditions shall be within the limits prescribed by the manufacturer.

The bearing shall be designed to permit motor running in either forward or reverse

28

direction.

4.9 Grounding

Provision shall be made on the motors for connecting purchaser's grounding conductors.

The grounding practice shall be decided in consultation with purchaser.

4.10 Tropical Treatment

The stator winding insulation, core punching and motor internal shall be tropicalised and

given a special treatment of a fungus inhibiting coating.

5. PERFORMANCE REQUIREMENTS

5.1 Starting Duty

5.1.1 The motors shall be capable of starting and accelerating the driven equipment

satisfactorily at a minimum voltage of 80% of the normal voltage at the motor

terminals.

5.1.2 The motors shall be capable of two successive restarts coupled to its drive equipment

with coasting to rest between starts under both cold and hot conditions and a third restart

shall be feasible after 20 minutes. The motor shall further be capable of three equally

time spaced starts per hour under normal service conditions.

5.1.3 Motors shall be designed for direct on line, full voltage starting and shall withstand all

stresses and give satisfactory performance when started with driven equipment connected

under all operating conditions specified for the driven equipment mentioned in Section A.

The total number of starts during the design life of motor shall be commensurate with the

requirements of driven equipment and taking into account design life of motor.

5.2 Fast Bus Transfer

Motors and driven equipment shall be capable of withstanding the voltage torque stresses

and forces developed due to the vector difference between the motor residual voltage and

the incoming supply voltage during fast changeover of the supply. Motor winding shall

be adequately braced to withstand mechanical forces developed during such conditions.

5.3 Over speed

The motors shall be capable of withstanding without mechanical damage at least 120% of

rated speed (for 2 minutes) or as imposed by the driven equipment whichever is higher.

5.4 Locked rotor current

Locked rotor current of motors shall have the lowest value consistent with good

performance and economical design for their torque current class, but this shall not

exceed 600% of full load current. The forgoing maximum permissible value of current

shall be inclusive of tolerance permitted by relevant BIS standard.

5.5 Pull out

Motor shall not pull out of step when the supply voltage drops to 70% of the rated

motor voltage for a short duration of 25 cycles. To meet this requirement, the

29

pull out torque of the motor at rated voltage shall be at least 200% of full load torque.

5.6 Critical Speed

The first critical speed of the motor shall be minimum of 130% of rated motor speed

to ensure that the first critical speed of the driven equipment-motor combination will

be above the rated speed.

5.7 Other requirements

Motors shall be capable of satisfactory operation at full load for 10 minutes without

injurious heating for the motor terminal voltage of 80% of rated voltage.

Accelerating time of the motor with rated driven equipment load connected to it

shall not exceed the corresponding safe stall time of the motor under hot condition,

at all applied voltages from 80% to 110%.

6. PAINTING AND FINISH

The external parts (non Stainless steel parts) shall be finished and painted to produce

a neat and durable surface which would prevent rusting and corrosion. The equipment

shall be thoroughly degreased, all rust, sharp edges, scale removed and treated with one

coat of primer and finished with two coats of paint.

7. INSPECTION & TESTING

7.1 All routine tests mentioned in BIS-325/9283 shall be conducted on motor by the

manufacturer at his work in the presence of main contractor and/or purchaser’s

representative. Inspection call for routine tests shall be given two weeks in advance from

date of commencement of routine tests as witness point. After lapse of the notice time,

manufacturer can proceed with the routine tests. Routine test certificates shall be

furnished to the Purchaser’s representative (QA) for review & acceptance. Cost for the

same shall be included in the equipment prices.

7.2 Test certificates for type tests performed on identical motors as per IS 325/9283 shall be

submitted along with the documents and data sheets for review and approval of the

Purchaser. In case type test reports are not acceptable to the Purchaser, type tests shall be

performed at no extra cost to the Purchaser and without affecting the delivery period.

Type test reports shall not be earlier than 5 years from the date of purchase order. Test

certificates shall be submitted for review and approval of the Purchaser.

7.3 The following type tests certificate are required to be submitted by the vendor.

a) Full load test to ascertain temperature rise at 90% or 110% of rated voltage and to

meet the requirements of pull out and heating.

NOTE: The full load test at 90% of the rated voltage or at 110% of the

rated voltage shall be performed depending upon whichever is more stringent

condition.

b) Torque values at starting, pull up, pull out and acceleration time with full load

connected under starting condition is to be furnished by the vendor. This will be

verified by testing.

30

c) Vibration test.

d) Speed-torque characteristics.

e) Starting current Vs. time characteristics at 80% and 100% voltage.

f) Stator temperature rise under locked-rotor condition: Temperature-time characteristics

should be obtained as per relevant BIS.

7.4 The Purchaser or his authorised representative shall at all reasonable times have access to

those parts of the supplier’ s or sub-supplier’s works concerned with the manufacture of

the motor for the purpose of witnessing tests and ascertaining compliance with the

requirements of this specification. The Purchaser shall also have the right to conduct at

his expense any additional tests or inspection he deems necessary.

7.5 All repairs and rework shall be informed to the Purchaser and his approval in writing

taken before proceeding further. All such repair work shall be documented and

photographic records shall be maintained. These documents shall be included in end

documents.

7.6 Certificate shall be provided for the motor for its radiation withstand capacity, which

shall be at least 100 Mega rad.

8. GUARANTEE

The motor shall be guaranteed for a period of 18 months after installation or 36

months from the date of shipment whichever is earlier, against any malfunctioning,

defects in design, materials or workmanship. If within the expiry of this guarantee

period the equipment fails to operate satisfactorily at its rated conditions or the subject

goods or any part thereof are found defective in design, workmanship or materials, the

supplier shall be responsible to arrange repairs/ replacement (at Purchaser's premises) at

his own cost. The guarantee period for the replaced parts or repair work shall be the

same as above

9. INSTRUCTION MANUALS

Supplier shall furnish copy of instruction manuals covering installation, operation and

maintenance of the motor.

10. DATA TO BE FURNISHED WITH TENDER FOR MOTOR

In addition to the data required as per specifications, the following information shall also

be furnished with the tender.

a) Schedule of delivery.

b) Schedule of guaranteed performance figures as per Annexure -5.

c) Schedule of Supplier's deviations from this specification.

d) Descriptive pamphlets of the pump-motor unit.

e) Description of insulation materials used and insulation treatment.

f) Description of weather protection features for motors.

g) List of accessories included in the scope of the supplier’s tender.

h) Material specification for motor shaft and bearings.

31

ANNEXURE-4: SALEINT REQUIREMENT FOR MOTOR

1. Motor Tag No. : As per pump-motor unit.

2. Type of rotor : Squirrel cage

b) Type of starting : STAR-DELTA if motor is of 5 kW and above.

DOL if motor is less than 5 kW

c) Service for which the : To drive horizontal

motor is intended seal less canned motor centrifugal pump

3. a) Voltage : 3 phase 415V

b) kW/ HP rating : Should be 110% of maximum kW/HP

Requirement of the pump considering to drive 120 %

minimum of the duty point flow

c) Frequency : 50 Hz

d) Synchronous speed : 3000 RPM

e) Phase : 3 phase.

f) Type of connection : Terminals to be brought out for STAR-DELTA

4. Degree of protection for :

a) Motor : } Equal to or better than IP-66

}

b) Power cable terminal }

box: }

: }

c) Auxiliary terminal }

boxes:

5. Type of cooling : To be mentioned by Manufacturer

6. Duty (whether any service : Yes, S1, Continuous

Factor intended)

7. Type of mounting : Horizontal

8. a) Short circuit rating

32

of power terminal boxes

i) MVA : To be indicated by the manufacturer

ii) Duration : To be indicated by the manufacturer

b) Size of Purchaser's power : As per rating of the

supply cables motor.

c) Type of cable : Copper conductor, XLPE insulated cable

9. Other requirement

a) Insulation details/ : Class C. Refer “Insulation” Clause of Section B

Class of insulation

b) Minimum rated torques : Break down : 300%

including tolerance as : Locked rotor : 220%

per IS:325 :Pull out : 200%

c) Maximum starting current : Not to exceed 6 times of the rated full load current under

DOL starting

10. Type test certificates : Yes

(as per BIS 325)

11. Acceleration time : Less than 1 sec for 100 % voltage

Less than 2 sec for 80% of voltage

12. Radiation withstand capacity : At least 100 Mega Rad.

33

ANNEXURE-5: MOTOR DATASHEET TO BE FILLED BY MOTOR

MANUFACTURER AND SUBMITTED THROUGH PUMP MANUFACTURER

Sl.No. Particulars

1.0 Guaranteed operating conditions for the motor

1.1 Ambient temperature, 0C

1.2 Altitude, M

1.3 Humidity at 400C, (%)

1.4 Type of environment (corrosive/non-corrosive)

1.5 Location (indoors/outdoors)

1.6 Hazardous condition (Yes/No)

1.7 Rated voltage & its variations, (V)

1.8 Rated frequency & its variations, (Hz)

1.9 Permissible un-balance in supply voltage, (%)

1.10 Permissible harmonic content in supply voltage, (%)

1.11 Combined voltage & frequency variations, (%)

1.12 Number of phases

1.13 Method of system grounding.

1.14 Whether the motors are adequately designed to operate

satisfactorily when supplied with power supply from

electronic drives intended to be used for the driven

equipment?

2.0 GENERAL

2.1 Make & Model no.

2.2

2.3 Application/Driven equipment

2.4 Method and type of coupling to driven equipment.

2.5 Type of motor

2.6 Frame size & design code no.

2.7 Mounting

2.8 Single shaft / double shaft extension.

2.9 Direction of rotation (viewed from drive end)

2.10 Rotation – uni /bi-directional

2.11 Reverse rotation stop provided?

2.12 Applicable standards/codes.

2.13 Stator winding connection

2.14 Winding resistance per phase*

3.0 RATING

3.1 Rated output (KW)

3.2 Rated speed (RPM)/Synchronous speed (RPM)

3.3 KW actually required by the drive equipment under specified

operating conditions.

4.0 DUTY

4.1 Type of duty

5.0 STARTING

5.1 Method of starting

5.2 Starting current (% of full load current)

34

5.2.1 At rated voltage

a) Including I.S. tolerance

b) Excluding I.S. tolerance (Committed value)

5.2.2 At 80% voltage

a) Including I.S. tolerance*

b) Excluding I.S. tolerance*(Committed value)

5.3 Minimum voltage required for starting (% of rated voltage)

5.4 Starting time with DOL starting with driven equipment

coupled

a) At rated voltage, (sec)

b) At 80% voltage *, (sec)

5.5 Max. No. of successive starts on full load

5.5.1 In cold condition

5.5.2 In hot condition

5.6 No. of equally spread starts per hour

6.0 INSULATION

6.1 Class of insulation for stator

6.2 Permissible temperature rise (by resistance method)

a) Under normal conditions, (0C)

b) Under extreme voltage conditions (90/110% of rated

voltage whichever is severe), (0C)

6.3 Tropical Treatment of motor

6.3.1 Material of insulation

6.3.2 Treatment of insulation, stator and rotor core for anti-fungal

growth

7.0 COSTRUCTION & MATERIALS

7.1 Degree of protection provided by the enclosure

7.2 Enclosure type (Fabricated type/ casting)

7.3 Enclosure material grade for different materials

a)

b)

c)

d)

e)

7.4 Material for stator conductors

7.5 Material for rotor bars, (Cu, Al)

7.6 Heat loss to environment for the purpose of ventilation design

*

7.7 Type of cooling

7.8 Painting

7.8.1 Primer , (Yes/ No)

7.8.2 Finish Coats (Yes/No)

8.0 TERMINAL BOXES

8.1 Type of main terminal Box

8.2 Degree of protection for T. Box enclosure

8.3 No. of cable entries*

35

8.4 Max. cable size suitable for the terminal box/Actual cable size,

(sqmm)*

8.5 Direction of cable entry

8.6 Size of cable gland plate suitable for Motor cable

9.0 BEARINGS

9.1 Type of bearing

9.2 D.E bearing number and make.

9.3 N.D end bearing number and make

9.4 Standard life of bearing.

9.5 Type and grade of lubricant*

9.6 Bearing end play (mm)* Axial

Radial

9.7 Thrust bearing losses*

9.9 Maximum permissible bearing temperature, (0C)

9.10 Whether bearings are designed considering all loads expected

during all operating conditions including seismic conditions (if

10 Details of ACCESSORIES, if any

10.1

10.2

10.3

11 WEIGHT OF MOTOR

11.1 Moment of inertia of rotating part of motor

11.2 Can thickness

a) Stator liner

b) Rotor sleeve

12 PERFORMANCE

12.1 Full load current (amps)

12.2 No load current. (amps)

12.3 Full load speed (rpm)

12.4 No load speed (rpm)

12.5 Efficiency

At full load (%)

At 75% load (%)*

At 50% load (%)*

12.6 Power factor

At full load

At 75% load*

At 50% load*

At starting*

12.7 Noise pressure level of motor at 1.0 m at no load, db (A)

12.8 Velocity of vibration at

a) No load (microns), mm/s

b) With load (microns), mm/s

12.9 Critical speed (rpm)

a) Lower

b) Upper

12.10 Safe stall time at 80% & 100% voltages, (sec)

36

i) When motor is at rated operating temperature

ii) When motor is at ambient temp

iii) Limiting stator and rotor temp. considered to determine

stall time, (0C)

12.11 Maximum number of starts permissible per year

12.12 a) Stator thermal time constant*

b) Stator cooling time constant*

12.13 Overload capacity:

12.14 Torque

12.14.1 Torque at full load, (% & time)

12.14.2 Starting torque (% of full load torque)

At rated voltage

At 80% voltage*

12.14.3 Pull-out torque (% of full load torque) at rated voltage

12.14.4 Pull-up torque (% of full load torque) at rated voltage

12.15 Winding temperature rise ( °C) over ambient

i) By thermometer

ii) By Winding resistance

12.16 Winding Temperature detector provided (Yes/ No)

12.17 Acceleration time (sec)

100 % Voltage

80 % Voltage

12.18 Radiation withstand Capacity (Mega Rad)

13.0 CONNECTIONS

13.1 Stator

13.2 Number of connections brought out

14.0 INSPECTION AND TESTING (As per Clause 7.0 of Section

B of this specification)

(Yes/ No)

15.0 Grounding device

Method and number of ground points

Location

Cable for which grounding connector is suitable

16.0 DRAWINGS, CATALOGUES, DATA SHEETS

15.1 Descriptive pamphlets for the offered motor enclosed?,

(Yes/No)

15.2 Torque vs. speed characteristics curve at rated voltage and

frequency*

a) For motor

b) For driven equipment

15.3 Current vs. speed characteristic curve at rated voltage and

frequency during acceleration*

15.4 Thermal withstand characteristic curve and data in digital form

for

37

a) Hot condition*

b) Cold condition*

15.5 Current vs. time characteristic curve during acceleration*

15.7 Efficiency, Power factor and current vs. load characteristics*

15.8 Dimensional drawing showing cross sectional view and

identification of components and their material specification,

shaft, fan etc*.

15.9 Dimensional drawing of the terminal boxes showing

dimensions, permissible cable size, degree of protection,

materials of fabrication, gasket material etc and the method of

terminating the purchaser’s incoming cables*.

16.0 Deviation from specification of Motor (Section B), if any

Note: Items marked * can be submitted after placement of order and after completion

of detailed engineering.

END OF SECTION B