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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
5
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.
6
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.
7
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,
8
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.
9
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
10
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.
11
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,
12
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
13
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
14
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