chapter 2 general requirements for mainline pumping...

16-QMP-05-3B

A 20.02.2012 AKC ARUS TBY

Rev. Date Description Prpd. Chkd. Appd.

Triune Energy Services Pvt. Ltd.

New Delhi

GENERAL REQUIREMENTS FOR

MAINLINE PUMPING UNITS

Std. / Doc. Number Rev.

9579-02-TS-101 A

Sheet 1 of 18

CHAPTER 2

GENERAL REQUIREMENTS FOR MAINLINE PUMPING

UNITS

AUGMENTATION PROJECT

OF

MUMBAI-PUNE SOLAPUR PRODUCT PIPELINE

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SPECIFICATION OF

HORIZONTAL AXIALY SPLIT

CENTRIFUGAL PUMP


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GENERAL REQUIREMENTS FOR MAINLINE PUMPING UNITS WITH HT MOTOR AS

PRIME MOVER, CENTRIFUGAL PUMP AND CONTROL PANEL

1.0.0 SCOPE

1.1.0 This specification covers the requirements of Mainline Pumping Units (MLPU) for pumping petroleum

product in cross-country pipeline on continuous duty operation.

1.2.0 This specification describes the minimum requirements for design, manufacture, testing, supply and

supervision of erection and commissioning of Electric motor driven Main Line Pumps (Horizontal

multistage Pumps) as described hereunder and in various attachments listed under Material

Requisition.

1.3.0 In case of any conflict between this Job Specification and other enquiry documents the following

preferential order shall govern:

a) Specific requirement Data Sheets

b) Specifications (Attachment to the tender)

c) API 610 specification (11th

Edition)

d) P&ID‟s and Other Drawings

e) Other Indian/International Standards/Codes attached herewith or referred to.

1.4.0 Compliance with this specification shall not relieve the bidder of the responsibility of furnishing

equipment and auxiliaries of proper design, materials and workmanship meet specified operating

conditions.

1.0.0 The pumping unit shall consist of a Horizontal split case High pressure centrifugal pump coupled to

Flame-proof squirrel cage induction electric motor, AC Variable speed drive and its bypass

arrangement, suitable coupling with spacer between pump and motor, bed plate, mechanical seal and

other accessories like motor and pump protective devices, gauges, grouting bolt, epoxy grouting

material, lube oil system (splash/forced) etc., complete in all respect, as detailed later in this

specification.

1.1.0 The handling capacity and the operating parameters as specified.

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1.2.0 The pumping units shall be in operation in single unit to achieve the operating parameters as specified.

2.0.0 GENERAL REQUIREMENT

2.1.0 The unit, complete with all accessories and controls supplied shall be designed meeting the specified

requirements for the project.

2.2.0 The offers of the bidders for the unit shall be evaluated on the long-term economic basis taking into

consideration of landed cost and the operating expenditures. The detailed methodology shall be as

furnished under “Evaluation criteria for Mainline Pumping units”.

2.2.0 The detailed requirement of Pump, Motor, Instrumentation and AC variable speed drive for the

pumping units are detailed in respective sections.

2.3.0 The vendor shall furnish the supply records of the pumping unit pump, motor and AC variable speed

drive (wherever required) of equivalent capacity under offer for handling of Crude oil / Liquid

Petroleum Products/ LPG for pipeline application similar to tender specification (parameters like Q, H,

NPSHR, Min. Efficiency) as a part of technical requirement for consideration. The client reference

shall include the name, telephone no., fax No. etc. of the contact person.

2.4.0 Vendor shall also quote for the spares of pumping unit as specified separately.

2.5.0 The vendor shall be responsible for:

a. Matching his offered equipment with specified requirements, making technical modifications as

may be called for.

b. Performing such other services as required under the detailed specifications.

c. Aligning, checking and commissioning the complete prime mover assembly with pumps including

electrical and instrumentation facilities at installation site. The services of Vendor‟s technician

used for the same shall be paid in accordance with the provisions covered elsewhere in the tender

documents.

d. Guaranteeing the performance of items of vendor‟s supply as well as guaranteeing sound

assembly of pump, motor, AC variable speed drive and pumping unit as a whole to ensure

compatible installation totally meeting with the Owner‟s stated requirements.

2.6.0 The offered pumping units shall fulfil the requirements of the specification as regards to the techanical

efficiency of the pump.

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2.7.0 All the equipment and accessories, which constitute the complete pumping unit shall be rated for

continuous operation.

3.0.0 EQUIPMENT QUALIFICATION CRITERIA (PUMP) – (EQC)

3.1.0 The pump model offered shall be from the existing regular manufacturing range of the pump

manufacturer. The mechanical as well as hydraulic performance (including NPSHR) for the complete

range of operation of the offered model shall have been established in the shop test.

3.0.0 The offered pump model shall meet the following minimum service and manufacturing experience

requirements.

3.1.0 Pumps shall be equal or superior in terms of power rating, hydraulic performance (including NPSHR),

inlet flow, Differential Head, operating pressure & Temperature, Pumping Liquid, Speed, Number &

Type of impellers, Mechanical Design (bearing span, diameter & speed), Materials etc. as compared

to at least ONE PUMPS of the proposed model designed, manufactured, tested and supplied from the

proposed manufacturing plant in the last fifteen years and the pumps shall have successfully operated

in the field for at least 8000 hours without any major problem as on bid due date.

3.2.0 The bidder shall complete the „Experience Record Performa‟s enclosed as Annexure-XIII with the

inquiry document to amply prove that the offered pumps meet the EQC for technical acceptance.

4.0.0 PUMPING ENVIRONMENT

4.1.0 The pumping units shall be installed at location where ambient temperature varies between 50C to +

500C with moderate to heavy rainfall during monsoon and relative Humidity is 98% (max.)

5.0.0 Design & Systems

5.1.0 Basic Design

5.1.1 Pumps shall conform to API 610-11th

edition.

5.1.2 Suction & Discharge Nozzles of the pumps shall be of same rating.

5.1.3 Pumps fitted with inducers for reducing NPSHR are not acceptable.

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5.1.4 Maximum allowable working pressure (MAWP) indicated by the bidder on the data sheet should

correspond to the standard maximum allowable working pressure for the proposed model with

proposed metallurgy at specified ambient and design temperatures. If applicable, the temperature

durating curves shall be furnished along with the offer to establish this.

5.2.0 Mechanical Seal

5.2.1 Mechanical seals shall be of cartridge design and shall be as per API-682, 3rd Edition. Mechanical

seals shall be offered and supplied from one of the following makes only: Flowserve, John Crane,

Eagle Burgman, Chetra.

5.2.2 The seal faces shall be from solid hard piece only. Coatings or inserts or metal carriers shall not be

accepted.

5.2.3 Split sleeves shall not be accepted.

5.2.4 The seal plates (or gland plates) shall be drilled for flushing/quenching and vent drain connections.

Seal plates shall be labeled to identify quench/flushing and vent and drain connections.

5.2.5 The design of sealing system shall be with pressure-temperature rating equal to the maximum

discharge pressure & temperature of the casing.

5.3.0 Coupling

5.3.1 Couplings shall be non-lubricated, all metallic flexible type with spacer.

5.3.2 The spacer length of the coupling shall be adequate to permit removal of the coupling, bearings and

seal with sleeve without disturbing the driver, pump rotor or suction/discharge piping.

5.4.0 Bearing and bearing lubrication system

5.4.1 In case pumps require pressurized lubrication, then the same shall be as per Sketch No. B.8 of API

610, 11th

Edition, along with necessary instrumentation and controls. In such a case, the following

requirements for pressurized lubrication shall be met.

5.4.1.1 Each pump-package shall be provided with an independent lube oil system which shall comprise of

the following:

-Lube-oil reservoir (of M.O.C. SS).

-Main oil pump (motor driven).

-Auxiliary oil pump (motor driven).

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-Lube oil cooler (air cooled).

-Twin fans (each designed for 100% heat load).

-Lube oil filters (duplex).

-Lube oil heaters

-Transfer valves

-Pressure control valves

-Other instruments and controls.

5.4.1.2 L.O. reservoir and all lube oil piping, valves, fittings and flanges shall be of 316 stainless steel. Any

tubing require shall be of 316 stainless steel with compressor type fittings of like material.

5.4.1.3 Lube Oil system shall be designed with adequate provision of safe shut down of the equipment.

Bidder shall describe the provisions included for the same in the proposal.

5.4.1.4 Lube oil cooler shall be air cooled type. Coolers shall be designed for maximum ambient temperature

of 50 degree C.

5.5.1.5 Two fans are to be provided for each oil cooler. Each fan shall be sized for 100% requirement. In

case of tripping of the working fan, the standby fan shall automatic come on. Either of the fan shall be

working or standby.

5.5.1.6 Main and Auxiliary L.O. pumps (both motor driven) shall be in accordance with API-676. Bidder shall

furnish the details for these pumps for purchaser‟s review and approval during detailed engineering

stage.

5.5.0 Electrical and Instrumentation System

5.5.1 These shall be in accordance with attached data sheets, specifications and codes/standards to. All

instrumentation and electrical components shall be suitable for area classification as indicated in the

electrical and instrumentation data sheets attached.

5.5.2 In case any additional instrumentation is required, bidder to include the same in his scope and

categorically define the same in his proposal.

5.5.0 Machine Monitoring System

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5.6.1 Vibration & temperature monitoring system shall be provided as per latest edition of API 670.

5.6.2 The radial and thrust bearing of each main line pump package shall have embedded RTDs for

bearing metal temp monitoring as per API-670.

5.6.3 AT least two RTDs located at the prominent places shall be provided and thrust bearing (both active

and inactive sides).

5.6.4 Each RTD above shall provide pre-alarm and trip alarm (audio and visual) on the annunciator located

on the unit control panel of each pump package. The alarm signals can be taken from the

temperature monitors to the annunciator. Also refer instrumentation specification.

5.7.0 Vibration Monitoring System

5.7.1 Each pump package shall be provided with non-contacting probes in X & Y direction and axial

displacement probes as per API 670. Bidder shall provide the complete vibration monitoring system

which includes probes/sensors, proximeters, cables and monitors.

5.7.2 Each probe shall provide pre -alarm and trip with simultaneous alarm (audio and visual) on the

annunciator located on the unit control panel in the event of high vibrations. Also refer instrumentation

specifications

5.7.3 Key phasor (one event per revolution ) on shaft shall be provided.

5.8.0 Performance Test and Unitization

5.8.1 Vendor shall carry out performance test for each pump as per applicable clauses of API 610, 11th

edition along and also as per HPCL standard specification no. In case of any dispute between the

above two HPCL specification shall have precedence.

5.8.2 Each pump package shall be unitized at the works of pump manufacturer to ensure proper

mechanical fitment before dispatch to site.

5.9.0 Spares

5.9.1 The vendor shall supply the spares required for 2 years of normal running as detailed.

5.9.2 The offer shall include the commissioning spares required for the pumping unit. Bidder shall indicate

list of commissioning spares considered by them separately.

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5.9.3 The vendor shall assure continued availability for all replacements/accessories or as an alternative,

make available to purchaser the shop fabrication drawing during the working life of the offered units.

6.1.0 BASE PLATE AND GROUTING:

6.1.1 The base plate shall be a combined type to accommodate Motor, pump and other located under the

pumping unit supports shall be welded so as to reinforce cross members.

6.1.2 Base plate shall be sturdy enough and shall have provision for lifting the assembled unit for

alignment purpose. Any part of Base place would not be allowed for grouting or embedding with grout

or cement material.

6.1.3 The supplier shall arrange the combined base plate such that any oil spillage from the pump can be

collected through a common drain point.

6.1.4 The base plate and its supports shall be so constructed and the equipments so mounted on the base

plate to minimise misalignment caused by mechanical forces such as normal piping strains, internal

differential thermal expansions and hydraulic thrust.

6.1.5 Requisite numbers of holding down anchor bolts with locking nuts shall be supplied for the combined

base plate, luboil cooler assembly and other ancillaries of pumping unit.

6.1.6 Owner shall provide a RCC foundation with pockets for grouting bolts based on the design provided.

Vendor shall supply the epoxy grout material for the foundation along with grouting bolts . This epoxy

grout shall combine excellent vibration damping characteristics with intimate surface contact with the

combined Base Plate to ensure permanent alignment so as to extend the life of seals, shafts coupling,

rotors and bearings. The above epoxy grout shall provide excellent resistance to degradation of

foundation by fuels, lubricants and acids. The total quantity of above grouting material required for the

foundation shall be clearly spelt in their offer and shall be supplied. The bidder shall also supply

additional 10% of the calculated quantity of the above grouting material considering undulations,

wastage etc.

6.2.0 Layout

6.2.1 Bidder shall furnish a preliminary layout for each station and pump set with its auxiliaries duly

indicating the major dimensions (length x breadth x height), and distance between the skids/base

plates after taking into account the maintenance requirements.

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Sheet 9 of 18

6.2.2 The following details shall be furnished by bidder during offer:

-Weights of individual equipment

-Total weight of pump-driver skid (with equipment mounted)

-Maximum erection weight

-Maximum maintenance weight

-Recommended capacity of material handling facility

-Clearance required between purchaser‟s crane hook and equipment

-Distance between adjacent pumps.

7.0.0 UTILITIES TO BE PROVIDED BY OWNER

7.1.0 Power Supply

The Owner shall provide necessary power supply from their MCC for the AC Variable speed drive &

electric motor

space heater shall be supplied at 230V, single phase

7.2.0 The Owner‟s responsibility for providing utilities on a continuous basis is limited to above. Any

provision for supply of running water or compressed air for cooling purpose is not agreeable.

8.0.0 SERVICE FOR INSTALLATION & COMMISSIONING

The supplier will render their services for installation and commissioning for all the pumping units in

totality. They shall be responsible for satisfactory installation & commissioning of each unit as system

with verification for performance of Motor, AC Variable speed drive (wherever required) & Control

system and for pump with flow parameter as designated to complete satisfaction of the Owner.

9.0.0 Installation

9.1.1 Installation services are hereby specified as follows:

a. Pre-commissioning check of base plate foundation including pre -grouting, grouting and post-

grouting.

b. Alignment of prime mover unit.

c. Alignment and other pre-commissioning checks for pump.

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d. Pre-commissioning checks for complete Electrical system.

e. Pre-commissioning checks for complete AC Variable speed drive (wherever provided).

f. Pre-commissioning check for complete instrumentation control system.

g. Any other technical assistance of similar nature as & when required during the process of

installation.

9.1.2 The supplier will provide special technical assistance to Owner‟s representative to overcome

bottleneck during installation stage, if any.

9.1.3 Installation Engineers/Technician deputed by the supplier for this assignment shall be fully conversant

with technical details of, Electrical system and instrumentation control system and shall be equipped

with all tools, test and calibration equipment required for the purpose.

9.1.4 The detailed planning will be finalised upon receipt of purchase order with approval of the owner.

9.2.0 Commissioning

9.2.1 The commissioning of complete pumping unit with SITE TEST including supply of commissioning

spare will be the responsibility of the supplier. The supplier will provide special assistance, to the

owner‟s representative to overcome bottleneck, if any, during the process of commissioning.

9.2.2 Commissioning Engineers/ Technician deputed by the supplier for this assignment shall be fully

conversant with technical details of motor, pump, gearbox & Electrical system & instrumentation

control system and shall be equipped with all necessary commissioning spares, tools and test &

calibration equipment.

9.2.3 Engineers / Technicians required for the purpose with duration are specified. The detailed planning

will be finalised with approval of owner upon receipt of purchase order.

10.0.0 NAME PLATES:

T10.1.0 The motor, pump and control panel shall be fitted with corrosion resistant name plates, securely

fastened by stainless steel pins at easily visible and accessible points on such equipment.

10.2.0 The nameplate shall be stamped with following information:

a) Type, Model & Manufacturer

b) Serial Number

c) Rating

d) RPM

e) Tag No.

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In addition to the above, an arrow shall be stamped at readily observable point on the motor and pump

and to indicate direction of rotation.

10.3.0 Nameplate with essential information shall be provided on electrical and instrumentation appliances

also.

11.0.0 PAINTING:

11.1.0 All external, unprotected metal surfaces shall be thoroughly cleaned, degreased & primer coated

strictly in accordance to manufacturer‟s application instructions.

11.2.0 All bare steel surfaces shall be corrosion inhibited by application of protective grease or oil film prior to

shipment.

11.3.0 All paints used shall be of 100% solid volume (high build) polyurethane paint suitable for the

environment and oil and grease resistant and/or heat resistant as necessary to suit the particular duty

of the component.

11.4.0 The finishing coats of paint shall have a semi-gloss surface. The colour externally shall be admiralty/

battleship grey.

12.0.0 PACKING:

12.1.0 The Motor, pump and all unit subassemblies shall be totally covered in water proof wrapping and

packed in wooden crates so that no part of the equipment/sub-assembly is exposed. The packing

shall be sea worthy, rugged against handling in ports and transportation by road.

12.2.0 All electrical equipment, cables etc. shall be securely anchored to the skid and wrapped in waterproof

wrapping. All fasteners shall be tightened.

12.3.0 All instruments/components that could be damaged in shipment shall be removed, tagged and crated

in waterproof boxes. The boxes shall protect the instruments in accorda nce with their sensitivity of

dynamic loads and will have a static desiccant container placed inside the waterproof wrapping.

12.4.0 Also the annular space in the box shall be filled with soft filler packing.

12.5.0 All boxes of instruments shall be securely attached to the skid for shipment.

12.6.0 All the openings, flange faces, thread connections and cables exposed as a result of instrument/

components removal shall be protected in a manner to prevent damage during shipment by use of

conduit plugs or rigid conduit boxes. Packing list shall be furnished along with each package of

shipment.

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12.7.0 All commissioning spares furnished by the Vendor shall be wrapped and packaged so that they will be

preserved in original as new condition under the normal condition of storage in India and shall be

properly tagged and coded so that later identification for the intended equipment usage will be

facilitated. These shall be packed separately, clearly marked as "Commissioning Spares” and shipped

at the same time as the main equipment.

12.8.0 All openings shall be provided with substantial wooden or metal enclosures. All components and

parts shall be identified with a securely attached metal tag number indicating part name.

12.9.0 Packing list shall be furnished so that parts can be handled with un-crating, if desired. Packing fillers

shall be used wherever required.

12.10.0 Exposed metallic parts, which could corrode during shipment, shall be coated with anticorrosive

agents before shipment.

12.11.0 An arrow marked on the visible side of the crates shall indicate the position of handling of crates for

shipment.

13.0.0 SHIPMENT / TRANSPORTATION:

13.1.0 All the imported material shall be properly transported from supplier works to desired location in good

condition.

13.2.1 STRUCTURAL SUPPORTS

The Vendor shall provide pre-fabricated structural and supports necessary for the mounting of the

MLPU, its auxiliaries and also the field piping from auxiliaries to the pumping units.

14.0.0 EVALUATION AND PENALTY CRITERIA

14.1.0 Evaluation and Penalty Criteria, as applicable for this tender, have been detailed in specific r

requirement for the project (Annexure-VIII).

15.0.0 WARRANTY:

15.1.0 All equipment and component parts shall be guaranteed by the Supplier against defective design,

materials, manufacture or performance during the warranty period specified in the General Conditions

of Purchase of this tender. All such defects, if any, shall be rectified and/or made good by repair or

replacement by Supplier at his cost.

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15.2.0 If it is noted that there is recurring type of failure because of any defective material or workmanship of

Supplier on any of the parts/subassemblies of the mainline motor/pump, the supplier shall replace

such parts/sub-assemblies and make defects good free of cost.

16.0.0 PERFORMANCE GUARANTEE:

16.1.0 The Supplier shall be responsible for and guarantee the performance of the entire pumping unit

including all ancillaries, auxiliaries, accessories, instruments etc. The supplier will furthermore be

responsible and guarantee the proper function of the whole pumping unit.

17.0.0 SITE TESTS:

17.1.0 Upon satisfactory installation and commissioning, pumping unit will be tested with the products to be

pumped through the pipeline and the performance / the operating parameters motor, pump and all

auxiliaries shall be verified with specified/indicated parameters within two weeks period for

commissioning (limited to maximum working of 12 hours per day).

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REQUIREMENT OF MAINLINE PUMPS

Clause Area Description Requirement /Remark

1.0 Scope Supply of Horizontal split case type centrifugal pump as per API 1610 (latest edition)

Rating and Quantity as specified

2. Service Petroleum Product i) Continuous service ii) Hazardous area, class-I,

Divn-I & II, Group C& D gases as classified in APIL RP-500 C.

iii) Product characteristic as per Annexure III

3.00 Design 1. Closed type impeller 2. For multi stage type-

The hydraulic balance shall be achieved by back-to-back arrangement of impellers.

3. Head –Capacity Curve for the pump shall be of continuously rising type up to shut off.

4. Best efficiency point (BEP) for the impeller shall coincide with that of duty point.

5. NPSHR in the complete flow range (MCSF to Rated ) shall be at least 1 meter below the NPSHA specified.

6. Vibration shall be within specified limits as per API 610

Thrust bearings may be used to take care of unbalanced force.

Shut off head 110% to 120%

Rated point shall be at left side within 5% of the BEP of the rated impeller

MCSF for pump shall not be more than 40% of the BEP

Rated impeller should be less than that of maximum impeller diameter of the casing.

4.00 Provisions Suction/discharge flanges- To be on opposite sides of the casing and fitted to the bottom half of the pump casing

Size and rating- As specified. Suction nozzle shall be located on right hand side looking from free en of pump.

Drains for casing & Throat bushing 1” Tapping

Mounting for pressure/Temperature control sensors/indications Vent

Includes casing temperature RTD (1/2 ” tapping)

Bearing housing: Replacement of bearing /bushes

without dismantling other assemblies like Mech. Seals, Pump casing etc.

Tapping of Temp. indicator and detection (RTD)

Bearing cooling by lubricating oil. Cooling system for lubricating oil.

In case of forced lube oil system for pump and motor same to be integrated independent system.

Mechanical seal (including sleeve)

Removable without dismantling the pump case.

Pressure-temperature rating of the seal shall be meeting the pressure class rating of the casing & discharge flange

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Seal leakage detection system

irrespective of the nos. of stages for all pumps.

Piping arrangement- As per applicable design and plan mentioned in the specific requirements and complying with API 682 latest edition for the specified application

Shaft extension shall be turned for taper fit coupling

Impeller, shaft and rotor assembly shall each be dynamically balanced.

Separately to ensure interchangeability

Cyclone filter In case of seal cooling by pumped liquid

Vibration sensors Required for horizontal & vertical measurements both for DE & NDE bearing

Lifting lugs, Jack screws To be provided

5.0 Materials Materials for pump parts shall be in accordance with those listed in API 610 latest edition, Column S6, Table H-1

6.0 Pump data sheet

Data sheet as per API-610 with performance curve

Vendor to provide in the prescribed form

7.0 Inspection & Test

i) Hydrostatic test W By Owner or TPIL (third party inspection) at Vendor‟s /Manufacturer‟s works Tests in accordance with

BSEN ISO 9906 and API-610

The acceptance tolerances will be to API-610

Performance tests (SPSH (R) test) at 5 points fro minimum to 110% of rated flow (including the rated point) as per API-610 and Hydraulic institute standards

Heat sample of the casing for each pump with the test results

Complete test report including test curve extrapolated to speeds at intervals of 200 RPM to be submitted

R-Review, W- Witness

ii) Performance test W

iii) NPSHR test for all pumps W

iv) Dismantling and strip dowun inspection

W

v) Re-assembly and re-run test (for 3 hrs)

W

vi) vii)

Measurement of Vibration (DE & NDE) Measurement of sound/noise level at 1 M & 5 M distance

W W

viii) Radiography inspection of impeller trip

R

ix) Ultrasonic testing of shaft R

x)

Dynamic balancing of impeller, shaft, pump coupling & complete rotor assembly

R

xi) Dimensional Inspection R

xii) Material test certificates (incl. Chemical analysis and Mech. Properties)

R

xiii) Test certificate for Mechanical seal

R

8.0 Instrumentation & Control

Pump control & protective devices to be provided

As specified

9.0 Name place Corrosion resistant nameplate with following information (securely

The pump serial No. shall be stamped on the pump casing

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fastened):- a) Manufacture‟s Name & address b) Model No. & Type of Pump c) Serial Number of the Pump d) Capacity M

3/Hr.

e) Pumping Head in M f) Specific Gravity of the liquid to

be handled g) R.P.M h) Bearing and seal Manufacture‟s

name and identity number i) Tag No. j) Any other information required

and an arrow shall be stamped at readily observable point on the pump to indicate direction of rotation.

10.0 Painting All external, unprotected metal surfaces shall be thoroughly cleaned, degreased and primed and painted in accordance to manufacture‟s application instructions The internal mechanical parts shall be greased to protect against rusting

After testing and before packing. Thorough cleaning and degreasing to be done prior to application

11.0 Packing & Shipment

All component parts and equipment shall be packed in accordance with good packing practice for shipment to tropical climate

12.0 Spares Spares for 2 years Operation and maintenance as specified

Vendor shall assure supply of spares till the normal life of the MLPU

13.0 Coupling Along with coupling guard Non sparking type guard

14.0 Site tests Upon satisfactory installation & commissioning , each Pumping Unit will be tested with the petroleum product to be pumped through the pipeline and the Pump‟s performance verified with station flow and pressure measurements including vibration and sound level well within specified limit as per governing specification for prime mover/gear box and pump.

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REQUIREMENT OF VARIABLE SPEED DRIVE SYSTEM

The equipment listed below shall be supplied in accordance with the requirements specified in this document, equipment data sheet, specification applicable codes and standards and other documents attached/ referred herein. SCOPE:

Sl. No.

Quantity STATION Description

1. 2 SET KHOPOLI

6.6kV, 3phase, minimum 18 pulse variable speed drive (VSD) system suitable for 2 Nos. New Pump Motor of 2750kW (Estimated rating) and 1 No. Existing 750kW (Refer Attach Motor Data Sheet for Detail) including Dry type VSD transformer. VSD Set/System shall be complete with the following as per attached system configuration:

1. One No. Synchronous Panel. 2. One No. Common Drive Logic Panel. 3. One Set. of Down Stream Breakers Panel Board

(Consists of 9 Nos. of Breakers). 4. Interconnecting Power & Control Cables required for the

above VSD System. 5. 3 Nos. of Local Control panels. 6. Addition/ Modification of Existing 6.6kV Switchboard. 7. Any required change in control scheme.

Note: Both VFDs shall have option for cross-selection of motor according to the pump which is under operation as per attached system configuration. Same VFD shall be suitable for both rating of motor i.e. 2750kW & 750kW.

2 1 SET

For each rating

- Special Tools and Tackles required for the erection, testing, commissioning, operation and maintenance of Complete System at Khopoli.

3 1 SET

For each rating

- Recommended Commissioning Spare Parts for Complete System at each location Khopoli.

4 1 SET

For each rating

- Mandatory Spares as per vendor recommendation for Complete System at each location Khopoli.

5 1 SET

For each rating

- Recommended 2 year operation & maintenance Spare (Vendor to submit unit rate separately for the same)

Notes: Vendor to visit site (At Khopoli) before submitting offer and analyze required 6.6kV switchgear modification/addition as per attached system configuration and indicate the same in their offer. All the required modifications/additions due to addition of VFD system in the 6.6kV switchboard are in the scope of vendor.

Vendor to check and indicate interface requirement with UCP Panel (Vibrat ion monitoring system and UCP

panel do not exist for exist ing motor-pumping units; UCP panel shall be upcoming only w ith new motor-

pumping units) and Station PLC. All interface requirements and any changes in control scheme are in the scope of vendor.

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SPECIFICATION OF


CENTRIFUGAL PUMP


9579-02-TS-101

Sheet 18 of 18

1. Vendor‟s scope of work includes design, engineering, manufacturing, shop testing, inspection of

bought out items and supply of all electrical equipments. 2. Pumps shall be fed from VSD system which includes input converter transformer. Protection and

Metering for VSD system shall be as per attached specifications for VSD system and referred codes and standards.

3. VSD panel shall be located in the sub-station. Vendor to indicate requirement of Air-conditioned room for the same (If any). However, equipment shall be suitable for operation even during failure of Air-Condition.

4. With reference to limits of harmonics as per IEEE 519, the harmonics are to be controlled at 6.6kV bus. The overall power factor of the drives at 100% load shall not be less than 0.99

5. Any other accessory, fixing hardware, switches etc. which shall be required for satisfactory operation and completeness shall be provided by vendor.

6. Type test certificates and utility consumption list shall be submitted with the offer. 7. Inspection and Testing at works shall be as per VSD specification. 8. Final Documentation: A. Vendor to furnish Hard Copy and electronic files of all the documents indicated for final

documentation in addition of hard copy. B. Vendor to furnish all drawings and documents either in MS Word, MS Excel, Autocad, Microstation

stored in electronic media. C. Final documentation shall be provided along with hard copies in compact disc compatible with

standard PC based application. D. All operating and maintaining instructions in electronic media or in scanned images converted in

electronic media. Final documentation shall be provided in CD with proper index along with hard copies. ORDER OF PRECENDENCE: 1. Statutory Rules and Regulations 2. This Requisition 3. Equipment Data Sheet 4. Standard specification 5. Codes and Standards

Requirements for Seal Flushing Piping (Plan to be selected shall be as per specific requirements

complying with API 682 latest edition for specified application)

1.0 The piping design & joint fabrication, examination and inspection shall be in accordance with ANSI B

31.3.

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SPECIFICATION OF


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9579-02-TS-101

Sheet 19 of 18

2.0 The complete seal system for each stuffing box including the reservoir shall be arranged as one skid

and supported/bolted to the base plate in a manner that the projection of any equipment/instruments

falls within the confines of base plate. The reservoir and the accessories to be mounted on a

substantial support furnished by the manufacturer and should not be affected by the pump vibration.

In case of between bearing pumps there shall be two such units, one each for each stuffing box

mounted on opposite ends of the pump.

3.0 Elimination of air pockets by the use of valve vents or non-accumulating piping arrangements.

4.0 Pipe threads shall be tapered in accordance with ANSI B1.20.1 Flanges shall be in accordance with

ANSI B16.5. For socket welded construction, a 2mm (1/16”) gap shall be left between the pipe end

and the bottom of the socket.

5.0 Piping shall be fabricated by bending and welding to minimize the use of flanges and fittings. Welded

flanges are permitted only at the equipment connections, at the edge of base plate and for ease of

maintenance. Threaded connections shall be limited to the final connections at the gland plate and

accessories.

6.0 In order to reduce pressure drop within the system, the length of lines and the use of fittings between

the reservoir and the seal glands shall be minimized. All lines shall slope up from the pump gland to

the reservoir at a minimum of 10mm per 250 mm using smooth long radius bends. Hot lines shall be

insulated, if required, as necessary for safety.

7.0 A nameplate, stamped with the design pressure, hydrostatic test pressure and the max. allowable

temp. shall be permanently attached to the reservoir (in case of chosen plan requires a reservoir).

8.0 The lines connecting the mech. Seal & the reservoir shall be seamless, 20mm (3/4”) minimum,

schedule 80S, 300 series stainless steel in case of pipe. In case of tubes, the same shall be

seamless, ASTM A269 stainless steel, 20mm (3/4”) diameter x 2.4mm (0.095 inch) wall thickness.

9.0 The cooling coil tubes shall be seamless, 15mm (1/2”) size x 1/6mm (0/065 inch) minimum wall

thickness (16SWG), ASTM A269 stainless steel.

10.0 The instruments shall be suitable for the specified area classification and shall be in accordance to

the instrument specification enclosed with the inquiry document.

11.0 The indicating instruments shall be mounted such that the same are visible from the grade level for

reading purposes.

12.0 All valves shall have bolted bonnets and glands and of suitable pressure class. For primary ANSI

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New Delhi

SPECIFICATION OF


CENTRIFUGAL PUMP


9579-02-TS-101

Sheet 20 of 18

service rating greater than or equal to class 900, block valves may be of welded bonnet or no-bonnet

construction with a bolted gland. These valves shall be suitable for repacking under pressure.

13.0 Block valves shall be supplied with applicable pressure class.

14.0 Pipe fittings and unions shall be forged class 3000.

Signature and stamp of Vendor

chapter 2 general requirements for mainline pumping...

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