nuclear power corporation of india limited (a … · (a government of india enterprise) madras...

NUCLEAR POWER CORPORATION OF INDIA LIMITED (A Government of India Enterprise)

MADRAS ATOMIC POWER STATION

KALPAKKAM

TENDER SPECIFICATION FOR HIGH VOLTAGE (6600V)

CONDENSER COOLING WATER PUMP MOTOR (CCWPM)

June 2015

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Nuclear Power Corporation of India Limited Madras Atomic Power Station

Technical Specification for Condenser Cooling Water Pump Motor CONTENTS

Section: CONTENTS of 91

Rev-0

CONTENTS

Section Title No. 0f sheets

CC Tender Technical Specification CC-1 Scope of Supply / Work / Services 3 CC-2 Applicable Codes, Standards and Specifications 2 CC-3 Specification of Main Equipment and Accessories 5 CC-4 Equipment Construction & Design Details 14 CC-5 Inspection & Testing 4 CC-6 Quality Assurance Plan 16 CC-7 Tender Evaluation 1 CC-8 Tests at Site on Motor 2 CC-9 List of Tools & Tackles 1 CC-10 List of drawings enclosed with tender 1 CC-11 Annexure 22 Ann-A Existing Motor and Pump specification details Ann-B Existing Pump-Motor Characteristics Curves Ann-C Existing Pump Pedestal dimensional drawing Ann-D Specification for UT and DPT test Ann-E Essential spares

Ann-F List of drawing and characteristic curves for motor to be submitted by the firm for motor

Ann-G List of Approved vendors Ann-H Scope of work for transportation

Ann-I Guaranteed Technical Particulars to be filled by Motor manufacturer along with tender

D Format for Submission of Part I (Technical) of the tender D2.1 Equipment manufacturer’s General Particulars 1 D2.2 Schedule of Tenderer’s Experience 1 D2.3 Drawings to be submitted along with the Tender 1

D2.4 Performance Data, including performance curves, etc. to be Submitted along with the tender NA

D2.5 Schedule of submission of drawings, data, instruction manuals, Test reports and end documents etc. 3

D2.6 Schedule of Performance guarantee 1 D2.7 Deviation from the tender specification 1 D2.7.1 Schedule of Deviations Technical 1 D2.7.2 Schedule of Deviation Commercial 1

D2.8 Schedule of Manufacturing, delivery and other related activities

1


Technical Specification for Condenser Cooling Water Pump Motor CONTENTS

Section: CONTENTS

of 91 Rev-0

D2.9 Schedule of Personnel for Erection, Testing & Commissioning

1

E Price Bid Format Ann - I Price format for submission of price Bid 2 Ann - II Price format for transportation and Commissioning 1 Ann-III Price format for Type test 1


Technical Specification for Condenser Cooling Water Pump Motor SCOPE OF SUPPLY / WORK / SERVICES

Section: CC-1 of 91

Rev-0

Specification for CCW PM Motor of MAPS June 2015

GENERAL STATEMENT ABOUT STATION

Madras Atomic Power Station Unit 1 and 2 is located near sea coast of Kanchipuram district in Tamil Nadu. The land mark near the station is Mahabalipuram. The distance between Mahabalipuram to station is around 16 KMs. It is located at 75 KMs from Chennai when travelled via East Coast road and 80KMs from Chennai when travelled in NH 47 via Chengalpattu. The distance between Chengalpattu and Station is around 30KMs.

ENVIRONMENTAL CONDITION AT SITE:

Altitude from Sea Level : 4 meters above mean sea level Wind speed : 52 KM/hr to 55KM/hr at 50m height maximum General Ambient temperature : 26oC Minimum and 50oC Maximum General Humidity level : 55% to 90% Atmospheric pressure : 1020mb 1.0 SCOPE OF SUPPLY / WORK / SERVICES This specification establishes the technical requirements of High voltage class

(6600V) Grease lubricated Vertical TEFC Motor for continuous service for driving Condenser Cooling Water Pump in Condenser water circulating system of Madras Atomic Power Station

This specification covers design, engineering, material, construction, manufacture, Inspection, conducting type test (if required) and routine test, inspection at works, packing, transportation and delivery to site, installation on either Unit 1 or 2, site no load & load performance testing, commissioning, putting into successful load operation, submission of complete documents in soft and hard copy format for Madras Atomic Power Station. Bidders are required to provide comprehensive offer including erection and commissioning and limiting to the scope to erection and commissioning supervision is not be acceptable. The time frame for completion of activities shall be as follows:

SL Activity Max. Completion time frame from date of

PO/LOI 1 Design, manufacturing and complete assembly

of Two numbers of motor at factory including approval of QAP and drawings etc as per dimensional drawing enclosed

120 days

1.1 Motor shall be complete with all necessary auxiliary components like space heaters, winding and bearing temperature sensors (winding temperature sensor shall be copper-constantan thermocouple and top & bottom bearing temperature shall be PT



Section: CC-1 of 91

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100 RTD), sealed terminal boxes for power, space heater and temperature sensors and other control elements (pull box for temperature sensors wiring termination), double compression type cable gland for space heater terminal box, shaft key and suitable stand so that it can be preserved in vertical position at site.

The Motor shall undergo complete tests as specified in section CC5 and CC6 of this specification in the presence of NPCIL QA engineer.

2.0 Essential spare parts (Refer Annexure-E) and maintenance tools, special tools and tackles required for dismantling and assembly of Motor shall be included in the scope of supply.

3.0 As the motor shall drive the existing pump, the base flange with holes and spi-guard of motor shall be made suitable to match with the existing pump flange without calling for any modification on pump flange or its pedestals etc at site.

4.0 As the locations of Pumps are already fixed, the overall size of the motor shall suit to the site requirement. No modification on existing pump orientation, pump pedestal or any other nearby equipment or extension of space is possible, hence the bidder shall visit the site and collect all the engineering inputs required for manufacturing of motors to suit site requirements, workout factory modifications and to ensure retrofitting as per site requirement. Still if any hindrances or modification requirement from equipment dimension point of view exist, the same shall be clearly brought out in the offer. After site visit by bidder, bid shall confirm retrofitting suitability.

5.0 Any modification requirement from equipment dimension point of view should be clearly brought out.

6.0 These motor will be powered by 6.6KV switchgear with direct on-line starting through 6.6KV Air Blast Circuit Breaker. The motor shall be able to accelerate the driven equipment whose specification details and characteristic curves are given in the enclosed Annexure-A and B

7.0 The scope of tender also includes submission of various end documents covered in subsequent sections, analysis and calculation reports and design review in consultation with PURCHASER. The documentation shall include all technical information as called in the referred IS / IEC / IEEE standards regarding the Motor. The documentation and drawings shall be updated for “As built” information and shall be matched with field details. The drawings of space heaters, RTDs, Thermocouple and any other major components shall be part of documentation. Operation & Maintenance manuals, calculations, procedures and test reports shall be part of “End Documentation”. The firm shall supply the complete assembly drawing



Section: CC-1 of 91

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giving detailed internal view in soft and hard form. Over all general arrangement drawing alone is not acceptable.

8.0 Any deviation to technical specification and tender condition shall be brought out clearly and bidder shall not submit offer with modified scope.

9.0 All accessories required for manufacturing the motor shall be purchased only from the approved vendor. The bearing shall be of M/s SKF make brass caged only. The firm shall submit the vendors list along with Quality Assurance Plan for approval. Some of the registered vendors list is given in Annexure-G for reference.


Technical Specification for Condenser Cooling Water Pump Motor APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

Section: CC-2 of 91 Rev-0


APPLICABLE CODES, STANDARDS AND SPECIFICATIONS 1.0 The design, material, construction, manufacture, inspection, testing and performance

of Motor and its accessories shall comply with the latest editions (including amendments thereto) of all currently applicable standards, statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. This specification may contain references to older versions of IEC / IEEE / IS, but since all standards are subject to revision, bidder shall offer equipment applying the latest revision of IEC / IEEE / IS standards.

2.0 In the event of any conflict between the requirements of the codes / standards and this

specification, the more stringent of the two shall govern. 3.0 Prior approval shall be obtained by the CONTRACTOR from the PURCHASER

regarding make and type of items as well as make and type of components, instruments and subcontracted items (if any) included in this scope but not covered in the Motor data sheets under Section-CC-3.

4.0 Other National Standards are acceptable if they are established to be equal to or

superior to the listed standards. In all such cases, however, copies of English translation of such National Standards shall be attached to the tender. The tenders not complying with this requirement are liable for rejection.

5.0 Type test report done at other country is not acceptable. 6.0 Applicable Bureau of Indian Standards and other Standards

Sl No IS standard Description of the IS standards

1 IS 5 Colours for ready mixed paints and enamels 2 IS 325 Specification for three phase induction Motors 3 IS 900 Code of practice for Installation and maintenance of induction

Motors 4 IS 1231 Dimensions of three phase foot mounted and vertical flange

mounted induction motors 5 IS 1271 Classification of Insulating materials for electrical machinery

and apparatus in relation to their thermal stability in service 6 IS 1940 Mechanical Vibration - Balance Quality Requirements for

Rotors in a Constant (Rigid) State - Part 1 : Specification and Verification of Balance Tolerances

7 IS 2073 Steel used for shaft 8 IS 2099 Bushings for alternating voltages above 1000 V 9 IS 2147 Degree of Protection 10 IS 2223 Dimension of flange mounted AC induction Motors 11 IS 2253 Designation for types of construction and mounting

arrangement of rotating electrical machines


Technical Specification for Condenser Cooling Water Pump Motor APPLICABLE CODES, STANDARDS AND SPECIFICATIONS



Sl No IS standard Description of the IS standards

12 IS 2254 Dimension of vertical shaft motors for pumps 13 IS 2848 Specification for Industrial Platinum Resistance Thermometer

Sensors 14 IS 3043 Dimension of Large size frame 15 IS 4029 Guide for testing of three phase induction motors 16 IS 4691 Degree of protection provided by enclosure for rotating

electrical machinery. 17 IS 4722 Rotating electrical machinery 18 IS 4728 Terminal marking & direction of rotation for rotating electrical

machinery 19 IS 4889 Method of determination of efficiency of rotating electrical

machines 20 IS 6098 Method of measurement of the airborne noise emitted by

rotating electrical machinery. 21 IS 6160 Rectangular conductors for electrical machines 22 IS 6362 Designation methods of cooling for rotating electrical

machines 23 IS 7816 Guide for testing IR of rotating electrical machines 24 IS 8789 Values of Performance Characteristics for Three Phase

Induction Motors. 25 IS 11353 Guide for uniform system of marking & identification of

conductors & apparatus terminals 26 IS 12065 Permissible limits of noise levels for rotating Electrical

machines. 27 IS 12075 Mechanical Vibration of Rotating Electrical Machines with

Shaft Height 56 mm and Higher - Measurement, Evaluation and Limits of Vibration Severity

28 IS 12802 Temperature rise measurement for rotating electrical Machines29 IS 12824 Type of duty and classes of rating assigned to rotating

electrical machines 30 IS 13107 Guide for measurement of winding resistance of an AC

machine during operation at alternating voltage 31 IS 13508 Tan delta and capacitance Measurement test 32 IS 14222 Impulse Withstand voltage test 33 IS 14568 P2 Dimensions and output series for rotating electrical machines

frame numbers 355 to 1000 and flange numbers 1180 to 2360 34 IS 14578 Induction Motors used in Nuclear Power Plants 35 IEC 60034 Rotating electrical machines, Rating and performance 36 IEC 60137 Bushings for alternating voltages above 1000 V 37 IEC 60529 Degrees of protection provided by enclosures (IP Code) 38 IEEE 522 IEEE Guide for Testing Turn Insulation of Form-Wound

Stator Coils for Alternating-Current Electric Machines


Technical Specification for Condenser Cooling Water Pump Motor SPECIFICATION OF MAIN EQUIPMENTS AND ACCESSSORIES



SPECIFICATION OF MAIN EQUIPMENTS AND ACCESSSORIES

This section covers data sheets for Condenser Cooling Water Pump Motor and accessories to be supplied along with it.

1.0 Condenser Cooling Water Pump Motor: SL No Specification parameter Unit Value required 1 Motor designation Condenser Cooling Water Pump Motor

(CCWPM) 2 Applicable standard IS 325 / IEC 60034 3 Type of motor 3 phase AC induction motor 4 Type of rotor Squirrel cage 5 Type of starting–Suitable for DIRECT-ON-LINE 6 Service for which Motor is

intended To drive - Vertical spindle mixed axial

flow pump type BHMa-83, single stage M/s Kirloskar make

7 Voltage with its variation V 6600 ± 10% 8 No. of phases 3 9 KW / HP rating KW Suitable for the driven pump of

specifications detailed but not less than 450KW

10 Frequency with its variation Hz 50 ± 5% Combined voltage &

frequency variations +10%

11 Rated Speed and direction of rotation

RPM 494. Clockwise rotation when viewed from Vertical Motor Non drive end side (From Top view)

12 Phase 3 13 Type of system Grounding Solid Grounding 14 Type of stator winding

connection Star

15 Type of enclosure / Degree of protection for

a Motor as per IS 4691 IP 55 or still better b Power cable terminal boxes

with phase segregated IP 65

c Auxiliary terminal Boxes IP 65 d Frame size Confirming to IS:1231, IS:2223. IS:

2254 and suitable for the existing pump pedestal

16 Type of Enclosure TEFC / CACA / CACW / PDV 17 Duty S1 - Continuous 18 Type of Mounting Vertical - Flange Mounted. The flange

shall suit for the existing pump pedestal ( Refer the enclosed drawing for pump pedestal details)





SL No Specification parameter Unit Value required 19 Single shaft / double shaft

extension Single shaft

20 Short circuit rating of power terminals boxes

a MVA MVA 500 b Duration secon

ds 0.25

21 Size of Purchasers power cable

3Core Aluminium 240sq.mm 11KV grade

22 Type of power cable PILC (Paper Insulated Lead Covered) or XLPE (Cross Linked Poly ethylene)

23 Size of purchasers power cable for space heater connection

Aluminium conductor 2C 6 sqmm PVC insulated cable

24 Size of Purchasers cable for RTDs external connection

2.5sqmm Copper conductor PVC cable

25 Auxiliary power supply 1. 240V AC, 50Hz 1ph for space heater 2. 240V AC, 50Hz 1Ph AC for

instrumentation and control 26 Special requirement

pertaining to

a Bearings for both DE and NDE

Anti friction ball / roller bearings having brass cage with grease for lubrication and cooling.

b Lubricant for bearings Servo gem2 grease c Bearing life More than 100,000 hours for normal

operation duty d Bearing temperature During normal operation from no load

to full load, the operating temperature of Both DE and NDE bearing shall not exceed 60deg C

e Re-grease facility Motor shall have re-grease facility at regular interval (firm shall give the re-greasing time)

f Bearing insulation If design warrants, bearing shall be insulated from shaft to avoid shaft current

g Bearing housing Cartridge type h Painting IS 5 i Coupling The Motor and Pump shaft will be

coupled with pin and bush type flexible coupling

j Critical speed >130% of rated speed k Inspection plug for air gap

measurement If feasible





SL No Specification parameter Unit Value required l Reverse rotation stop Not required m Temperature detector 1. Copper constantan thermocouple for

winding temperature measurement. (2 Nos per phase) 2. RTD PT 100 for both top and bottom

bearings n Vibration Peak to Peak

amplitude / Velocity at NO load and ON load

< 25 microns and 2 mm/sec

o Starting duty Direct ON Line p Acceleration time of Motor With DOL starter 2.5 sec q Insulation details / Class of

Insulation Vacuum impregnated / Class F or high

with temperature limited to Class B r Stator winding Insulation

system offered Subject to approval of purchaser,

Insulation system shall be able to with stand the specified condition during normal and abnormal condition. (Type test certificate to be submitted as a proof otherwise shall be tested for the required environment condition).

s Ambient temperature and humidity level during normal operation

50 deg C / 90%

t Balancing of rotor with all the shaft mounted components as per clause IS 1940 to be conducted in the presence of NPCIL QA Engineer

Yes, Balancing quality grade shall be G 2.5 or still better at the rated speed for which motor is designed for.

u Maximum No. of successive starts

To suit the full load Duty requirements

i In cold condition ii In hot condition

Minimum 2 successive starts for each condition, third start after one hour and fourth start after winding temperature reaches the room temperature

v Operating duty At 80 % of the voltage the motor shall be capable of starting and run on full load without injurious heating.

w Locked Rotor current Amps 600% x Pull out torque of the motor

at rated voltage not less than 200% of full load torque

y Over load capacity Shall be furnished by the firm 27 Materials requires for a Motor stator body / frame /

Flanges / Terminal boxes Rigid fabricated steel or In case of

casting it shall be either mechanite or approved equivalent





SL No Specification parameter Unit Value required b Stator and Rotor core Higher grade CRGO steel in laminated

form c Shaft Cooled rolled steel suitable for with

standing high starting torsion torques and starting duties with vertical motor application

d Rotor Retaining ring is used Non magnetic Forged material e Stator winding Electrolytic grade copper f Rotor winding Preferably copper bars g Wedges Non magnetic to with stand rotational

centrifugal forces h Insulation materials Suitable to with stand temperature

grade, different operating mode and hazardous environment.

28 Testing of Motor shaft and retaining ring shall be subjected to ultrasonic test as per enclosed specification PP-P-1981 and Dye-penetrant test as per the enclosed specification PP-P-2398

Required

29 Material specification certificates for shaft, retaining ring and bearings shall be offered for review

Required

30 Testing of RTDs and thermocouple as per CC4 SL No 1.6 and IS 2848

Being bought out item, Test Certificate for type test and calibration data sheet shall be submitted for review. In addition test for Insulation Resistance and HV test at 2KV to be conducted in the presence of NPCIL QA engineer

31 Should all the type test as per IS 325 specification on motor to be conducted in the presence of Purchasers representative

If valid type test is submitted and acceptable to Department QA Engineer then type test need not be performed. Otherwise all the type test as per IS specification shall be performed in the presence of Department QA Engineer.

32 Any other test Full load test to ascertain satisfactory performance of Motor with respect to successful driving of driven equipment at site.

33 Submission of quality plan as per CC 6 of specification.

Required

34 Submission of fabrication drawings to QA engineer for

Required





SL No Specification parameter Unit Value required Inspection

35 Visual inspection of all the components and dye penetrant testing of all machined surface

Required

36 Location of Motor Condenser cooling water pump vertical pedestal type structure at sea water pump house near sea shore

37 Service life of all the components with the exception of the bearings and parts specifically designed for easy replacement

Years Minimum 40Years

38 The overall size and height of the motor assembly shall be such that it can be installed and maintained in existing pump pedestal

Shall be met with

39 The overall diameter and height of the motor shall not be more than the existing motor dimensions by a large margin. (Refer Enclosed Drg No. M1/71212/2510/DD/Rev-5 )

Shall be met with

40 Terminal boxes and other sealing gasket

EPDM rubber to withstand temperature and prevent moisture entry


Technical Specification for Condenser Cooling Water Pump Motor EQUIPMENT CONSTRUCTION AND DESIGN DETAILS



EQUIPMENT CONSTRUCTION AND DESIGN DETAILS

1.0 Design Requirement 1.1 General

1.1.1 Motor shall be designed, manufactured with equipments and accessories in accordance with this specification and applicable standards indicated in section CC2 and CC3. Material and components not specifically stated in this specification and which are necessary for meeting requirements of this specification shall be included in the scope of supply

1.1.2 The design and workmanship shall be in accordance with the best engineering practice to ensure satisfactory performance and service life as specified herein. The intent of the specification is that the vendor supplying the equipment shall provide motor which shall be suitable for effectively starting and satisfactorily operating the driving and driven equipment under different operating condition and environment specified in the specifications continuously.

1.1.3 Design and manufacture of the motor shall be coordinated with the requirement of the driven equipment that is the condenser cooling water pump whose details are enclosed as Annexure A in Section CC 11 as part of this specification. The motor manufacturer shall fully cooperate with the purchaser by furnishing following information necessary for assembly and operation of the unit as a whole.

a) Overall General arrangement and detailed assembly / disassembly drawing with dimension giving complete internal details of motor including ventilation air flow and direction of rotation

b) Drawing detailing assembly of Bearing and grease lubrication arrangement. c) Complete name plate details along with Weight of the motor, the rotor and the

moment of inertia of the rotor assembly. d) Complete technical particulars of Motor, Bought out items and lubrication

(Grease) for bearings and characteristic curves in the Annexure B in Section CC 11 of this specification.

e) Complete power and control terminal box arrangement

1.1.4 It shall be noted that the motors proposed to be purchased will be driving pumps

which are already in service at site. Efforts will be made by the purchaser to submit maximum possible information on the driven equipment. It is the responsibility of the Motor manufacturer to match the characteristics of Motor to suit with the characteristics of the driven equipment as specified. Further the motor manufacturer





shall also take into consideration of the support structure stability presently existing, to ensure the motor will operate within the allowable vibration limits at all conditions of operation.

1.1.5 The motor is intended for replacing the existing 410KW motor for getting improved running parameter like winding and bearing temperature, vibration etc. The maximum KW rating of the motor shall not be less than 450KW and shall be suitable for accommodating in the existing location & base frame without causing any vibration / over temperature. Motor shall have a KW rating based on continuously driving the connected equipment for the conditions specified.

1.1.6 As the procurement is for more than one motor of same specification, Manufacturer shall ensure that the replacement of motor from one position (pump) to other shall be possible without requirement any modification. In addition its accessories also shall be fully interchangeable without the need for modification

1.1.7 The overall size and height of the motor assembly shall be such that it can be installed and maintained in the existing pump pedestal. The overall weight of the motor shall be suitable for the existing foundation and shall not contribute for vibration.

1.1.8 The overall diameter and height of the motor shall be so designed that it is possible to install the motors in the space available. Ref Drg No M1/71212/2510/DD. However, the dimensions of the motors shall not exceed the dimensions of the existing motors by a big margin as the space is limited for accommodating the higher size of motor.

1.1.9 All material used shall be of best quality and of the class most suitable for working under the conditions specified and shall withstand the variations of temperature and atmospheric conditions without distortion or deterioration or the setting up of undue stresses in any part and also without affecting the strength and suitability of the various parts for the work which they have to perform.

1.1.10 Pipes and pipe fittings, screws, studs, nuts and bolts used for external connections shall be as per the relevant standards. As the equipment will be installed at Sea water pump house, Steel bolts and nuts exposed to atmosphere shall be galvanised or cadmium plated and passivated to prevent corrosion

1.1.11 Materials in contact with lubricating grease shall be such as not to contribute to the formation of any acid or any other chemical which is harmful for the performance of bearing and Motor.

1.1.12 Labels, indelibly marked, shall be provided for all identifiable accessories like main terminal box, space heater terminal box, RTDs, thermocouple terminal box, etc. All label plates shall be of non-corrodible material.





1.1.13 Internal connections and fastenings shall be capable of operating under overloads and over-excitation allowed as per specified standards without injury.

1.1.14 Terminal bushing base plate, gland plates etc. in high current exposed zones shall be of non-magnetic material.

1.2 Enclosure

1.2.1 The enclosure shall be as specified in the specific requirement data sheet in Section CC3

1.2.2 The Motor shall be self ventilated unless otherwise specified. The type of cooling of the motor shall be as specified in the specific requirement data sheet in Section CC3

1.3 Stator Frame, Core, End shields and other fabricated items

The motor frame may be of rigid fabricated steel or casting. In the later case, the material shall be mechanite or approved equivalent. Specific mention of the material offered shall be made in the offer indicating complete details of materials

The stator & end shields are machined to close tolerances for providing perfect alignment & fit

Both stator and rotor cores are made of high quality low hysteresis loss high permeability material such as CRGO Silicon magnetic steel. Magnetic steel sheet shall be laminated to reduce the eddy current loss minimum

1.4 Rotor and shaft

1.4.1 The rotor design shall provide a rigid cage construction with bars firmly wedged in bars 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. The motor cage shall be designed to operate satisfactorily under respective repetitive starting and load cycles. The motor end lamination shall be rigidly fixed to prevent flaring

1.4.2 The motor shall be designed to operate at 120% of full speed for 2 minutes. The rotor bars shall not be insulated in slot portion between iron core lamination and the bars. The material of construction of the rotor frame, rotor bars, end rings, brazing, assembly of rotor slots, rotor stamping rotor shaft etc shall be designed and manufactured to withstand stress due to various electromagnetic forces and centrifugal forces under starting and operating conditions specified. Features provided in rotor design to meet these conditions shall be fully described in the offer

1.4.3 When specified, the shaft shall be ultrasonically tested as per Purchaser specification no. PP-E-1981 enclosed along with the tender and dye penetrant tested as per Purchaser Specification No PP-E-2398 enclosed along with the tender





1.4.4 The rotor bars shall be brazed to the end rings by a procedure approved by the purchaser

1.4.5 The retaining rings if used shall be made of non magnetic forged material. Retaining rings forging shall be subjected to ultrasonic test as per Purchaser specification no. PP-E-1981 enclosed along with the tender and dye penetrant tested as per Purchaser Specification No PP-E-2398 enclosed along with the tender

1.4.6 Shaft

Material specification sheet shall be submitted for review and as document. Shaft shall be subjected to Ultrasonic test as per Purchaser specification no. PP-E-1981 enclosed along with the tender and dye penetrant tested as per Purchaser Specification No PP-E-2398 enclosed along with the tender. In addition it shall be verified for machining finish. Shaft projection at Drive end of the Motor, key and key way shall be in line with the existing motor so that coupling with the driven pump will match without any change or modification at site. It shall be ensured that the distance between motor flange face to Drive end shaft face matches with the existing motor.

1.5 Insulation

1.5.1 Motor should be insulated to Class F or higher class with a temperature raise limited to Class B insulation.

1.5.2 The insulating system shall have high dielectric strength, high mechanical strength and long life. The coil insulation shall be such that installation and removal are easy. The insulation system of the motor shall have either resin rich type of insulation or vacuum pressure impregnated type of insulation. In case of resin rich type of insulation, it shall allow easy replacement of coils. In case of vacuum pressure impregnated system, the whole assembly of stator winding and overhang shall be impregnated in resin and heat cured. The complete core pack should be removable in case of vacuum pressure impregnated system.

1.5.3 The supplier shall fully describe the insulation and insulation treatment and its capacity to meet the operating requirement specified. The insulation system shall be subject to purchaser approval. Details shall be submitted along with offer

1.5.4 The stator winding insulation core punching and internal shall be tropicalised and given special treatment of fungus inhibiting coating

1.5.5 The motor winding shall be given special tropical and fungicidal treatment for protection against a) tropical weather condition, b) fungus growth, c) moisture, d) oil e) abrasive and conductive dust and f) sulphur fumes in combination with weak acid or alkali fumes respectively that are likely to be encountered in and around the power





plant area. Epoxy gel coat on winding Overhang shall be applied to get additional protection.

1.5.6 Any joint in the motor winding such as at a coil connections etc shall be insulated to the same level as complete motor. Additionally joints should have least resistance, shall be mechanically strong and braced to withstand the stresses

1.5.7 Insulation system for the motor shall be designed to withstand satisfactorily without any deterioration the voltage surges produced due to chopping of currents by Air Blast circuit breakers controlling the motors. Suppliers shall indicate clearly the procedures adopted along with the level of inter-turn insulation provided to meet this requirement. Suppliers shall furnish the type test report or carry out the switching surge tests for main and inter-turn insulation.

1.5.8 Motor winding shall be given a “power house” treatment. Power house treatment shall comprise of an additional treatment to the winding, over and above a normal treatment, generally given to such winding by the manufacturer. After coils are placed in slots, and all the connection are made, entire motor assembly shall be impregnated by completely submerging the core and winding in suitable insulating compound or varnish followed by proper baking. At least two additional submersions and bakes shall be applied either to the end windings or to the whole assembly making a total of at least three submersions and bake treatment

1.5.9 The overhang portion shall be adequately brazed to withstand the forces due to repeated restarts at voltage conditions varying from 80% to 110%. The supports for the overhang portion shall be non-magnetic materials

1.5.10 Stator slot wedges shall be of non magnetic materials

1.6 Winding and Bearing temperature sensor

1.6.1 Motor shall be provided with Copper constantan thermocouple to measure the winding temperature. Minimum two Nos. shall be provided for each phase of the windings embedded at al location where highest temperature may be expected.

1.6.2 Resistance temperature detector RTD each shall be installed for both DE and NDE bearings temperature measurement.

1.6.3 The RTD element shall be subject to the following tests

Insulation resistance test: The insulation resistance between the element and the ground wall shall not be less than 10Mohms at 250V DC and at an ambient temperature





HV Test: The insulation of the element shall withstand 2KV for one minute applied between the element and ground

1.6.4 The RTDs shall comply with the latest edition of IS 2848

1.6.5 Calibration test certificate for RTDs and thermocouples shall be submitted

1.6.5 A protective device shall be provided in the RTD terminal box to protect purchaser external control circuit components in the event of a shirt circuit between winding and RTD. Details of the protective device shall be furnished.

1.7 Terminal Boxes and Bushing

1.7.1 Independent phase segregated power terminal boxes shall be provided for connection of 3 core, 240sqmm Aluminium armored PILC (Paper Insulated Lead Covered) or XLPE power cable. For all other terminal boxes, in case the restriction in space arises, the purchaser can opt for un-segregated type provided the phase clearances as per standard are maintained.

i) Neutral terminal box if provided

ii) Space heaters

ii) Temperature detectors (For bearing temperature and winding temperature sensors

iii) Neutral terminal boxes, where specified. (In case, separate neutral box demand for more space, it can be internally connected to form the required Y (STAR) connection and can be accommodated in phase terminal box itself or all neutral terminal can be brought out and star connected inthe phase terminal box.

1.7.2 The terminal box shall be fabricated from steel. The stator leads shall be brought into the terminal box as an insulated cable through a suitable barrier and terminated in clasp or compression type terminals. The three phases shall be segregated with insulated metal barriers within the terminal box. The power cable terminal box shall be suitable for fault level specified in CC-3 for one seconds rating and the supplier shall provide test certificates to prove that power terminal box can meet this requirement.

1.7.3 Terminal box shall be suitable for top and bottom entry of cables and shall be provided with EPDM rubber gaskets (or approved equivalent) on all bolted joints to make it moisture proof. The terminal box shall be suitable for terminating the Purchaser's cables as specified in CC-3. Terminal box on motors for outdoor service shall be weather proof. The terminal box for neutral and stator leads shall be of the detachable type.





1.7.4 Special care shall be taken in designing the terminal box for purchaser’s existing power cables so as to allow sufficient space for bending of cables and adequate electrical clearances.

1.8 Bearings and Bearing housing

1.8.1 Motor bearing housing shall be constructed so as to exclude dirt, water etc and to prevent lubricant from reaching winding.

1.8.2 The motor bearings shall be grease lubrication.

1.8.3 Motor bearings / housing shall be constructed so as to exclude dirt and water and to prevent lubricant from reaching the windings. Bearings shall have grease lubrication and arrangement for easily accessible to facilitate re-greasing operations with extended tubing. Auto re-grease facility can be considered if required. The bearing and its cooling shall be selected in such a way that the temperature shall not exceed 60oC at any operating condition. This shall be supplemented by the necessary calculation. Being vertical motor, it shall be provided with single or double (as required) thrust and guide bearings

1.8.4 All bearings shall be grease lubricated. The supplier shall suggest the recommended properties of the lubricant grease. However, the purchaser’s preference is to use SERVOGEM-2 (manufactured by IOC) in view of standardization. Suitable venting arrangement shall be available for bearing to avoid dry running. Both bearing shall have regreasing facility with lid or cover to prevent entry of foreign material. Bearing life shall be more than 100000 operating hours after considering all the forces that occur normally and seismic forces. The bearings lubrication system shall preferably be such that no external means of cooling is necessary to maintain the specified bearing temperatures within design limits. The design and operation of the system shall include instruments to monitor bearing temperature to prevent in-advertent operation of bearings without lubrication.

1.8.5 The bearing shall be designed to permit motor operation in ether forward or reverse direction without affecting its cooling and lubrication requirement

1.8.6 Both the bearing shall be with brass cage. Polymeric cage bearing is not acceptable

1.8.6 Both drive and non drive end bearings shall be provided with bearing temperature sensor so that the value of bearing temperature can be measured from remote area.

1.8.7 If felt necessary, bearing shall be provided with suitable insulation to avoid shaft current

1.8.8 The lubricant shall be selected for prolonged storage and normal use of the motor in a tropical climate and the specified levels and shall contain corrosion and oxidation





inhibiters. Data regarding grease replacement frequency and condition monitoring requirement on grease lubrication shall be furnished along with offer. Type of bearings used in the DE and NDE shall be indicated along with the mounting arrangement while submitting the offer.

1.8.9 In respect of forced lubrication, motor manufacturers should provide details regarding the lubrication system and scope of supply such, as piping etc. Copper piping is preferable.

1.9 Balancing, vibration and noise level

1.9.1 The Motor vibration in all the direction (radial with 90deg displacement and in axial direction) shall be well within the limits specified in IS 12075. Tests confirming to IS 12075 for measuring amplitude and velocity on all the direction and with all compartment mounted shall be carried out in the presence of Purchasers representative. The test data with the test diagram showing amplitude and velocity on vibration at various locations be submitted along with test reports. The motor test shall be done by simulating the structural support available at site to establish the vibration behavior of the motor.

1.9.2 Balancing of the rotor with all the components mounted shall be carried out at rated speed.

1.9.3 Components such as fly wheel if provided, fan etc that are to be mounted on the shaft shall be preferably balanced individually to enable future replacements

1.9.4 Weights added for the purpose of balancing shall be free of defects and shall be firmly fixed such that there is no displacement while in service

1.9.5 Noise level of the motor shall be below 85decibals at 1.8meter from the equipment.

1.10 Grounding

1.10.1 Provision shall be made on the motor body and terminal boxes for connecting two numbers of purchasers grounding conductors.

(i) Motor stator Body

(ii) All the Terminal boxes

1.10.2 For all motors, a non-corrodible metal pad shall be welded or brazed at two locations on the motor frame and each shall have a threaded hole of Ml2 size and shall be provided with suitable bolts, nuts, washers and spring washers. The threaded hole shall be of sufficient depth to ensure adequate electrical contact between bolt and motor frame. Separate earthing terminals of M12 size shall be provided for the power terminal box.





1.10.3 Power terminal box also shall have the facility to connect to station ground at two locations

1.11 Space heaters:

Adequate capacity of Space heater shall be provided to maintain motor internal temperature above the dew point to prevent moisture condensation when the motor is not in operation. The heaters shall be mounted inside the motor in accessible places so that their removal and replacement during major overhauling is a simple operation. Space heater shall be rated for 240V AC single phase 50 cycle operation and shall be located in lowest part of the motor. The quality of space heater shall be so chosen such that they give sufficiently long life so that the requirement of replacement requires once in 10years of operation or more

1.12 Direction of rotation:

1.12.1 Definition: The direction of rotation shall referred to the drive end on the machine

1.12.2 The direction of rotation shall be so designed to meet the existing pump direction of rotation, accordingly the lock nut provided on the shaft for bearing or for any other purposes shall be provided. The existing motor has a direction of rotation of Clock wise direction when viewed from Non- drive end

1.12.3 Motors shall have the specified direction of rotation as determined by the phase sequence on the terminal marking marked by an arrow on the stator body or fame or on the name plate details

1.13 Mounting and dowelling:

1.13.1 Being vertical motor the motor shall be of flange mounted type

1.13.2 The motor flange dimension, number of holes, PCD of holes and hole diameter shall be exactly suitable for mounting on the existing pump pedestal flange

1.13.3 The existing motor flange details is enclosed as Annexure C of CC 11

The motor seating area shall have spigot of OD suitable for the corresponding spigot ID in the pump stool with just adequate clearance so that no major alignment need to be done after placing the motor on pump stool.

1.14 Lifting facility:

Motor shall be provided with adequately designed eye bolts, lugs or other devices to facilitate safe lifting and handling operations





1.15 Drain plugs:

Even though requirement is for totally enclosed type, there shall be a drain opening with plug to permit removal of water if any accumulated inside the motor

1.16 Shaft projection at Drive end:

To suit with the existing pump shaft the shaft projection length, diameter and profile with key way shall be exactly identical to the existing design. Existing shaft projection length, diameter and profile with key way is indicated in drawing No. M1/71212/2510/DD. Projection of the shaft from the motor base and diameter of the shaft projection are critical for coupling the pump and motor. Hence these dimensions shall be maintained as per the drawing dimensions indicated in the drawing M1/71212/2510/DD.

1.17 Name plate and diagram connections

Motor shall be provided with a name plate showing all the particulars specified in the relevant clause of IS 325. In addition the nameplate shall also indicate a) the type and mounting of bearings used for Motor b) details of lubricant and its quantity c) temperature raise in deg C over an ambient of 50 Deg C d) Limits and conditions for successive starts

1.18 Dimension and threads

All the motor dimension shall be in millimeters and shall be subject to tolerance specified in IS 1231, IS 2223 or IS 2254. All the nuts and bolts shall be fabricated in metric units.

1.19 Painting:

Manufacturer’s standard paint systems shall be furnished along with the bid. High quality, modern environment friendly paint systems shall be proposed. The detailed painting procedure shall also be submitted along with the bid which shall be finalized before award of contract. The quality of paint should be such that its colour does not fade during vapour phase drying process and shall be able to withstand temperature up to hot spot temperature. Metal parts not accessible for painting shall be made of corrosion-resistant material.

2.0 ELECTRICAL AND PERFORMANCE REQUIREMENTS

2.1 Supply Voltage, frequency variation

Unless otherwise noted, the motor shall be suitable for continuous operation under the following conditions in supply voltage and frequency without exceeding the specified temperature limits





Sl No Parameter Variation limits a Sustained variation in frequency ± 5% b Sustained variation in Voltage ± 10% c Sustained variation in frequency and voltage

(arithmetic addition) 10%

d Harmonic content in AC supply voltage 5% as defined in IS 325 e Unbalance in supply voltage ± 3%

2.2 Starting Duty 2.2.1 Unless otherwise specified, the motor shall be capable of at least two successive starts

coupled to its driven equipments under cold and hot conditions and a third restart shall be feasible after 20 minutes. The motor shall further be capable of three equally time spread starts per hour under normal service conditions.

2.2.2 The motor shall be designed for Direct ON line start, full voltage starting and shall withstand all stress and give satisfactory performance when started with their driven equipments connected under the specified operating conditions.

2.2.3 The end windings of stator and rotor shall be adequately braced and supported to cater to the different starting duty conditions, bus transfer, etc.

2.2.4 The motor shall be capable of starting and accelerating the driven equipment satisfactorily at a minimum voltage of 80% of the nominal voltage at the motor terminals. Total number of starts during the designed life of the motor shall be 2000 starts approx.

2.2.5 Motor shall be able to operate satisfactorily for minimum of 10 minutes with a system voltage reduced to 80% without exceeding the temperature limit as specified in IS 325

2.3 Locked rotor current

Unless otherwise specified the locked rotor current of the motor shall not exceed 600% of full load current excluding the tolerance permitted by latest IS 325 or 300Amps whichever is less.

2.4 Fast Bus transfer

Motor shall be capable of withstanding voltage torque stress developed due to the vector difference between the motor residual voltage and the incoming supply voltage equal to 150% motor rated voltage during fast changeover of the supply. Expected duration of dead time will be about 200 millisec. Features incorporated in the motor design to comply with this requirement shall be clearly indicated in the proposal.

2.5 Pull out torque





Motor shall not pull out of step when the power supply drops to 70% of the rated motor voltage for a short duration of 25 cycles. To meet this requirement, the pull out torque of the motor at rated voltage shall be at least 200% of the full load torque.

2.6 Over speed

The motor shall be capable of withstanding without mechanical damage at least 120% of the rated speed or as imposed by the driven equipment whichever is higher.

2.7 Other requirements

2.7.1 Motor shall be capable of satisfactorily operating at full load for ten minutes without injurious heating at a motor terminal voltage of 70% of rated voltage

2.7.2 Accelerating time of the motor with rated load of driven equipment connected to it shall not exceed the corresponding safe stall time of the motor under hot condition, at all the applied voltage from 80% to 110%. A margin of 5secs shall be provided between accelerating time and safe stall time.

2.7.3 The first critical speed of the motor shall be a minimum of 130% of the rated speed to ensure the first critical speed of driven equipment and motor combination will be above the rated speed.

3.0 Temperature rise:

Under normal operating conditions the temperature raise of the motor shall not exceed the limits specified by IS 325 for an ambient temperature of 50 deg C. The temperature raise can exceed the above limits by 5 deg C only under the extreme voltage variation conditions indicated below

3.1 Full load operation at 110% of rated voltage 3.2 Full load operation at 90% of rated voltage 3.3 Full load operation at 105% of rated frequency 3.4 Full load operation at 80% of rated voltage for 10 minutes.

4.0 Design Review:

4.1 The Motor shall be designed, manufactured and tested in accordance with the best international engineering practices under strict quality control to meet the requirement stipulated in the technical specification. Adequate safety margin with respect to thermal, mechanical, dielectric stress etc. shall be maintained during design, selection of raw material, manufacturing process etc so that the motor provide long life with least maintenance. Design reviews shall be conducted by Owner or an appointed Consultant at different stages for all motor covered under this specification; however the entire responsibility of design shall be with the manufacturer.





4.2 The design review will commence after placement of award with successful bidder and shall be finalised before commencement of manufacturing activity. These design reviews shall be carried out in detail to the specific design with reference of the motor under scope of this specification. Purchaser may visit to the manufacturer’s works to inspect design, manufacturing and test facilities and manufacturer shall arrange for photographs of motors under various stages of manufacturing

4.3 The manufacturer will be required to demonstrate the use of adequate safety margin

for thermal, mechanical, dielectric and vibration design etc. to take into account the uncertainties of his design and manufacturing processes.

4.4 The scope of such a design review shall at least include the following:

1. Core and magnetic circuit design 2. Winding design 3. Shaft, Rotor and end ring design 4. Short-circuit withstand capability 5. Thermal design including review of localised potentially hot areas. 6. Cooling design for various operating conditions. 7. Overload capability 8. No load losses and Load losses 9. Seismic design calculations & requirement fulfilment 10. Insulation co-ordination 11. Bearing and its cooling design 12. Corrosion protection 13. Earthing 14. Processing and assembly 15. Testing capabilities 16. Inspection and test plan 17. Transport and storage 18. Sensitivity of design to specified parameters 19. Vibration and Acoustic Noise 20. Spares, inter-changeability and standardization 21. Maintainability

4.5 For Motor, the maximum current density of the winding conductors used and the

maximum magnetizing current values at 90%, 100% and 110% rated voltages shall be submitted by the CONTRACTOR for review by the PURCHASER.

4.6 Every care shall be taken to ensure that the design and manufacture of Motor shall

be such as to reduce vibration and noise to the level obtained in good modern practice.

4.7 Design analysis for Motor and its components shall be submitted for review and

approval of PURCHASER. For enabling proper review by PURCHASER, CONTRACTOR shall submit a detailed write- up on the design and operation of the motor including all auxiliary components under normal operation, during starting,





shut down and abnormal conditions etc as indicating set points for alarm and trip points, various operator actions required during different scenarios etc, provisions made for in service inspection, testing and maintenance.

4.8 The design of cooling system for the motor winding and bearings covered under this

specification shall be proved to be sufficient for effective cooling of the motor winding and bearings during various modes of operation without exceeding the allowable temperature rise limits. The contractor shall submit the supporting calculations for design of cooling system / method adopted.

4.9 All rated quantities subject to the Contractor’s guarantees shall be within the

tolerances given in applicable standards / as modified in this specification.

5.0 DRAWINGS AND DATA

As part of the proposal, the CONTRACTOR shall furnish the following drawings and data for scrutiny.

a) General arrangement drawing of Motor with overall dimension with inside view

giving location of various components and terminal blocks. b) Schematic wiring diagram of the winding, RTDs, Thermocouples, and Space heaters. c) Bill of material listing equipment designation, make, type, ratings, etc. of the various

equipment mounted on the motor (after placement of order). d) Duly filled up guaranteed technical particulars e) Deviation from specification if any

6.0 TESTS & TEST REPORTS

Type, Acceptance, routine tests and special test for all supply equipments /

component parts will be subjected to QAP as detailed and shall be carried out as per the relevant standards for the respective equipment. These test reports and available type test reports shall be submitted to the PURCHASER before dispatch of the equipment.

7.0 TRANSPORTATION

The Contractor shall be responsible to select and verify the route, mode of

transportation and make all necessary arrangement with the appropriate authorities for the transportation of the equipment as detailed in Annexure – H of Section CC-11.


Technical Specification for Condenser Cooling Water Pump Motor INSPECTION AND TESTING



INSPECTION AND TESTING

This section covers the tests to be carried out on the Motor and its major components at works before final dispatch of equipment to site and commissioning test at site. The test certificate for the materials used for all the motor shall be submitted for verification to NPCIL QA Engineers as per QA plan.

1.0 Type test certificate conducted within the last 5 years from the date of tendering shall be submitted for the identical design motor with capacity within same range for review and acceptance. If case if type test is not available or is the submitted type test is not acceptable to the purchaser, the complete type test shall be conducted by the supplier in the presence of department QA engineer without any additional cost

2.0 Tests for Main Equipment:

The tests to be conducted are categorized as follows:

Description of test Category of test Type test generally as per IS-325 / IEC 60034, in the absence of type test as indicated in clause No. 1.0 of this section

Category “A”

Routine test generally as per IS-325 / IEC 60034 Category “B” Commissioning test to be done at site Category “C”

The Contractor shall conduct all the above mentioned category tests as detailed hereafter on the motor as per Purchaser’s requirement. Broadly category A, and B tests shall be done generally in accordance with IS-325 / IEC 60034 unless specific data or additional requirements are detailed against the test in the Section CC-5 or QAP. Any stringent requirement due to revision in latest standards (IS or associated IEC) shall be applicable as on the date of testing.

2.0 The type test, special test and routine tests are to be conducted on motor as per PURCHASER’s requirement detailed in this section and section CC-6 (QAP).

Since KW rating and other technical parameters are specific to Purchaser’s existing pump requirements and Motor is to be manufactured to customer specific design data.

For all tests, testing details, procedures including methods, circuits, expected results with tolerances, proposed instruments etc shall be submitted for Purchaser’s review and approval. As a part of technical offer, bidder shall include a tabulation detailing various tests on each type of equipment along with acceptance criteria and test values. Temperature rise test shall be conducted on Motor. The charges for conducting Type tests (Category A) shall be quoted independently and charges for routine test





(Category B) shall be included in the basic price of motor. Charges for conducting commissioning test (Category C) shall be included as part of commissioning charges

Type Test:

In the absence of type test report to the satisfaction on the purchaser, one motor shall be subjected to undergo type test as per IS 325 and special test at manufacturers work or registered laboratory in the presence of purchaser representative. Additional type test as specified herein also shall be carries out

Type test as per IS 325 are Dimension verification Measurement of winding resistance No load test Locker rotor test Full load test to determine efficiency and slip Temperature raise test Momentary over load test Insulation resistance test High voltage test Test for vibration severity Test for Noise level Test for Degree of protection Temperature raise test at limiting values of voltage and frequencies Over speed test Test on insulation system Tangent delta and delta tangent delta and capacitance test Impulse voltage withstand test Impulse test for inter turn insulation Impulse withstand test for main insulation Terminal box fault withstand capability test (Test report is acceptable if made

available for similar design) EMC test as per IEC 60034 Pull up torque test as per IEC 60034 Routine test as per IS 325 are Insulation resistance test Measurement of winding resistance No load test Locker rotor test Reduced voltage running up test High voltage test Dimension verification

Commissioning test at site

Measurement of winding resistance





No load test Insulation resistance test Test on RTDs and thermocouple Test on space heater Actual load performance test at site 3.0 Details of Tests on Motor and its components:

SL No

Test Category of test

To be conducted on

Extent of test

3.1

Measurement of Winding resistance, Inductance and corrected to 75oC.

A, B and C

Motor 100%

3.2 No load test at rated voltage to find out input power and speed

A, B and C

Motor 100%

3.3 Locked rotor test and recording of Voltage, Current, input power at suitable reduced voltage

A and B Motor 100%

3.4 Full load test to find out power factor, slip and efficiency

A and B Motor 100%

3.5 Temperature raise test at normal voltage & frequency as well as at limiting voltage and frequency

A Motor 100%

3.6 Momentary over load test A Motor One motor

3.7 Insulation resistance test A, B and C

Motor 100%

3.8 High Voltage test A and B Motor 100% 3.9 Test for vibration severity A Motor 100%

3.10 Test for noise level A Motor 100%

3.11 Test for degree of protection of

enclosure A Motor 100%

3.12 Over speed test A Motor 100%

3.13 Reduced voltage running up test B Motor 100% 3.14 Test on insulation system

a Capacitance and tan delta A Motor 100% b Impulse voltage withstand test A Motor 100%

3.15 Actual load performance test at site C Motor 100%

3.16 Test on RTDs and thermocouple A, B and C

Bearing and winding and temperature sensors

100%

3.17 Test on space heater A, B and C

Space heaters 100%





3.18 Pull up torque test as per IEC 60034 A Motor 1 motor 3.19 EMC test as per IEC 60034 A Motor 1 motor

Type test and special test (A and C) may performed on one motor 4.0 Auxiliary components (RTDs, Thermocouple and Space Heaters)

All other auxiliary components shall be tested as per the relevant standards. Test certificates shall be submitted for all the bought out items. High voltage withstand test shall be performed on auxiliary equipment and wiring after complete assembly.

5.0 Test Reports

Three set of Test report for the first motor shall be submitted independently. Three copies of test reports shall be submitted for Purchaser’s approval before dispatch of Motor for all the remaining Motors.

6.0 Rejection

Purchaser may reject motor during testing if any of the following conditions arise:

6.1 No load losses exceed the guarantee value by 20%.

6.2 Load loss exceeds the guarantee value by 20%.

6.3 Motor is proved at any stage to have been manufactured not in accordance with the agreed technical specifications and approved quality control plan and approved drawings.

6.4 Motor fails on type test, special test as per IS / IEC, MAPS site load test, HV test, temperature rise test, Insulation system test etc.

7.0 Inspection: Motor will be inspected at every stage of manufacturing and testing by NPCIL QA

engineers as per the approved Quality Assurance plan as detailed in CC 6 of this specification.

For stage inspection and final testing as per QAP, Contractor has to give inspection call a minimum 7 days in advance for Purchaser’s inspection / witnessing of tests.


Technical Specification for Condenser Cooling Water Pump Motor QA PLAN


QUALITY ASSURANCE PLAN

SCOPE AND PURPOSE:

This document indicates the requirements expected from the contractor/manufacturer of the above equipment. Subsequent to the placement of Purchase order contractor/manufacturer shall submit for purchaser's approval a quality assurance plan in line with this document incorporating specific document numbers for "format of records", "acceptance norms" and "reference documents".

Abbreviations:

V Verified by P Performed by

W Witnessed by (After laps of due notice to NPCIL, manufacturer may proceed with manufacture)

H Hold (Unless a written clearance is obtained from NPCIL, manufacturer shall not proceed to next stage)

1 NPCIL 2 Prime Supplier / Third party inspector 3 Approved External Laboratory or Sub Vendor QC (if vendor QC / facility not available)

AD NPCIL Approved document such as Tender document, Purchase order, Drawings & Test Procedures

TR Test Report / Record PS Plant Standard / Purchase Specification IEC International Electro-technical Commission standards

IEEE Institute of Electronic and Electrical Engineers standards IS

ASTM Indian Standard American Standard for Testing




Notes:

1. Photos shall be furnished to NPCIL during manufacturing and testing of Motor

2. Continuous surveillance check will be done by NPCIL engineer during manufacturing and testing of Motor

3. Wherever V & W are both indicated, NPCIL to witness test or review TRs.

4. All the important tests will be witnessed by NPCIL Engineering & Procurement Group & Clearance will be given

5. TRs not more than five year old from date of purchase order shall be reviewed for acceptance. Otherwise test shall be carried out.

6. Minor: The characteristics of a component, process or operation whose failure neither materially reduce the ability of the product in operation,

7. Major: The characteristics of a component, process or operation whose failure may cause operation failure which cannot be readily corrected at site.

8. Failure of a characteristic means failure to meet the "acceptance norms".

9. Sampling: Generally in accordance with IS: 2500. If 100% "witness" is carried out by "Prime contractor", NPCIL will witness on sample basis,

10. Wherever more than one standard is specified for acceptance norms, the standard which gives the better value will be the considered for acceptance.




Typical QA plan is shown in the following table

AGENCY Sl. No Components Characteristics checked

Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

1.0 RAW MATERIALS . 1.1 Copper conductor for stator and rotor

a Dimensions and visual control

Critical

Measurement

Sampling

IS /PS IS /PS TC 1,2 3

b Tensile strength and elongation, proof stress

Major Mechanical Sampling


c Electrical Resistivity / conductivity, breakdown voltage on enameled conductor

Major Elect. Sampling


d Conductor finish Major Visual Sampling


e Chemical analysis Major Chemical Sampling


f

Insulation test between strands on finished conductor.

Major Elect. Sampling


All raw materials (copper, Insulating material) shall be procured from NPCIL approved sources





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

g Enamel thickness Minor Measurement

Sampling


h Verification that there is no joint within a coil

Major Verification of Records

Certification by supplier

IS / PS IS / PS TR 1 3 2

i Bonding of Insulation material to conductor, flexibility and adherence of enamel covering

Minor Visual In process check.

IS / PS IS / PS TR 1,2 3

1.2 Insulating materials a pH value of

Insulating material, density, moisture content

Major Chemical One Sample from each consignment

IS /PS IS / PS TC 1,2 3

b Electric strength in air, conductivity

Major Elect. One Sample from each consignment






Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

c Tensile / Bursting strength

Major Mechanical One Sample from each consignment


d Thickness Major Measurement

One Sample from each consignment


e Reaction of hot oil and grease

Major Test One Sample from each consignment


f Ageing test Minor Chemical Random


g Physical condition and cleanliness

Major Visual In process check


h pH of Aquesious extract

Major Elect. Random






Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

i Water absorption, air permeability, ash content

Major Chemical Random


1.3 Insulation spacers, Wedges and insulating supports

a Dimension and visual control

Minor Measurement

Sample IS /PS IS /PS TC 1,2 3

b Tensile strength, elongation and oil/grease absorption

Minor Mechanical Sample IS /PS IS /PS TC 1,2 3

c Physical condition and cleanliness

Major Visual 100% IS /PS IS /PS TC 1,2 3

d Electrical strength in lubricating oil

Major Elect. Sample IS /PS IS /PS TC 1,2 3

e

Density, thickness, moisture content, Cohesion , compressibility, chemical properties, pH value, conductivity, shrinkage in air for PB

Minor Mechanical Sample IS /PS IS /PS TC 1,2 3





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

f Reaction with hot oil and grease

Major Chemical Sample IS /PS IS /PS TC 1,2 3

1.4 CRGO Silicon sheet steel laminations for stator and rotor

a Specific loss before and after ageing test

Critical

Elect. Sample IS /PS IS /PS TC 1,2 3

b Stacking factor Major Measurement

Random


c Magnetizing characteristics

Major Elect. Critical IS /PS IS /PS TC 1,2 3

d Ductility Major Elect. Random


e Grade of steel & Thickness

Minor Measurement

Random


f Ageing test Major Chemical Type test


g Chemical analysis Major Chemical Random


h Edge burr & Waviness

Critical

Measurement

Random


i Insulation resistivity

Major Elect. Random

IS/PS IS/PS TC 1,2 3





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

j Dimensions of laminations

Minor Measurement

Random


Gaskets and sealing components ( As per IS-4253)

IS 4253

a Visual (Shall be smooth and free from all harmful defects)

Minor Visual 100% IS/PS IS /PS TC 1,2 3

1.5

b Specific gravity, Thickness, Hardness, Compressibility at 28Kg/Sq.cm & 60Kg/Sq.cm, recovery at 28 and 60 Kg/Sq.cm, tensile strength before lubrication oil absorption, compression set and flexibility.

Minor Chemical /Physical



c Change in acidity after ageing in lubricating medium

Major Test Type Test

IS / PS IS / PS TC 1,2 3





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

1.6 Polyester resin impregnated weft less unidirectional glass tape (If used)

a Width, thickness and length of Roll

Minor Measurement



b Tensile strength, Polyester resin content, sealing solder test, warp yarn, softening point of resin, breaking load at room temperature, elongation at break at 20 deg C and arc resistance of cured tape.

Minor Mechanical One Sample from each consignment


c

Shelf life Minor Chemical each role


1.7 Shaft material a Ultrasonic test Major Test PP-P

1981 TC 2 1





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

b DPT Major Test PP-P-2398

TC 2 1

c Machined surface for finish

Major Visual 2 1

1.8 Stator and other cast iron bodies a DPT Major Test 2 1 b Machined surface

for finish Major Visual 2 1

1.9 EPDM rubber gaskets Physical

Characteristics Major Chemical

/Physical One Sample

IS IS TC 1 2, 3

2

2.0 Rotor complete Dynamic balancing

at rated speed Major Electrical 100% ISO

1940 Gr. 2.5

ISO 1940 Gr. 2.5

TR 1 2 1

3.0 Rotor Retaining ring (End ring) and Brazing joint for

a UT Major Electrical 100% PP-P 1981

Drg. TR 2 1 1

b DPT Major Electrical 100% PP-P-2398

Drg. TR 2 1 1

4.0 Stator complete Inter-turn

insulation surge voltage (Baker) test

Major Electrical 100% IEEE 522

IEEE 522

TR 2 1





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

5.0 RTDs and thermocouple for bearing and winding temperature measurement.

a Type test on RTDs and thermocouple

Major Electrical IS 2848

IS 2848 TC 1 3 2

b IR and HI Pot test Major Electrical 100% PS PS TR 1 2 6.0 Space Heaters a Rating and Heater

resistance Major Electrical 100% PS PS TR 1 2

b IR Value Major Electrical 100% TR 1 2 c HI POT Test at

2KV Major Electrical 100% TR 1 2

7.0 Motor Assembly 7.1 Factory test as CC5 7.1.1 Routine test a Dimensional

checks (Shaft centre height, Key & Key way dimensions, shaft ext. dimensions)

Major Mechanical Measurement

100% Approved OGA Drawing

Approved OGA Drawing

TR 2 1

b Measurement of Winding resistance and corrected to 75 deg C.

Major Electrical 100%

IS 325 IS 325 TR 2 1





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

c No load test at rated voltage to find out input power, speed, starting current, acceleration and run down time


IS 325 IS 325 TR 2 1

d Locked rotor test and recording of Voltage, Current, input power at suitable reduced voltage


IS 325 IS 325 TR 2 1

e Insulation resistance test

Major Electrical 100% IS 325 IS 325 TR 2 1

f High Voltage test Major Electrical 100% IS 325 / IEC 60034

IS 325 / IEC 60034

TR 2 1

g Reduced voltage running up test

Major Electrical 100% IS 325 IS 325 TR 2 1

7.1.2 Type test a Dimensional

checks (Shaft centre height, Key & Key way

Major Mechanical Measurement

One Motor

Approved OGA Drawi

Approved OGA Drawing

TR 2 1





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

dimensions, shaft ext. dimensions)

ng

b Measurement of Winding resistance and corrected to 75 deg C.

Major Electrical One Motor

IS 325 IS 325 TR 2 1

c No load test at rated voltage to find out input power and speed


IS 325 IS 325 TR 2 1

d Locked rotor test and recording of Voltage, Current, input power at suitable reduced voltage


IS 325 IS 325 TR 2 1

e Insulation resistance test


IS 325 IS 325 TR 2 1

f High Voltage test Major Electrical One Motor

IS 325 / IEC 60034

IS 325 / IEC 60034

TR 2 1

g Full load test to find out power factor, slip and


IS 325 IS 325 TR 2 1





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

efficiency h Temperature raise

test. Major Electrical One

Motor IS 325 / / IEC 60034

IS 325 / / IEC 60034

TR 2 1 1

i Temperature raise test at limiting voltage and frequency


IS 325 / IS 12802 / / IEC 60034

IS 325 / IS 12802 / / IEC 60034

TR 2 1 1

j Momentary over load test


IS 325 / / IEC 60034

IS 325 / IEC 60034

TR 2 1 1

k Test for vibration severity

Major Mechanical / Electrical

One Motor

IS 325 / IS 12075

IS 325 / IS 12075

TR 2 1 1

l Test for noise level Major Electrical One Motor

IS 325 / IS 12065

IS 325 / IS 12065

TR 2 1

m Test for degree of protection of enclosure

Major Mechanical / Electrical

One Motor

IS 325 / IS 4691 / IEC 60529

IS 325 / IS 4691 / IEC 60529

TR 2 1

n Over speed test Major Mechanical / Electrical

One Motor

IS 325 / IEC

IS 325 / IEC

TR 2 1





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

60034 60034 o Test on insulation

system

i) Capacitance and tan delta


IS 325 / IS 13508

IS 325 / IS 13508

TR 2 1

ii) Impulse voltage withstand test fir inter turn and overall winding


IS 325 / IS 14222

IS 325 / IS 14222

TR 2 1

p Terminal box fault withstand ability test


IS 325 / IS 14222

IS 325 / IS 14222

TR 2 1

q Pull up torque test Major Electrical One Motor

IEC 60034/IS 325 / IS 14222

IEC 60034/IS 325 / IS 14222

TR 2 1

r EMC test Major Electrical One Motor

IEC 60034/IS 325 / IS 14222

IEC 60034/IS 325 / IS 14222

TR 2 1

7.2 Site load test Commissioning test Major Electrical One PS PS TR 1,2 1, 1 Will be done at





Category

Method of check

Extent of check

Reference document

Acceptance norm

Format of record

V P W H Remarks

and Actual load performance test at site as per CC5

Motor 2 MAPS site under site engineer supervision

8.0 Painting a Material, shade,

number of coats (shade 631 of IS-5)

Minor Visual 100% IS IS TR 1 2

b Quality of paint, Dry film thickness.(DFT)

Minor Verification 100% IS IS TR 1 2

c Paint adhesion test. Minor Mechanical Sampling

IS IS TR 1 2

d Peel test & Scratch test

Minor Mechanical Sampling

IS IS TR 1 3

9.0 Packing a Soundness of

packing Minor Visual 100% AD AD TR 1 2,

3 2

10.0 Documentation End document

Completeness. Major Visual 100% AD AD NA 1 2 To be

submitted before dispatch


Technical Specification for Condenser Cooling Water Pump Motor TENDER EVALUATION

Section: CC-7 of 91

Rev-0


TENDER EVALUATION

1.0 Formula for Evaluation of Tenders

The tenders will be evaluated for losses as per the loading formula given below: L = (A1 X D) + (B1 X E)

L = Cost of loading for losses in Rupees

A1 = Difference in KW of Iron losses from base case.

B1 = Difference in KW of Copper losses from base case.

D = Rs. 50000/- per KW of Iron loss for Motor.

E = Rs. 50000/- per KW of Copper loss for Motor

2.0 For evaluation, guaranteed losses shall be increased by 10 % to reflect + 10 % tolerance permitted by IS.

3.0 The offer with lowest loss will be considered as the 'Base'.

4.0 Penalty for excess loss after manufacture of Motor

4.1 Rates of penalty for exceeding guaranteed losses are as follows: a) Iron loss = Rs. 115000/- per KW.

b) Copper loss = Rs. 115000/- per KW for Motor

4.2 Rates of penalty for exceeding time frame as given in Section CC-1 for completing the activities are as follows:

Refer General Contract Conditions for the penalty clause

Contractor has to keep a log record of all inspection calls and time taken to turn up by Purchaser’s representative.


Technical Specification for Condenser Cooling Water Pump Motor TESTS AT SITE ON MOTOR



TESTS AT SITE ON MOTOR

The scope of this section covers the details for Receipt & Storage, Erection, Pre-commissioning checks and tests to be done at site. The CONTRACTOR shall carry out a detailed inspection and testing programme for field activities covering areas right from the receipt of material stage up to commissioning stage. An indicative programme for such activities as envisaged by the Employer is given below. However, it is CONTRACTOR's responsibility to draw up and carry out such a programme duly approved by the Employer. 1.0 Receipt and Storage Checks

The motor and their accessories shall be duly receipt at site and stored by adopting

proper preservation method till erection work is taken-up. The CONTRACTOR shall ensure following points for safe receipt and storage of equipment:

1.1 Check and record condition of each package, visible parts of the motor for any damage.

1.2 If equipment is received in good physical condition with no visible damage during transportation, ensure its safe storage.

1.3 Carry out basic healthiness checks on equipment during storage. 2.0 Erection checks The motor and their accessories shall be shifted to their designated location in

seawater pump house depending upon which pump is under shutdown after removal of the existing motor from any one pump location.

The CONTRACTOR shall ensure following points for the erection of equipment: 2.1 Physical inspection of equipment after transportation up to sea water pump house. 2.2 Install the motor coupling (Coupling will be provided by department) 2.3 Install the motor on pump pedestal and check matching of flange holes 2.4 Check after installation, the motor does not obstruct with any other system /

equipment / components 2.5 Check the clearance between motor coupling and pump coupling, if clearance is not

available provide packing between motor and pump flange so that the clearance is created between coupling faces.

2.6 Establish power cable, space heater cable and instrumentation cable such as RTDs, thermocouple.

3.0 PRECOMMISSIONING CHECKS The following pre commissioning checks and tests shall be carried out by the

CONTRACTOR after completion of erection of motor at site. CONTRACTOR shall prepare detailed pre commissioning check list as per requirement of motor manufacturer’s installation & commissioning instruction manual. Procedures for pre commissioning checks shall be submitted for approval and complete instructions shall form part of the procedure. The CONTRACTOR shall ensure inclusion of following points in the pre commissioning checks:


Technical Specification for Condenser Cooling Water Pump Motor TESTS AT SITE ON MOTOR



3.1 Check motor IR value, winding resistance and inductance values, compare them with

works test report values. 3.2 Check space heater resistance and IR value 3.3 Check Bearing temperature sensing RTDs, and winding temperature sensing

thermocouple resistance and compare them with ambient temperature reading 4.0 Commissioning checks The following commissioning tests shall be conducted by the CONTRACTOR at site

as per Standards specified. Contractor shall prepare a comprehensive commissioning procedure including No load and ON load testing of Motor. CONTRACTOR shall also submit report including all commissioning test results and forward to Employer for future record.

4.1 No Load test

4.1.1 Start the motor from 6.6KV switchgear room. 4.1.2 Do no load operation of the motor until winding and bearing temperature

reached stabilized value. 4.1.3 Measure no load acceleration time, direction of rotation, no load speed,

current, and power, vibration and temperature readings and record them. 4.1.4 Ensure no abnormality is developed from the motor, vibration reading, No-

Load current are normal, no abnormal sound from top and bottom bearing assembly.

4.1.6 After successful No load test operation arrange for coupling the motor 4.2 ON Load test 4.2.1 Start the motor from 6.6KV switchgear room. 4.2.2 Do ON load operation checks until winding and bearing temperature reached

stabilized value. 4.2.3 Measure acceleration time, direction of rotation, load current, power, vibration

and temperature readings and record them. 4.2.4 Check motor is able to drive the pumps satisfactorily by verifying all the

process parameters of the pump and system.

Nuclear Power Corporation of India Limited

Madras Atomic Power Station Technical Specification for Condenser Cooling Water Pump Motor

LIST OF TOOLS & TACKLES



LIST OF TOOLS & TACKLES 1.0 The TENDERER shall supply all the necessary special tools, tackles, appliances and

lifting devices for the effective maintenance and servicing of the complete equipment and components which may be submitted by the bidder.

2.0 All the tools & tackles necessary for handling, erection, installation & commissioning

of Sample Motor should be arranged by the CONTRACTOR and the same shall be removed from the site after use.


Technical Specification for Condenser Cooling Water Pump Motor LIST OF DRAWINGS ENCLOSED WITH TENDSER



LIST OF DRAWINGS ENCLOSED WITH TENDER S.

No. Drawing Rev

No. Description

1. M1/71212/2510/DD GA diagram of Pump and Motor 2. MAPP1&2/71212-1501-

GA GA and assembly Existing M/s BHEL Make

Motor 3. MAPS-71212-CCWP Motor

Base - stool dimension Existing Motor flange dimension with pump

stool

Note: The above drawings are submitted for the purpose of understanding the existing

Pump-Motor dimensional details.


Technical Specification for Condenser Cooling Water Pump Motor ANNEXURES ENCLOSED WITH TENDER



ANNEXURE: A EXISTING MOTOR AND PUMP SPECIFICATION DETAILS

A. Existing Motor details SL No

Performance characteristics Unit Value

1 Make M/s. BHEL, BHOPAL India 2 Motor frame code RVS 16884 3 Type of Motor 3 phase Squirrel cage Induction Motor 4 Rated Voltage V 6600 5 Rated frequency Hz 50 6 Rated Output KW 410 7 Full Load Line Current Amps 48.9A 8 Starting current / rated current % age 600 10 Starting torque / Rated torque % age 200 11 Efficiency at rated load % age 93% 12 Power factor at rated load 0.91 13 Air gap mm 14 Weight of motor Kgs 4000 15 Rated speed RPM 494 16 Synchronous speed RPM 500 17 Duty Continuous rated 18 Stator winding connection STAR 19 Pull out torque % age 200 20 Full load efficiency 93% 21 Full load power factor 0.77 22 Starting method Direct on-line starting from 6.6KV

breaker 23 Type of Enclosure Drip Proof Screen Protected 24 Top bearing type SKF make bearings 7330 BECBM

2Nos in Tandom mounting 25 Bottom bearing type 1 No of bearing SKF 7326 M C3 26 Lubrication for top bearing Servogem-2 grease 27 Lubrication for bottom bearing Servogem-2 grease 28 Interval of re-greasing of

lubrication for top and bottom bearings

Once in 3 months

29 Maximum allowable top bearing temperature

Deg C 60

30 Maximum allowable bottom bearing temperature

Deg C 60

31 Temperature detector for both bearings

Platinum type RTD 100 ohm at 0 deg C

32 Temperature detector for winding

Copper constantan 3 Nos

33 Starting time of the motor at seconds 2.5





rated voltage with load (pump coupled to it)

34 Safe stall time of the motor at rated voltage when cold (At ambient temp)

seconds 50

35 Safe stall time of the motor at rated voltage when hot (At rated full load temp)

seconds 15

36 Space heater finned 2Nos of 250W each 240V AC connected in parallel

37 Class of Insulation F 37 Type of Mounting Vertical 39 Shaft projected length from

bottom flange face mm 283

40 Type of coupling Pin and Bush Flexible coupling

B. Existing Pump details SL No Characteristics Details

1 Pump Supplied by M/s KIRLOSKAR 2 Type / size / Model Vertical spindle mixed axial flow pump

type BHMa-83, single stage, pull out construction

3 Rated flow 11000 M3/hr at a total head of 9.5 MWC 4 Total dynamic Head excluding

losses in the pump 9.5M

5 Losses in the pump Approximately 0.655M 6 Total Bowl head approximately 10.155M 7 Shut off Head approximately 19M 8 Bowl efficiency 86% Fluid handled by the pump Sea Water

9 Normal operating temperature of fluid

Sea water at 30 to 35 deg. C and specific gravity 1.023

10 Ambient temperature 35 deg. C 11 Pump shut off head with rated

impeller Shall not be less than 115% of the rated head

12 Nominal Rated speed 494 RPM 13 Power absorbed at Bowl 372KW 14 Transmission and other losses 4KW 15 Power required at pump coupling 376 to 400KW 16 Pump efficiency 72% 27 Characteristic curves enclosed a Pump discharge Vs Efficiency Enclosed in graph sheet b Flow rate Vs Velocity head Enclosed in graph sheet c Flow rate Vs Pump developed head Enclosed in graph sheet





ANNEXURE: B EXISTING PUMP CHARACTERISTIC CURVES:





ANNEXURE C

Existing Pump Pedestal dimensional drawing





ANNEXURE: D

Specification for UT, DPT test

PP-E 1981 - Specification for Ultrasonic test

PP-E 2398 - specification of Dye Penetrant test





ANNEXURE: E Essential Spares

The supplier shall recommend a list of spares required for 5 years of operation to be stocked for maintenance purpose. However as a minimum, supplier shall furnish prices for the following in his offer

1. One set of space heaters

2. Two set of Protective instruments and control switches provided on the motor

3. Five set of Seals and other materials that require periodic replacement (indicate quantities

required for the operating life of the motor), if any.

4. One set of Bearing temperature sensing RTDs, and winding temperature sensing

thermocouples.

5. 1 set of Shaft insulating sleeves to prevent shaft current if provided

6. One set of top and bottom end shield assembly of motor.





ANNEXURE-F

LIST OF DRAWINGS AND CHARACTERISTIC CURVES FOR MOTOR TO

BE SUBMITTED BY THE FIRM FOR MOTOR

List Of Drawings for Motor Sl No. Drawing Description DRAWING NO.

1 Outline GA of Motor with overall dimension

2 Internal assembly – disassembly drawing indicating with complete internal details

3 Bearing assembly drawing 4 RTDs, thermocouple calibration detail

drawing

5 Motor flange with projected shaft details

List Of Characteristic curve for Motor Sl. No.

Characteristic curve Description DRAWING NO.

1 Thermal Withstand characteristic curve (Hot and Cold Condition)

2 Current Vs Time at rated voltage and frequency

3 Torque Vs Slip curve 4 Torque Vs Speed curve 5 Efficiency curve 6 Negative phase sequence current capability

curve (Unbalance current capability of Motor)

7 Motor expected life v/s temperature rise curve

8 Any other curve relevant to Motor

Note: The list mentioned above is indicative. However final list will be finalized during detailed engineering stage.





ANNEXURE -G

LIST OF APPROVED VENDORS

The Bidder shall satisfy himself regarding NPCIL approved subcontractors / Vendor for their technical and financial capabilities. The bidder at the time of submission of Part-I (Technical) bid may indicate additional subcontractors / Vendor for any of the given items, for evaluation by the Purchaser and if found acceptable, inclusion of such subcontractor / Vendor in approved subcontractors / Vendor list, before opening of Price Bid. In so far as no Subcontractors are listed against any such item or items not covered in the list, the Contractor shall prepare and submit to Purchaser a list of Subcontractors for such items for approval and inclusion in such list with the Part-1 bid. List of Approved sub-contractors / Vendors as issued with the Contract shall be strictly adhered to for procurement of goods/services from designated subcontractor(s) / Vendors.

1.0 All the bidders shall quote the prices on the basis of the approved sub-contractors/ sub-vendors indicated below. Bidders may kindly note that revision of prices will not be entertained on account of additional sub-vendor proposed by EPC contractor and subsequently approved by Purchaser, in line with GCC.

2.0 Approval by the Purchaser for any of the Subcontractors shall not relieve the Contractor from any of its obligations, duties or responsibilities under the Contract.

3.0 Followings are list of Approved vendors / Sub contractors / Sub vendors for this

Package.

4.0 The following table gives the tentative list of item to be bought out for motor manufacturing. Any other item if required to be included, the same shall be included with the proposed vendor name from whom it is proposed to buy for approval by NPCIL.

SL.NO. DESCRIPTION APPROVED VENDORS 1 CTC Conductor SAM DONG, KOREA KSH INTERNATIONAL PRECISION WIRES CHANDRA PROTECO ASTA, AUSTRIA VIJAI ELECTRICALS 2 Copper Wire Rod BIRLA / HINDALCO STERLITE 3 CRGO (Lamination Supplier) NIPPON STEEL, JAPAN JFE, JAPAN BRITISH STEEL, UK POSCO, KOREA A.K. STEEL 4 Cables and control wires NICCO





UNIVERSAL CABLES FINOLEX UNIFLEX CABLES KEI HAVELLS POLYCAB CABLES TORRENT CABLES 5 CRGO Lamination Processors BHEL TELK ALSTOM CGL MAHINDRA STEEL SERVICES VIJAI ELECTRICALS DELTA 6 Porcelain Insulators BHEL WSI JAYSHREE / BIRLA 7 Press Boards WEIDMANN FIGEHOLMS RAMAN BOARDS, MYSORE 8 Terminal Blocks ELEMEX CONNECT WELL 9 Paints ASIAN / AKZO NOBEL/ JOTUN

10 MS Steel (As per IS- 2062) SAIL TATA STEEL RINL

11 Welding Electrodes As per NPCIL Approved List





ANNEXURE-H

SCOPE OF WORK FOR TRANSPORTATION

MADRAS ATOMIC POWER STATION DATA

The site of Madras Atomic Power Station ( Here in after refer to as site) is located at Kalpakkam, District Kancheepuram, Tamilnadu about 80 km by road from Chennai, 35 km by road from Chengalpattu and 18 km by road from Mamallapuram. The site is on the east coast of Bay of Bengal region exactly center between Chennai and Pondichery. Scope of Transportation Activity

1.0 Transportation Activity from Manufacture end:-

a. Packing, covering, Loading, lacing & safe transportation of Sample and Main supply Motors and spares along with its accessories from factory premises to MAPS, Kalpakkam (Tamil Nadu) site. In case, destination location is changed, same will be communicated to bidder in advance prior to transportation of Motor.

b. Unloading and shifting of sample Motor along with its accessories to the specified location at MAPS, Kalpakkam (Tamil Nadu) site. Again after completion of site test again packing and transportation to Manufacturing facility or the place where equipment qualification test is proposed to be done.

c. Packing and transportation of Motor from the premises where equipment qualification test done to Manufacturing facility

d. For all above transportation requirement, the necessary transit insurance shall be arranged by the contractor. Cost to be included in transportation charges.

e. Other transportation requirements are already detailed in General Contract Conditions

2.0 Transportation Terms & Conditions:-

1. The transportation activities shall be carried out through specialized agencies that are well equipped with necessary equipments and have the experience of similar types of jobs.

2. All the jobs shall be carried out as per approved quality plan. In case any additional requirement other than specified, Contractor has to arrange the same at his own cost.

3. Only brief details of transportation have been given above. It is not possible to specify each & every activity in detail. For ensuring satisfactory performance, in case any additional activity is required, same is to be performed by the contractor at his own cost.

5. The Transport contractor shall arrange permissions from all concerned central/state govt. authorities such as CPWD/PWD, Railways, Electricity boards, R.T.O. Forest, Municipality, Home department, Police etc. for transportation of the consignment from both sides before the consignment is moved out to ensure safe and trouble free





transportation up to the required destination. All the expenses incurred to obtain such permission, if any, shall be borne by the contractor. However, necessary letter for obtaining such permission, if any, from respective authorities, will be issued by NPCIL. The contractor shall submit Xerox copies of all applications, which he has applied to different agencies for obtaining the permission. MAPS will retain them for record. The contractor shall be responsible for any delay/damage/loss occurred to any property en-route during the movement due to non-availability of any such permission or otherwise.

6. Any infrastructure development work required during the movement of consignment will be contractor’s responsibility without any additional charges.

7. The transportation from Manufacturer’s premises to MAPS, Kalpakkam, Tamil Nadu will be at Carrier’s risk without transshipment en-route. However, in case of any emergency or unforeseen situations consignment can be shifted from one carrier to another with approval of Motor / Motors manufacturer (in this case Contractor). Transport contractor should be able to do all these on his own and no departmental assistance in terms of man and material will be provided by MAPS. The contractor should arrange even the lifting equipment like crane etc. No additional charges will be given.

8. All drivers should possess valid driving license and all documents of the vehicles such as R.T.O. passing certificate, registration book, tax book etc. shall be current and valid.

9. The contractor shall also adhere to the safety aspects with regard to the consignment movement as covered under relevant prevalent Motor vehicle Act.

10. MAPS shall not be responsible for payment of any compensation to the contractor for injuries/accident to their manpower suffered during the performance of the contract or damage to vehicle and other material under any circumstances whatsoever.

11. Contractor shall make all necessary arrangements to load / unload Motor. At MAPS, NPCIL will provide Forklift required for this purpose, free of cost and if available only, if required.

12. The vehicles should normally be plied within the metallic width of the road.

13. The contractor shall be responsible for all losses including non-delivery, theft, pilferage, damage due to any cause whatsoever from the time he receives the consignment and during the period it is held by him till the consignment is safely delivered to the consignee.





14. In order to arrange safe transportation of the consignment, it may be necessary to carry out modification on the trailers & said modifications, if any, will have to be carried out by the Contractor without any additional cost to NPCIL.

15. Certification of transport equipment: The contractor shall provide all relevant

documents/ certificates for the equipment being used by him to transport above consignments to ensure good health of equipment and validity of equipment i.e. Trailers/Crane etc. However decision of the NPCIL about suitability of the transport equipment will be final.

16. The Corporation will not be responsible for payment of any compensation to the

contractor for any injuries to his employees/agents which they may suffer during the performance of the contract or damage to the vehicle, under any circumstances whatsoever.

17. The contractor shall be in close liaison during the entire operation i.e. from the time

of loading the consignment till the time of unloading and safe delivery of the consignment at above indicated destinations,

3.0 LIABILITIES OF CONTRACTOR REGARDING LOSSES / DAMAGES

The contractor shall abide by all the instructions that may be given to him from time to time by the Corporation or by an officer authorised to act on behalf of the Corporation and / or by the other officers authorised to operate the contract. The contractor shall be bound to act with the diligence and shall be responsible to pay due compensation towards any losses / damage that NPCIL might suffer in consequence of the negligence of his employees and /or agents.

4.0 TRANSIT INSURANCE:

Necessary transit insurance cover shall be arranged by the contractor for shipment of Motor / Motors from manufacturer’s premises to NPCIL / MAPS, Kalpakkam, Tamilnadu. The contractor shall be fully responsible for all the losses including non- delivery, theft, pilferage, damage due to any cause whatsoever from the time he receives the consignment till delivery of the same at destination.

5.0 Desired time schedule for transportation activities:-

S.No. Description Months

1 Time required for transportation of Motor from Manufacturing premises including safe loading to MAPS, Kalpakkam (Tamil Nadu) site, safe unloading etc..

15 days





ANNEXURE - I

GUARANTEED TECHNICAL PARTICULARS

(TO BE FILLED IN BY MOTOR MANUFACTURERS ALONG WITH TENDER) Sl No Description Unit Value 1 Make 2 Frame size and design code Number 3 Type (Squirrel cage / Slip ring) 4 Rotor type (single bar /double bar type) 5 Application (Driven equipment) 6 KW rating 6.1 Rated capacity KW 6.2 KW actually required by driven equipment

under specified operating conditions KW

6.3 Designed for an maximum altitude of m 6.4 Applicable standards / Codes 7 Rated voltage 8 Rated frequency 9 Permissible variation of 9.1 Permissible voltage variation under normal

operating condition

9.2 Permissible Frequency variation under normal operating condition

Hz

9.3 Permissible combined voltage and frequency variation under normal operating condition

10 Minimum voltage and frequency required to bring the driven equipment up to rated speed

11 No of phases 12 Stator winding 12.1 Connection (Star /Delta) 12.2 Resistance per phase Ohms 12.3 Resistance between terminals 12.4 Inductance per phase 12.5 Inductance between terminals 12.6 Air gap mm 13 At rated voltage frequency and voltage 13.1 No load speed RPM 13.2 No load current Amps 13.3 Full load speed RPM 13.4 Full load current Amps 13.5 Starting current (% of full load current) %age 13.6 Starting torque (% of full lad torque) %age 13.7 Maximum torque (% of full lad torque) %age





13.8 Full load efficiency %age 13.9 Efficiency at 75% load 13.10 Efficiency at 50% load 13.11 Full load power factor 13.12 power factor at 75% load 13.13 power factor at 50% load 13.14 Power factor at No lad 13.15 Starting power factor 13.16 Full load running Power factor 13.17 Negative phase sequence with stand

capability in percentage of Positive sequence current

14 Starting 14.1 Is it designed for DOL starting 14.2 Torque in percentage of full load torque

expected with limiting starting current to 250% and 300% of full load current

14.3 Acceleration time with full load connected at 80%, 90% and 100% of rated voltage

sec

14.4 Starting current Vs time characteristics in DOL starting

15 Duty cycle 15.1 Type of duty as per IS 4722 15.2 Permissible starting duty cycle 15.3 Average Number of starts permissible during

24 Hours if started on DOL Nos

15.4 Extra precaution taken in the motor design to meet 150% of nominal voltage during high speed bus transfer

15.6 Limiting rotor / Stator temperature at 80%, 90%, 110% of rated voltage

Deg C

15.7 Limiting stator body temperature Deg C 15.8 Limiting DE bearing temperature Deg C 15.9 Limiting NDE bearing temperature Deg C 16 Safe stall time in sec at 80% and 100% of

rated voltage

16.1 When Motor is at rated operating temperature

sec

16.2 When Motor is at ambient temperature sec 16.3 Limiting stator and rotor temperature used to

determine stall time Deg C

17 Over load capacity 17.1 Overload (Percent of full load) that can be

carried out by motor without impairing overall performance and period for which this overload is applicable

%age





17.2 Stator thermal time constant 18 Insulation system 18.1 Class of Insulation 18.2 Insulation material chosen 18.3 Material and treatment of insulation 19 Temperature raise in deg C over ambient

under normal and accidental conditions (State ambient temperature applicable)

19.1 By thermo meter deg C 19.2 By winding resistance deg C 19.3 Designed ambient temperature deg C 19.4 Designed humidity level 20 Shaft orientation 20.1 Horizontal 20.2 Vertical 21 Method of connection to driven equipment 22 Direction of rotation 22.1 Direction of rotation offered to drive

equipment and corresponding terminal designating on motor

22.2 Designed for uni-directional or bi directional Enclosure 23 Type of Enclosure / Protection 23.1 Type of enclosure 23.2 Degree of protection to IS 4691 24 Type of cooling to IS 6362 25 If the safe stall time of the motor at rated

operating temperature is less than the accelerating time at 80% rated voltage

25.1 Is the motor offered with speed sensing switch

25.2 Furnish details of speed sensing device 26 Bearings DE and NDE 26.1 Type and catalogue Number 26.2 Mounting arrangement 26.3 Is it fixed on end shield or shaft or with

bearing cartridge

26.4 Oil lubricated / Grease lubricated 26.5 Life in hours at rated speed Hrs 26.6 Recommend lubricant 26.7 Bearing end play in mm mm 26.8 Top bearing thrust load Kgs 26.9 Thrust bearing losses Kw 26.10 Regreasing requirement frequency Hrs 26.11 Grease quantity required Kg/Grams 27 Terminal connection





27.1 For stator leads type and number 27.2 For purchasers incoming cable type and

number

28 Grounding devices 28.1 Method and number of grounding points 28.2 Location 28.3 Cable for which the grounding connector is

suitable

29 Power Terminal boxes 29.1 Type and number provided 29.3 Is it phase segregated 29.4 Fault withstand capacity at rated voltage a MVA and duration b Let through energy of Breaker 29.5 Degree of protection for Power terminal Box

enclosure to IS 4691

29.6 No.of cable entries 29.7 Size and max. dia of cable 29.8 Direction of cable entry 29.11 Terminal box for space heater is

independently provided

29.12 Terminal box for Bearing and Winding RTDs, thermocouple is independently provided

30 Weight 30.1 Net weight of complete Motor Kgs 30.2 Weight of rotor alone Kgs 30.3 Weight of stator alone Kgs 30.4 List of items weighing 25Kgs and more

31 Moment of inertia Kg-cm2 32 Critical speeds 32.1 Higher then Synchronous speed rpm 32.2 Lower the synchronous speed rpm 33 Speed torque curve for Motor provided 34 Thermal withstand characteristic 34.1 When motor is at an ambient temperature 34.2 When motor is at operating temperature 34.3 Heating time constant 34.4 Cooling time constant 35 Shipping dimension and weight 35.1 Length * Breath * height mm 35.2 Weight Kgs 36 Space heater rating 36.1 No of heaters proposed Nos 36.2 Voltage rating V





36.2 Wattage of each heater W 37 Critical dimensions of Motor 37.1 Height of Motor from centre of RTD,

thermocouple terminal box to bottom flange face

mm

37.2 Height of Motor from centre of space heater terminal box to bottom flange face

mm

37.3 Height of Motor from centre of Main terminal box to bottom flange face

mm

37.4 Shaft projected length from bottom flange face

mm

37.5 Bottom base flange OD mm 37.6 Bottom base flange ID (spi-guard) mm 37.7 Bottom base Flange projection depth mm 37.8 Bottom base flange face to bottom level

indicator pipe center mm

37.9 Over all height of Motor from top surface to bottom shaft face

mm

37.10 RTD, thermocouple terminal box projection from motor body

mm

37.11 Length between Motor top surface to top bearing fill point top surface

mm

37.12 Space heater terminal box size mm W and H

37.13 Main terminal box size mm W and H

37.14 Distance between Main terminal box cover face to motor center

mm

37.15 Bottom flange fixing holes PCD mm 37.16 Bottom flange fixing hole size mm 37.17 Load end shaft diameter mm 37.18 Load end shaft Key size mm 38 The following drawing shall be submitted

within two weeks from the date of placing PO

38.1 Outline dimension of assembled motor 38.2 Dimensional drawings of the terminal boxes

showing the method of terminating the purchaser incoming cable

38.3 Assembly and disassembly drawing with complete internal derails

38.4 Directional drawing of bearing housing with lubrication and cooling

39 Other data’s to be furnished with tender 39.1 Schedule of price and delivery 39.2 Schedule of suppliers departure (Deviation)





from this specification 39.3 Description of insulation material used and

insulation treatment

39.4 List of accessories included in the scope of suppliers

39.5 Material specification for motor shaft and bearing housing

40 Material of stator frame and end shields 41 Type test certificates or design calculation to

prove the specified fault with stand ability of terminal box

42 Residual voltage of Motor terminals Vs time characteristics after supply disconnection to Motor at full load (To be furnished after placement of PO)

43 All the components with the exception of the bearings and parts specifically designed for easy replacement shall be suitable for a minimum of 40Years of continuous service.

44 The overall diameter and height of the motor shall not be more that the existing motor dimensions by a large margin

Agreed / disagreed

45 Stator body has facility to fix vibration sensor

46 Designed service life of Motor 47 Complete details of the material used for

stator frame

48 Special Features provided in Rotor design 49 Describe insulation material and its treatment 50 Amplitude and velocity of vibration at

various location

51 Balancing of rotor at rated rpm 52 Balancing of Fan and any other rotating mass

at rated RPM

53 Pull out torque of the motor at rated voltage 54 Technical particulars and Characteristic

curves that will be submitted by the firm

55 Recommended electrical protections to be provided by the purchaser

56 Recommended requirements for maintenance / calibration of devices so as to ensure proper operation of Motor and associated equipment and getting full service life of the equipment.

57 Indicate expected life of the Motor when operating under the site conditions. Also submit Motor expected life v/s temp. rise curve





58 Whether all drawings and documents to be submitted after the award of contract will be submitted within specified time as given in sec D-2.5

59 Whether compliance to QAP and stage wise inspection ensured

60 Whether compliance to recommended list of sub suppliers and related Provisions ensured

61 Whether space adequacy in the seawater pump house service position/existing pedastal has been considered while designing the motor?

62 List of routine tests to be carried out 63 List of other tests which will be carried out

against extra price

64 CONTRACTOR's drawing no. of general outline drawing enclosed with the TENDER showing Motor with all its fittings and accessories in plan, front and side elevations and other details.

65 Shipping schedule provided? 66 Size of the largest package (LxBxH)mm 67 Weight of the heaviest package kg 68 Manufacturer's recommended procedure for

preservation of spare Motor

69 Manufacturer's recommended Procedure for off-line preservation and maintenance of Motor and accessories

70 List of make and type designations of all bought out items

71 All accessories supplied as specified (Yes/No)

72 Whether all catalogues enclosed? (Yes/No)

73 Design review requirements 74 a Design review aspects and requirements as

outlined in tender are taken into consideration and whether they are met adequately?

b Design review report will be prepared and submitted as end documents

75 Does Motor comply with all requirements outlined in tender specification?

76 Electrical and mechanical endurance life data with maintenance and between specified maintenance intervals





77 Indicate facilities available and experience in the following activities

78 Design and engineering of: 78.1 High Capacity flange mounted vertical motor

with grease lubrication

78.2 Insulation system 78.3 Grease lubricated bearing system for both

top and bottom bearing

78.4 Heat transfer system so as to ensure that hot spot temperatures in winding are within the controlled limits:

79 Indicate jobs proposed to be outsourced 80 Indicate the details for erection and

commissioning at site including tests, test equipments and proposed site organisation etc

81 Facilities at factory for testing 81.1 Facilities available at factory for conducting

type tests

81.2 Facilities available at factory for conducting Special tests

81.3 Facilities available for conducting winding Temperature rise by injecting 105% of full Load current with documentary evidence

82 Maximum MVA rating available at factor for testing Motor

MVA

SIGNATURE __________________ DESIGNATION __________________ COMPANY SEAL COMPANY ___________________ DATE ___________________


Technical Specification for Condenser Cooling Water Pump Motor MANUFACTURER’S GENERAL PARTICULARS

Section: D-2.1 of 91 Rev-0

SPECIFICATION NO: PP-E-787M-MAPS June 2015

The TENDERER shall furnish here the following general particulars: 1.0 Name of the TENDERER/ MANUFACTURER : 2.0 Address of the TENDERER : 3.0 Telegraphic and telex addresses of the TENDERER : 4.0 Name and designation of the Officer of the TENDERER to whom all reference shall be made for expeditious technical co-ordination : 5.0 If equipment is manufactured in foreign Collaboration, please furnish necessary details : 6.0 Place of manufacture & assembly :

7.0 Current registration number with DGS & D : 8.0 Whether service facilities available, if so details : 9.0 Whether sufficient spares are available in stock : 10.0 The place where the motor will be offered for inspection and testing: 11.0 List the Testing facilities available at manufacturing / testing place: SIGNATURE ______________ SEAL OF COMPANY DESIGNATION ____________ COMPANY ________________ DATE ___________________


Technical Specification for Condenser Cooling Water Pump Motor SCHEDULE OF TENDERER’S EXPERIENCE



The TENDERER shall furnish here a list of all similar jobs executed by him to whom a reference may be made by the PURCHASER in case the PURCHASER considers such a reference necessary.

Sr. No.

Description Of work Including Qty. of Items

Work Order Or P.O. No. & Date

Value Of work

Delivery Date as Per P.O.

Actual Date of Delivery

Contact Address Of Purchaser

SIGNATURE ______________ SEAL OF COMPANY DESIGNATION ____________ COMPANY ________________ DATE ___________________


Technical Specification for Condenser Cooling Water Pump Motor DRAWINGS TO BE SUBMITTED ALONG WITH THE TENDER



1.0 Vendor shall submit list of drawings and curves for Condenser Cooling Water Pump Motor as per details given in Annexure-F after the award of contract.

2.0 Vendor shall submit all necessary literature, catalogues, pamphlets for all

equipment and accessories covered under this contract.


Technical Specification for Condenser Cooling Water Pump Motor SCHEDULE FOR SUBMISSION OF DRAWINGS, DATA,

INSTRUCTION MANUALS, TEST REPORTS ETC.



DATA and DOCUMENTS TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF CONTRACT FOR MOTOR. 1.0 Schedule for Data and drawings The CONTRACTOR shall furnish the following drawings and other details for

the Motor within the time indicated, after issue of LOI for PURCHASER'S/ CONSULTANT'S approval.

a) Detailed dimensional GA drawings for Motor 2week b) GA of terminal boxes showing dimensions, terminal details, mounting details 2week c) Rating and diagram plates 2week d) Quality assurance plan and vendor list for approval 2week e) Any other drawing/document considered necessary including all manufacturers technical literature for all equipment and accessories 2 week f) Engineering schedule giving a list of all drawings, documents, data, performance curves, test certificates, manuals, etc. to be submitted by the CONTRACTOR together with dates of submissions and category of approval, ie., for approval or for reference 2 week g) List of recommended spare parts 1 month

2.0 DATA The CONTRACTOR shall furnish the guaranteed technical particulars as per

D1.1 with complete information within 1 month of placement of order.

3.0 INSTRUCTION MANUALS The CONTRACTOR shall furnish 2 draft copies of the manual for

PURCHASER's review 1 months before despatch of the equipment. After the PURCHASER's clearance, the manuals shall be furnished along with equipment.

The CONTRACTOR shall furnish 6 set of copies of the instruction

manuals as specified which would contain detailed instructions for all erection, testing, commissioning, operation and maintenance requirements. The manual shall be furnished at the time of despatch of the equipment and shall include the following aspects :






a) Outline dimensional drawings showing relevant cross sectional views,

earthing details and constructional features. c) Full technical information which may be necessary for the erection, testing,

commissioning, safe operation and maintenance of the Motor. d) Catalogues of all the components which are liable to be replaced during the

life of the Motor and all the component parts. e) Unpacking. f) Handling at site. g) Erection drawings with written assembly instructions that would enable the

PURCHASER to carry out erection with his own personnel. h) Detailed instructions for the operation and maintenance of the Motor and its

accessories. i) Pre-commissioning tests and test procedures. j) Procedures for removal and replacement of any faulty component with the

spare one. k) Precautions to be taken during operation and maintenance work. l) Complete set of motor characteristic curves and performance data.

4.0 TEST CERTIFICATES

Type test, , special tests, site load test as per IS and Special test Specific to NPCIL (which are to be carried out on sample motor as per QAP) certificates for all the tests specified for the Motor and the component parts shall be submitted by the CONTRACTOR within one week on completion.

b) Routine test & special routine test certificates for all tests specified for the motor and the component parts shall be submitted by the CONTRACTOR at least 1 month after the date of despatch.

c) Equipment shall not be despatched unless the test certificates are duly

approved by the PURCHASER/ CONSULTANT. d) The specified number of copies of the compiled and approved test

certificates shall be submitted to the PURCHASER within one month of the despatch of the equipment.






e) Records of radiography tests and other NDT as specified, shall be submitted within two weeks of completing the tests.

5.0 Design Review Report:

The firm shall submit design review report indicating complete details of the

motor as per specification for approval within one month on placing PO

6.0 End Documents: The following end documents shall be submitted in hard copy (3 sets) and soft copy (2 CDs) along with delivery of the motors

• Design review report • The load performance test report done at site on motor • Capability and performance curves of the motor • Type test, Routine test and special test reports • All the material certificates • All the catalogues and instruction manual for bought out items • Operation, Installation and Maintenance Instruction Manual for Motor • Final set of complete drawings • Any other document which are essential for the motor for future reference


Technical Specification for Condenser Cooling Water Pump Motor SCHEDULE OF PERFORMANCE GUARANTEE



1.0 The TENDERER shall furnish performance guarantee in respect of the following parameters(r). Any variation of values stated below during the performance Tests will be taken into account by the PURCHASER for penalty or rejection.

a) Temperature of

• Stator winding at full load : • Top bearing • Bottom bearing

b) Vibration level i) Stator body ii) Top bearing location iii) Bottom bearing location : deg C c) No-load losses at 100% rated voltage and frequency : kW e) Load losses at rated current at 50 deg C ambient) : kW

2.0 REJECTION

2.1 Purchaser may reject any Motor if during test or service any of the conditions indicated in clause No. 6.0 of sec-CC-5 arise.


Technical Specification for Condenser Cooling Water Pump Motor SCHEDULE OF DEVIATIONS FROM TECHNICAL

SPECIFICATIONS

Section: D-2.7.1 of 91 Rev-0


All deviations from the technical specification shall be filled in by the TENDERER clause by clause in this schedule.

Section Clause No Deviation

The TENDERER hereby certifies that the above mentioned are the only deviations from the technical specification of the enquiry.

SIGNATURE ________________

SEAL OF COMPANY DESIGNATION COMPANY ________________

DATE ________________


Technical Specification for Condenser Cooling Water Pump Motor SCHEDULE OF DEVIATIONS FROM CONTRACT

CONDITIONS

Section: D-2.7.2 of 91 Rev-0


All deviations from the contract conditions shall be filled in by the TENDERER clause by clause in this schedule.

Section

Clause No. Deviation

The TENDERER hereby certifies that the above mentioned are the only deviations from the General Conditions of the Contract.

SIGNATURE ________________

SEAL OF COMPANY DESIGNATION _______________

COMPANY _______________

DATE _______________


Technical Specification for Condenser Cooling Water Pump Motor SCHEDULE OF MANUFACTURING, DELIVERY AND OTHER

RELATED ACTIVITIES



The TENDERER shall indicate the time for manufacture, delivery and other activities of each equipment as shown below:

Equipment

Time from date of order to works test

Time for works test, dismantling, packing & ready for dispatch from works

Time required for shipment to site

Total time from date of order to receipt at site

Time required for erection/ time required for testing and commissioning

(Days) (Days) (Days) (Days) (Days)

We, the undersigned hereby undertake to meet the above time schedule from the date of order.

SIGNATURE _____________

SEAL OF COMPANY DESIGNATION _____________

COMPANY _____________

DATE _____________


Technical Specification for Condenser Cooling Water Pump Motor SCHEDULE OF PERSONNEL FOR ERECTION TESTING AND

COMMISSIONING



The Tenderer shall indicate below the number and category of personnel required for erection, start-up and performance testing and commissioning.

Erection Testing & Commissioning

Number Number

Category

Expatriate

Personnel

Local

Recruitment

Expatriate

Personnel

Local Recruitment

The Tenderer shall also indicate here those section of works or items for which specialist services on site are required.

SIGNATURE _____________

SEAL OF COMPANY DESIGNATION_____________

COMPANY _____________

DATE _____________


Technical Specification for Condenser Cooling Water Pump Motor FORMET FOR SUBMISSION OF PRICE BID (PART II)

Section: E of 91 Rev-0


FORMAT FOR SUBMISSION OF PART II (COMMERCIAL) OF THE TENDER

Price Bid Format

Tender No: Annexure - I

Nuclear Power Corporation of India Limited (For Madras Atomic Power Station)

PRICE FORMAT FOR SUPPLY OF MODERATOR MOTOR

Sl. No. Item Description Quantity

Unit Price on Ex-

works price including Packing

and Forwarding

in INR

Total Price on Ex-works

price including

Packing and Forwarding

in INR

Limiting CIF Value of

Imported Raw Materials

included in the Indigenous Supply as in Column - 'E'

(if any)

A B C D E = C * D H

1.0 Design, Manufacture, Testing, Packing and Forwarding of 450KW 6.6KV 3 Phase squirrel cage AC induction motor for Condenser cooling system circulating pump in complete with all accessories as per specification attached

2 Nos

2.0 Supply of Essential Spares for Moderator Motor as per Annexure - E of Section CC-11

2.1 Motor space heaters 1 set

2.2 Set of complete Protective instruments and control switches provided on the motor

2 set



Section: E of 91 Rev-0


2.3 Set of Seals and other materials that require periodic replacement (indicate quantities required for the operating life of the motor)

5 set

2.4 Complete set of bearing RTDs 5 set

2.5 Shaft insulating sleeves to prevent shaft current if provided

2 set

2.6 One set of top and bottom end shield assembly of motor

2.7 Stool for preserving Motor during overhauling and storing

2 Nos

TOTAL

Notes

1 All columns shall be filled up completely & where there are no charges it shall be shown as zero.

2 In case there is a discrepancy between the unit price and the total price which is obtained by multiplying the unit price and quantity, the unit price shall prevail and the total price will be corrected accordingly.

3 (a) Imported raw materials meant for manufacture of intended item for this tender will attract concessional Custom Duty as per Sr.No.370 under General Exemption No.122 of Customs Tariff Act. Necessary Recommendatory Letter will be provided by the Purchaser. In view of this, the bidder shall submit their price bid based on this assumption. Further, the bidder shall avail CENVAT credit and pass on the benefits to NPCIL.

(b) Limiting CIF Value of Imported Items / Raw Materials included in the indigenous Supply in Column 'G' is Rs. ________________.

4 Taxes & Duties & compliance to the General Condition of Contract i.e. GCC/Supply-1/R.2 shall be as per Annexure - B enclosed herewith.

5 Place of Use : Madras Atomic Power Station, P.O. Kalpakkam, Kancheepuram Dist, Kalpakkam - 603 102

Stamp & signature of Tenderer





Tender No. Annexure - II


(For Madras Atomic Power Station)

PRICE FORMAT FOR TRANSPORTATION, INSTALLATION AND COMMISSIONGOF MOTOR

Sr. No. Item Description Unit Total Charges

A B C D Currency : INR

1.0 Loading, Transportation of all Motor from Manufacturers premises to Purchaser's premises

2.0 Shifting, Erection, testing of sample motor at location for evolving its actual load performance as per tender specification

TOTAL

Note: All columns shall be filled up completely where there are no charges it shall be shown as zero.

Stamp & Signature of the Tenderer





Tender No. Annexure - III


(For Madras Atomic Power Station)

PRICE FORMAT FOR Type test as per tender specification (No changes shall be demanded for conducting Routine tests on all the motors as it shall be p

of basic price of the motor)

Sr. No. Item Description Unit Total Charges A B C D

Currency : INR

1.0

Conducting Type tests as per IS 325 / IEC 60034.

TOTAL

Note: All columns shall be filled up completely where there are no charges it shall be shown as zero.

Stamp & Signature of the Tenderer