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PT. PERTAMINA (PERSERO) Document No.: CLP-PSP-020-003-A4 JASA KONSULTANSI PENYUSUNAN FRONT END ENGINEERING DESIGN (FEED) UNTUK PEMBANGUNAN TERMINAL LPG PRESSURIZED DEPOT LPG CILACAP Revision: 2 Status: IFB Discipline: MECHANICAL SPECIFICATION FOR PUMPS OWNER : PT. PERTAMINA (PERSERO) DIREKTORAT PEMASARAN DAN NIAGA PROJECT : JASA KONSULTANSI PENYUSUNAN FRONT END ENGINEERING DESIGN (FEED) UNTUK PEMBANGUNAN TERMINAL LPG PRESSURIZED DEPOT LPG CILACAP LOCATION : DEPOT LPG CILACAP REV DATE DESCRIPTION PT. TALYA TEKNINDO PT. PERTAMINA By Chkd Apvd Chkd Apvd 1 07/01/2015 Issued For Approval (IFA) FRL AND KS 2 04/02/2015 Re-Issued For FRL AND KS

CLP-PSP-020-003-Rev 1 Specification for Pumps (Review HH).doc

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Page 1: CLP-PSP-020-003-Rev 1 Specification for Pumps (Review HH).doc

PT. PERTAMINA (PERSERO)

Document No.:CLP-PSP-020-003-A4

JASA KONSULTANSI PENYUSUNAN FRONT END ENGINEERING DESIGN (FEED)

UNTUK PEMBANGUNAN TERMINAL LPG PRESSURIZED

DEPOT LPG CILACAP

Revision:

2

Status:

IFB

Discipline:

MECHANICAL

SPECIFICATION FOR PUMPS

OWNER : PT. PERTAMINA (PERSERO) DIREKTORAT PEMASARAN DAN NIAGA

PROJECT : JASA KONSULTANSI PENYUSUNAN FRONT END ENGINEERING DESIGN (FEED) UNTUK PEMBANGUNAN TERMINAL LPG PRESSURIZED DEPOT LPG CILACAP

LOCATION : DEPOT LPG CILACAP

REV DATE DESCRIPTIONPT. TALYA TEKNINDO PT. PERTAMINA

By Chkd Apvd Chkd Apvd

1 07/01/2015Issued For Approval

(IFA)FRL AND KS

2 04/02/2015Re-Issued For Approval

(Re-IFA)FRL AND KS

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SPECIFICATION FOR PUMPS

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REVISION HISTORICAL SHEET

PAGEREVISIONS

REMARKSATTACHMENTS

REMARKSATT PAGE

REVISIONS1 2 3 4 0 1 2 3 4 0

1 X2 X3 X4 X5 X6 X7 X X8 X X9 X X

10 X11 X X12 X13 X14 X15 X16 X17 X18 X X19 X20 X21 X22 X

EXHIBITS23 X24 X X

EXHI. PAGEREVISIONS

REMARKS25 X X 1 2 3 4 026 X X27 X28 X29 X30 X31 X32 X33 X X34 X35 X

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SPECIFICATION FOR PUMPS

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TABLE OF CONTENTS

REVISION HISTORICAL SHEET................................................................................2

TABLE OF CONTENTS..............................................................................................3

1.0 INTRODUCTION.................................................................................................5

2.0 GENERAL SCOPE.............................................................................................5

3.0 DEFINITIONS......................................................................................................6

4.0 REFERENCES....................................................................................................6

4.1 Code & Standards.....................................................................................7

4.2 Project Specifications...............................................................................7

5.0 GENERAL REQUIREMENTS.............................................................................8

6.0 SCOPE OF SUPPLY.........................................................................................11

6.1 Fire Pump................................................................................................11

6.2 LPG Filling Pump....................................................................................12

7.0 EXECUTION......................................................................................................12

8.0 FIRE PUMP DESIGN REQUIREMENTS..........................................................12

8.1 General.....................................................................................................12

8.2 Prime Mover............................................................................................14

8.3 Electrics...................................................................................................19

9.0 LPG FILLING PUMP DESIGN REQUIREMENTS............................................24

9.1 General.....................................................................................................24

9.2 Design......................................................................................................25

9.3 Mechanical Shaft Seal............................................................................26

9.4 Vibration..................................................................................................27

9.5 Base Plate................................................................................................28

9.6 Lubrication..............................................................................................28

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9.7 Electric Motor & Drive.............................................................................28

9.8 Performance............................................................................................29

9.9 Noise........................................................................................................30

9.10 Material....................................................................................................30

10.0 SPARE PARTS FOR THE PUMP ORDERED..................................................31

11.0 SPARE PARTS FOR ENGINE ORDERED.......................................................31

12.0 INSPECTION AND TESTING...........................................................................31

12.1 Fire Pump................................................................................................31

12.2 LPG Filling Pump....................................................................................32

13.0 PERFORMANCE GUARANTEE.......................................................................34

14.0 NAME PLATE...................................................................................................34

15.0 PREPARATION FOR SHIPMENT....................................................................35

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1.0 INTRODUCTION

PT. Pertamina (Persero) Directorate of Marketing and Commerce, intends to carry out the construction of pressurized LPG terminal in line with the government's program to reduce fuel subsidies of land for household tumble to LPG.

By the conversion of fuel from kerosene to LPG, the LPG demand in the future will continue to increase while the facility receiving, storage and distribution of liquefied petroleum gas (LPG terminal) available is not sufficient, so it should be added hoarding LPG facility, to anticipate the needs of LPG in the future in order to avoid a crisis availability of LPG in the community.

Prior to the development activities conducted prior Pre-Project activities and preparation of Front End Engineering Design (FEED) for the construction of LPG Terminal pressurized LPG Depot Cilacap.

Cilacap Depot LPG Pressurized Location

2.0 GENERAL SCOPE

Scope of work Consultancy Services Preparation FEED pressurized LPG Terminal Development, among others, prepare, plan, inspect, supervise, evaluate, analyze of the following are :

Preparation Document Engineering;

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Preparation of Tender Documents; UKL / UPL Document and Permits.

The Overall scope of this work requires conduct field survey, re-survey and measurements back to the planning details so that the facility is built to operate as desired output performance.

3.0 DEFINITIONS

The definition contained in the contents of this procedure and other procedures are as follows :

PTM : PT. Pertamina (Persero) Directorate of Marketing and Commerce as the owners and users of the facility or equipment.

Work : Consultancy Services Preparation of Front End Engineering Design (FEED) For pressurized LPG Terminal Development LPG Depot Cilacap.

Consultant : PT. TALYA TEKNINDO to do the preparation work Front End Engineering Design (FEED) on the WORK.

MIGAS : The Representatives of the Indonesian government which is responsible for the issuing of licenses and permits operation of oil and gas.

Third Party : A third party inspector to be appointed by Pertamina to inspect the works of Contractor.

QA / QC : Quality Assurance / Quality Control.

Issuer : The person / party who develop and release the document and correspondence.

Project Documents : All documents which are prepared, revised, and issued for accelerating the project execution, such as correspondence, drawings, specifications, requisitions, purchase orders, and Vendor Prints, etc

SITE : the right-of-way and places provided by the Employer where the construction works are to be executed and any other places as may be specifically designated in the Contract as forming part of the Site.

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4.0 REFERENCES

The following applicable section of the latest edition of the code and standards, including addenda and referenced documents, project's specification shall form an integral part of this specification.

Where the requirement of the subject is defined by two or more references, the more stringent reference shall govern.

4.1 Code & Standards

API 610 : Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries

ASME B 73.1 : Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process

ASME B 73.2 : Specification for Vertical In Line Pump Centrifugal Pumps for Chemical Process

ASME B16.5 : Steel Pipe Flanges and Flanged Fittings

ASTM : American Society for Testing and Materials

API RP 7B-11C : American Petroleum Institute - Internal Combustion Engines for Offshore Facilities

BS 5265 : Mechanical Balancing and Rotating Bodies

EEMUA 140 : Noise Procedure Specifications

HI : Hydraulic Institute Standard

ISO 1940 : Mechanical Vibration, Balancing Quality of Rigid Rotors

ISO 5199 : Technical Specifications for Centrifugal Pumps – Class II

ISO 9906  : Rotor-Dynamic Pumps Hydraulic Performance acceptance tests Grades 1 and 2

ISO 2017 : Vibration Isolators

ISO 3046 Points 1 to 7 : Reciprocating Internal Combustion Engine

ISO 10474/ BS EN 10204 : Metallic Products: types of inspection documents

ISO 13709:2009 : (Identical), Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries

NFPA 20, 2010 Edition : National Fire Protection Association - Standard for the Installation of Stationary Pumps for Fire Pumps

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OSHA : Safety Regulation

4.2 Project Specifications:

CLP-PSP-040-001-A4 : Piping Material Specification

CLP-PSP-040-003-A4 : General Specification for Painting

CLP-PSP-030-001-A4 : General Specification for Electrical System

CLP-PSP-030-006-A4 : Specification for Induction Motor

CLP-DSH-020-005-A4 : Datasheet for LPG Filling Pump

CLP-DSH-020-007-A4 : Datasheet for Jockey Pump

CLP-DSH-020-008-A4 : Datasheet for Fire Water Pump

5.0 GENERAL REQUIREMENTS

a. In the case of any conflict in the requirements specified in the documents attached to the inquiry/order, the most stringent of the specified requirements shall govern. PTM interpretation in this regard shall be final and binding on the vendor.

b. The pumps shall be designed for continuous use in an exposed, tropical, onshore, offshore, salt laden, corrosive atmosphere with 15.5 oC to 38 oC ambient temperature and 90% to 100% relative humidity. Easy to operating for prevent the risk of operational error and facilitate of correct operation.

c. The pump rated capacity, total dynamic head and other performance requirements shall be as per the requirement indicated in the pump data sheet.

d. Pump casing shall be made of suitable material for handled liquid and hydrostatically tested at pressure as per code requirement.

e. The pump shall be suitable for parallel operation.

f. The complete assembled unit shall be designed so that all covered parts including shafts and bearings shall be easily accessible for inspection, maintenance and replacement with minimum down time.

g. The rotor assembly with impeller and shaft sleeve shall be dynamically balanced at 1.5 times of operating speed.

h. A common base plate mounting both for the pump and drive shall be furnished.

i. The Contractor shall supply the pump set as described herein and in accordance with the quantities, size, features, type and accessories as detailed including supply of pump driver.

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j. Spare parts for two (2) years operation of the pump including pump driver.

k. All drawings, load data and other information to be furnished for PTM approval shall be progressively submitted in three (3) copies and the entire submission of documents completed within a month’s time from the date of PTM’s telex / letter of acceptance.

l. The supplier shall get the equipment inspected by approved Third Party agencies before dispatch of the equipment to site. The approval / comments, if any, of/on the drawings shall be communicated by PTM within 10 days of receipt of the same. Changes, if any in the drawings have to be incorporated and submitted to PTM for their record.

m.Approval of supplier’s drawings by PTM shall not relieve the supplier of any responsibility covered by the requirement of the Contract.

n. The supplier shall supply operation and maintenance manuals along with the equipment. The manuals shall meet the following requirements:

The instruction manuals shall present the categories of information in practical, complete and comprehensive manner prepared for use by operating and/or maintenance personnel.

Drawings and other illustrations shall be included or copies of drawings shall be bound in the manual. Test, adjustment and calibration information as appropriate shall be included and shall be identified to the specific equipment. Safety and warning notices and installation, maintenance and operating cautions shall be emphasized.

A parts list shall be included showing part nomenclature, manufacturer’s part number and/or other information necessary for accurate identification and ordering of replacement parts.

If a standard manual is furnished covering more than the specific requirement purchased, the applicable model No., parts No. and other information for the specific equipment purchased shall be clearly identified.

The instruction manual shall include a list of all special tools and tackles furnished with complete drawings and instructions for use of such tools and tackles.

o. Other miscellaneous works:

Foundation drawing, bolt size and numbers, grouting method, etc. should be advised in advance after order placement. The scope of supply includes supply of foundation bolts.

The scope also including brief training of the working personnel at site about predictive maintenance, do’s & don’ts, daily checks etc.

Matching flange with studs, nuts and gasket has to be supplied by the Vendor.

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2 (two) Nos. of pressure gauges per pump (on suction and discharge) have to be supplied by the Vendor as per pressure range as specified on each data sheet of pumps.

6.0 SCOPE OF SUPPLY

6.1 Fire Pump

Fire Water pump package shall include the following listed major components which shall be assembled and fully shop tested prior to shipment from the Vendor facilities:

a. Centrifugal pump as per NFPA standard

b. Pump Driver (Electric motor as per NEMA standard or Diesel Engine as per UL/FM).

c. Driver and pump coupling connection.

d. Fire pump controller (as per UL/FM standard)

e. Non sparking coupling guard.

f. Structural skid.

g. Gland packing and seal system

h. For Diesel Engine: Fuel system including fuel storage tank, Lube oil system, Cooling water system, batteries, exhaust system with silencer and engine mounting with anti vibration.

6.2 LPG Filling Pump

LPG Filling pump shall be Centrifugal type and manufactured, tested and installed shall accordance with API 610 latest edition. LPG Filling pump package shall include the following listed major components which shall be assembled and fully shop tested prior to shipment from the Vendor facilities:

a. Centrifugal pump as per API 610 standard

b. Electric motor as per NEMA standard.

c. Motor and pump coupling connection.

d. Coupling guard.

e. Structural skid

f. Mechanical Seal and system

g. Lube oil System

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7.0 EXECUTION

Unloading and installation of pump sets along with all accessories; fuel piping from tank to engine, extension of exhaust pipe from silencer/flexible element onwards at site has been excluded from the scope of work of the Contractor. However commissioning and supervision of erection of pumps are included in the scope of work of the Contractor.

8.0 FIRE PUMP DESIGN REQUIREMENTS

8.1 General

- The pump shall be manufactured, tested and marked in accordance with NFPA 20.

- Pumps shall be capable of developing not less than 150% of rated capacity at a head of not less than 65% of the rated head. The shut-off head shall not exceed 120% of rated head. The pump shall have a continuous rising head capacity characteristic from the specified duty point towards the shut-off point, the maximum being shut-off. The horse power characteristic shall preferably be non-over loading type beyond the rated capacity point.

- The pump rated capacity, total dynamic head and other performance requirements shall be as per the requirement indicated in the pump data sheet.

- The pump shall be designed to have the best efficiency at the specified duty point. The pump set shall be suitable for continuous operation at any point within the range of operation wherever specified.

- The pump shall have a continuous rising head capacity characteristic from the specified duty point towards the shut-off point, the maximum being shut-off. The horse power characteristic shall preferably be non-over loading type beyond the rated capacity point.

- For diesel engine driven fire water pump, the rated horse power of the diesel engine shall be higher of the following two (2) values:

- 20% in excess of the maximum horsepower required to drive the pump set at its duty point.

- The BHP required driving the pump set at 150% of its rated discharge.

- The main pump casing shall be horizontally split casing type. End suction centrifugal pump and multi stage centrifugal jockey pump shall be end suction back pull out as specified in the data sheet enclosed.

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- The fire water system will be automated by other agency; hence provision should be kept in the local panel for remote start at full speed, potential free contacts and other contacts for feedback & actuation.

- The shaft sealing of Fire pump shall be Gland Packing type. The gland packing should be easily accessible for changing without having to disassemble the pump and suitable of gland packing material.

- Suction and discharge flanges shall be drilled in accordance with the NFPA 20 standard.

- Pumps shall be direct-coupled. Belt driven pumps will not be accepted.

- Others additional required information should be refer to Data sheet

- Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of non-corrosive metal as specified in the data sheet.

- The coupling between the prime mover and the pump shall allow each unit to be removed without disturbing the other.

- The material of construction for components other than those specified shall be as per standard of the pump manufacturer and shall be indicated separately

- The pump set shall be designed in such a way that there is no damage due to reverse flow through the pump which may occur due to any mal-operation in the system.

- Pump along with its drive shall run smooth without undue noise and vibration.

- The main pump casing shall be horizontally split casing type and the jockey pump shall be end suction back pull out as specified in the data sheet enclosed.

- Replaceable / renewable wearing rings shall be provided for both the casing and the impeller or for the casing only.

- The complete assembled unit shall be designed so that all covered parts including shafts and bearings shall be easily accessible for inspection, maintenance and replacement with minimum down time.

- The rotor assembly with impeller and shaft sleeve shall be dynamically balanced at 150% of operating speed.

- Pump casing shall be made of cast iron and tested at 150% of shut-off head or 200% of rated total head whichever is higher.

- Suction and discharge flanges shall be drilled in accordance with the standard NFPA 20.

- The gland packing should be easily accessible for changing without having to disassemble the pump.

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- A common base plate mounting both for the pump and drive shall be furnished. The base plate shall be of rigid construction, suitably ribbed and reinforced. Base plate and pump supports shall be so constructed and pumping unit so mounted as to minimize misalignment caused by mechanical forces such as normal piping strain, hydraulic thrust etc. Suitable drip taps and drip lip shall be provided.

- The following drawings shall be submitted for approval after placement of order.

Outline and general arrangement drawings incorporating all principal dimensions and also foundation design data for pump set.

Sectional drawing of each pump and diesel engine incorporating data on materials of construction.

Predicted performance curves for pumps.

Static and dynamic loads.

Engine Control Panel details including schematics.

- Other miscellaneous works for Fire Water Pump:

Initial visit of service representative and finalization of pump skid layout, fuel piping routing, fuel tank positioning, panel positioning, cable routing, power cable requirement for panel, exhaust pipe location etc. and other details and freezing of layout plan for pump, engine and accessories and reconciliation of materials received at site to identify missing items, if any. During final visit, supervision of commissioning work has to be carried out by the Contractor. The written intimation to the Contractor shall be given by PTM for commissioning visit and the Contractor shall ensure that their personnel are available at site within a week from the date of intimation.

The fuel pipe sizing and end connection should be advised in advance during Data Sheet Approval.

Cable from panel to batteries to be kept as 2 runs of 4 meter length (for working and standby battery set)

All consumables for engine for initial commissioning to be supplied by the Pump Vendor excluding first fill of Lube Oil, Fuel & coolant.

The battery shall be sealed maintenance free (SMF)

Vendor shall recommend cladding material for exhaust pipe and supervise the cladding operation during commissioning of the engines.

All other accessories between pump, engine, local panel and fuel tanks which are not mentioned specifically but required for successful commissioning of the system have to be supplied by the Pump Vendor.

Provision shall be available in the Local control panel for auto start based on the feedback from Pressure transmitter / pressure switch.

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8.2 Prime Mover

The prime mover of the pump shall be diesel engine and/or AC electric motor as indicated in the data sheet.

8.2.1. AC Electric

Refer to clause 8.4

8.2.2. Diesel Engine

a. General

Suitable diesel engine to drive the main fire water pump shall be supplied with all standard accessories. Diesel engine supplied shall be provided by removable enclosure. Suitable anti-vibration mounting (type, quantity and size) for diesel engine shall be required to ensure there will be no execessive vibration occured during operation of the fire water pump. While rating the diesel engine, the site conditions and climatic data of the place of installation shall be taken into account. The engine shall be capable of delivering the rated output continuously. The diesel engine shall be multi-cylinder type four-stroke cycle with mechanical (airless) injection, cold starting type. All parts susceptible to temperature changes shall have tolerance for expansion and contraction without resulting in leakage, misalignment of parts or injury to parts.

b. The Engine

Engine heater shall be provided. The Engine shall be:

Compression ignition mechanical direct injection type, capable of being started without the use of wicks, cartridges, heater plugs or ether, at an engine room temperature of 2°C and shall accept full load within 15 seconds from the receipt of the signal to start.

Naturally aspirated, supercharged or turbo-charged and either air or water-cooled. In the case of charge air cooling by means of a belt-driven non metallic fan or of a belt driven auxiliary water pump there shall be multiple belts such that should half the belts break, the remaining belts would be capable of driving the fan or pump. Driving belt shall be from anti static material.

The diesel engine as fire pump driver shall be started and brought up to rated speed without interruption within 20 seconds.

Provided with an adjustable governor to control the engine speed within 10% of its rated speed under any condition of load upto the full load rating. The governor shall be set to maintain rated pump speed at maximum pump load.

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Provided with an in-built tachometer to indicate the speed (rpm) of the engine. Any manual device fitted to the engine that could prevent the engine from starting shall return automatically to the normal position. Engines, after correction for altitude and ambient temperature, shall have bare engine horsepower rating equivalent to the higher of the following two values

20% in excess of the maximum brake horsepower required to drive the pump at its duty point.

The brake horsepower required to drive the pump at 150% of its rated discharge

c. Cooling System

A heat exchanger, the raw water being supplied from the fire pump discharge (taken off prior to the pump discharge valve) via a pressure reducing device, PSV, strainer and pressure gauge, to limit the applied pressure to a safe value as specified by the engine manufacturer. The material of heat exchanger shall be selected with consideration the properties of service fluids. The raw water outlet connection shall be so designed that the discharged water can be readily observed. The water in the closed circuit shall be circulated by means of an auxiliary pump driven from the engine and the capacity of the closed circuit shall not be less than that recommended by the engine manufacturer. If the auxiliary pump is belt driven then there shall be multiple belts so that if half of the belts break, the remaining belts shall be capable of driving the pump. A failure actuated audio-visual alarm shall also be incorporated. The engine cooling loop shall have pressure reducing valve / orifice & pressure solenoid valve and it should allow flow through cooling loop only in the event of start of engine. PTM may route the outlet of the cooling line back to suction header/ tank and therefore the system should work under back pressure of 1.5 kg/cm2.

d. Lubrication System

The lubrication system shall be self-contained with the following equipment:

Sump, to store sufficient oil for circulation, suitable sump shall be provided in the engine.

Pump, suitable pump shall be provided for forced lubrication.

Filter shall be dual filter and material shall be duplex.

Oil dipstick

Make up lube oil tank

Lubricating oil cooler

Interconnecting piping

e. Exhaust System

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The exhaust shall be fitted with a suitable silencer and the total backpressure shall not exceed the engine maker’s recommendation. When the exhaust system rises above the engine, means shall be provided to prevent any condensate flowing into the engine. All the hot parts located at the working level shall be insulated. The exhaust system has to be designed assuming stack height as per PCB norms. The exhaust system shall include:

Exhaust manifold.

Exhaust piping material shall be non corrosive material for high temperature above 300 oC.

Silencer: Sufficient length of straight pipe shall be provided after the exhaust silencer to leave the gases at sufficient height above the engine room and outside the room.

Expansion joint.

f. Engine Shut Down Mechanism

The fire water system will be automated default, hence the engine should be suitable for starting in a predefined sequence, the shutting down operation shall be manual operated and the engine should return automatically to the starting position after use.

g. Fuel System

Fuel: The engine fuel oil quality and grade shall be as specified by engine makers. These shall be kept on hand at all times.

Fuel tank: The tank shall be mounted above the engine fuel pump to give gravity feed unless otherwise recommended by the manufacturer. The tank shall be fitted with an indicator showing the level of the fuel in the tank. The capacity of the tank shall be sufficient to allow the engine to run on full load for 6 hours operation. Fuel tank sizing shall be as per NFPA 20 standard: 5.07 liter/kW plus 5% for expansion plus 5% for sump. There shall be one fuel tank per engine. The tank should also have level switch for low fuel level and tripping of pump / alarm. Each tank should be fitted with isolation valve. Fuel tank shall have venting, drain and filling connection.

Any valve in the fuel feed pipe between the fuel tank and the engine shall be placed adjacent to the tank and it shall be locked in the open position. Pipe joints shall not be soldered and plastic tubing shall not be used. The following shall be provided:

- Fuel pump shall be gear pump type, fuel injection and control system for compression ignition.

- Manual priming pump.

- A sludge and sediment trap.

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- A fuel level gauge and a level switch of approved make to signal fuel less than or equal to 30% of tank capacity.

- An inspection and cleaning hole.

- A duplex filter between the fuel tank and fuel pump mounted in an accessible position for cleaning.

- Means to enable the entire fuel system to be bled of air. Air relief cocks are not allowed; screwed plugs are permitted.

h. Starting Mechanism

Provision shall be made for two separate methods of engine starting.

Automatic starting by means of a battery powered electric starter motor incorporating the axial displacement type of pinion, having automatic repeat start facilities initiated by a fall in pressure in the water supply pipe to the sprinkler and/or hydrant installation. The battery capacity shall be adequate for ten consecutive starts without recharging with a cold engine under full compression and 15 seconds of cranking and 15 seconds of rest in six (6) consecutive cycles as per NFPA 20 standard.

Manual starting by electric starter motor (thru Push Button in Panel or Key in Local start station). The starter motor used for automatic starting may also be used for manual starting provided there are separate batteries for manual starting.

Battery shall be placed in battery rack for and shall be provided with battery isolation for protection any short circuit.

i. Governing System

The engine shall be provided with an adjustable governor capable of regulating engine speed within a range of 10% between shut-off and maximum load conditions of the pumps. The governor shall be set to maintain rated pump speed at maximum pump load.

j. Instruments

Instrument control and protection required for the safe operation of the engine shall be provided. Instrument panel on engine shall consist of (minimum):

Starter Switch

Lube Oil Temperature Gauge

Water temperature Gauge

Lube Oil Pressure Gauge

Ammeter

Tacho meter and

Hour meter

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k. Tools

A standard kit of tools shall be provided with the engine and kept on hand at all times.

l. Name Plate

A corrosion resistant nameplate shall be permanently attached to the pump and prime mover. The nameplate shall be stamped with the following information:

Manufacturer’s name

Serial number

Model number

Rated capacity

Rated head

Speed in rpm

Rating of the prime mover

m. Protection

Unpainted exterior like machined surfaces shall be coated with suitable rust preventive. All threaded openings shall be plugged and flanged openings shall be provided with full flange protective covers. The cover material shall be 4.5 mm thick metal plate bolted to the flange with a gasket in between using a minimum of four (4) bolts.

n. Packing

The pump set shall be packed, securely anchored and protected for domestic shipment. All unmounted components shall be suitably crated and firmly attached to the main pump unit for shipment. The purchase order number and equipment number shall be stenciled on the crate. One complete set of installation, operation and maintenance instruction shall be packed with the pumpset.

8.3 Base Plate

a. The pump, driver and electric motor shall be mounted on a rigid base plate suitable for full grout support.

b. Grouting holes of 4 inch in diameter with raised edges shall be provided.

c. A pan under the pump shall drain leakage to a 1 inch diameter flange connection at the pump end of the base plate, as well as a 1 inch drip rim around the skid.

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d. Jacking bolts shall be provided for all motors 45 kW and greater, to enable axial and transverse positioning. Stainless steel shims shall be provided for height adjustment.

e. Lifting lugs shall be provided on the base plate.

8.4 Electrics

8.4.1. Diesel Engine Control Panel

Each diesel engine driven firewater pump shall have an independent control panel.

a. The panel shall be of 230 V supply & shall give following Audio (A) Visual (V) alarm.

Engine Fails to Start : (A&V)

Low Lube Oil Pressure : (A&V)

High Lube Oil Temperature : (A&V)

High Water Temperature : (A&V)

Low Fuel Oil Level : (A&V)

Engine Over Speed : (A&V)

Engine Running Normal : (V)

Fuel Oil Level Normal : (V)

Power ‘ON’ (Battery Charged): (V)

b. In case if the diesel engine fails to start even after receipt of command from the pressure switch, the succeeding engine should start immediately bypassing its own pressure switch automatically.

c. In case the preceding engine does not start due to failure of pressure switch & subsequent engine started due to to drop in pressure & actuation of its own switch, the preceding engine should start AUTOMATICALLY.

d. Set of potential free contact points should be provided to connect the panel to REMOTE PANEL. The panel shall consist of:

Push buttons, Auto/manual selector switches, circuits with auxiliary contactors and interlocks form starting/stopping/ regulating of diesel engine pumps as per technological requirements mentioned elsewhere in the specification. Electronic timers shall be provided for achieving the logic of engine starting (for 3 trial starts) etc.

Provision of auto start of engine driven fire fighting pump sensed by pressure loss.

Facility to start engine manually by means of push button.

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Panel should be suitable for engine with manual fully shut off arrangement for stopping the engine.

Battery charger with provision of boost & trickle charging and SC & O/L protection. Two separate battery charger should be provided to keep both engine battery &stand by battery under float charge. The charge current should get adjusted automatically depending on the condition of the battery. The disconnection of any one of the batteries should not affect the system. One set of voltmeter & ammeter should be provided for each set of battery. Change over facility to be provided for changing over the engine starter motor from main battery to stand by battery without the need for reconnecting the cables. The system should withstand 600 Amps minimum continuous current & 5000 Amps for short duration.

Battery charger with provision of boost & trickle charging and SC & O/L protection.

Indication lamps and hour run meter.

Indications and PB viz. AC supply On, Start failure, Low lube Oil pressure, high water temperature, over speed trip, low fuel level, pump on demand, water heater ON, header pressure normal, hour run meter, engine running, start, stop and reset PB.

Switches like A/C supply On/Off, Water heater On/Off, Charger trickle/boost, Auto/Off/Manual mode, Hooter On/Off

Ammeter for Battery-1 & 2 charging and DC voltmeter

Provision of terminals for interlocking for start/stop of engine from header pressure switches

Requisite no. of NO/NC potential free contacts and wire up to terminal block for external interlocking of the jockey pump.

Two numbers additional (spare) auxiliary contactors (24 VDC 2 No. + ve relays) for Contractor use, fully wired up to terminal block.

e. The control panel shall be floor mounted type sheet steel (2 mm thick) enclosed, with hinged door completely wired with terminal block. The wiring shall be carried out with 2.5mm2 PVC insulated, copper wires. Earthing studs (2 Nos.) shall be provided at two ends of the panel.

f. Diesel engine pump shall has independent 24 VDC lead acid battery (SMF) with teak wood stand and accessories, rated for quick starting of diesel engine. All power and control cabling (supply) between diesel engine control panel and engine/battery charger/batteries (working and standby) is included in the scope. The Battery shall be 1+1 (1 working + 1 standby) with manual change-over facility.

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8.4.2. Motors

a. General.

Motors shall be of squirrel cage TEFC design induction motors conforming to project specification no CLP-PSP-030-001-A4 General Specification for Electrical System. The make/type of motor offered shall have track record of faultless service for a min. period of 3 years continuous service in similar installation. Documentary evidence in support of the same shall be furnished along with the offer. Motors shall be suitable for giving the rated output, without reduction in the expected life span when operated continuously under the following system conditions.

Motors shall be capable of starting and accelerating the load with any of the above mentioned methods of starting, (without exceeding the specified limits of temperature)

The locked rotor current of motors shall not exceed 600 % of the full load rated current.

Motor's vibrations shall be within limits as per applicable standards.

Motor's insulation shall be class 'F' with temperature rise limited to class 'B'. The motors shall be given tropical and fungicidal treatment for successful operation of motor in hot, humid and tropical environment.

b. Constructional Features

The stator frame and end shields shall be fabricated steel or cast iron of high quality conforming to project specification no CLP-PSP-030-006-A4, Specification for Induction Motor. They shall be ribbed externally to maximize heat dissipation. The feet shall be integrally cast with the stator frame, bolted feet construction is not acceptable.

The stator and rotor cores shall be of low loss, high permeability steel stampings duly varnished to reduce eddy current losses. The stampings shall be hydraulically pressed, keyed and clamped to ensure rigidity.

The motor shaft shall be of cylindrical design made of high carbon steel. The cross - section shall be chosen to provide high torsion strength and minimize deflection. The shaft shall be finely machined to ensure fit and eccentricity shall be minimized. Unless specified otherwise, the motor shall be with single shaft extension with slotted keyway. Motor shall be provided with half key.

The motor shall be cooled by means of an external fan mounted on the rotor shaft. The fan shall be protected by a cowl which shall be bolted to the stator frame. The fan shall be of cast iron preferably.

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The body of the fan shall be provided with 2 numbers, diametrically opposite drilled holes to enable removal of fan without breakage. The fan shall be designed to ensure low noise and adequate ventilation. The fan should be suitable for bi-directional rotation.

The motor shall be provided with ball/roller bearings with grease lubrication. Greasing nipples and arrangement for drainage of excess/old grease shall be provided as a standard feature. Seals shall be provided to ensure that excess grease does not reach the windings. Bearings shall be suitable for bi-directional rotation.

The terminal box for motor shall be of sheet steel /cast-iron and shall be mounted on R.H.S when viewed from DE side. The terminal box shall be suitable for rotation in steps of 90º. The design of terminal box shall be spacious to suit termination of armore daluminum conductor cable. Six (6) ends of windings shall be brought to the terminal box and shorting links shall be provided.

The terminal box shall be provided with gland plate. If required, cable spreader box/trifurcating box shall be provided additionally to facilitate termination of large size cables. Double compression brass cable glands shall be provided along with the motor.

One no internal earthing terminal shall also be provided in the terminal box as a standard feature

The terminal box shall also feature a cover plate. The cover plate shall be bolted to the terminal box with Allen bolts.

Where space heaters / thermistors are specified, separate TBs for each shall be provided for these accessories.

Phase terminals shall be stud type of FRP material. Terminals for space heaters shall be stud type; terminals for thermistor / RTDs may be clip-on type suitable for 2.5 sq.mm conductor.

The rotor shall be dynamically balanced with half key. Other shaft mounted components viz fan, coupling half etc., shall be balanced separately. Balancing shall be carried out at rated rspeed of the motor. The balancing weights shall be firmly secured to the rotor. The balance quality grade shall conform to project specification CLP-PSP-030-001-A4, General Specification for Electrical System

The motor shall be provided with lifting lugs/eye bolts to facilitate erection/ maintenance requirements.

All nuts, bolts, studs shall be based on metric units.

The motor shall be provided with a stainless steel rating plate with punched markings.

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The painting of motor shall be epoxy-powder-coated type. Final paint shade shall be as indicated in ordering data sheet.

The overhang of the stator windings shall be given an additional coat of epoxy gel to minimize the effect of end turn forces at switch-on. The Contractor shall furnish the details of bracing method employed.

Stator slot wedges shall be of non-magnetic material.

Rotor shall be of rigid cage design. Rotor bars shall be of high conductivity ETP copper and shall be firmly wedged in the rotor slots. The portion of rotor bars in the rotor slot shall be un-insulated. The rotor bars shall be brazed to the end short-circuiting rings, which shall be of annealed high conductivity copper. If retaining rings are provided in Contractor’s design, same shall be forged non-magnetic material.

Motor rated 30 kW and above shall be provided with single phase anti-condensation heaters as a standard feature. The heaters shall be placed in the lower part of the motor and shall be accessible for easy replacement/maintenance.

The main terminal box of the motor shall be rated for 40 kA/ 0.25 sec at 415V.

The motor frame shall be provided with two diagonally opposite tapped holes for earthing along with required hardware viz. bolts/screws, plain and spring washers. The hardware shall be electro-galvanised type.

c. Performance Requirement

Motor shall be able to start and accelerate under rated load at 80% of rated voltage, without exceeding the specified temperature.

If while running, the voltage drops to 70% the motor shall be capable of delivering rated torque and continue to run without stalling for 3 minutes.

The motor shall be capable of withstanding 150% of rated voltage for 2 minutes without damage.

The motor shall be designed to provide the required starting torque where speed-torque characteristics of load are included in the specification. Where the specification does not contain the load characteristics, motor shall be designed to provide minimum 160% starting torque. The pull-out torque of the motor shall not be less than 250% at rated voltage and frequency.

d. Test Requirement

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All tests shall be carried out at the manufacturing works. Test methods shall be in accordance to project specification no CLP-PSP-030-001-A4, General Specification for Electrical System

The Contractor shall furnish type Test Certificates along with the bid.

Test for vibration severity.

Test for noise level

Temperature rise test at limiting values of voltage and frequency variation as given in this specification.

Over speed test.

e. Documentation Requirement

GA drawings of motor, main terminal box, space heater thermistor RTD.

Wiring diagram for space heater TB, thermistor/RTD.

Motor data sheet duly filled up.

Type test certificates

Quality Assurance Plan for PTM’s inspection.

Motor characteristics curves.

8.5 Fire Pump Controller

a. The main fire pump controller shall be a factory assembled, wired and tested unit and shall conform to all the requirements of the latest edition of NFPA 20, Standard for the Installation of Stationary Pumps for Fire Protection and NFPA 70, National Electrical Code.

b. The controller shall be listed by Underwriters Laboratories, Inc., in accordance with UL218, Standard for Fire Pump Controllers, approved by Factory Mutual for fire pump service.

c. Starting Method The controller shall be of the combined manual and automatic type.

d. The controller enclosure shall be NEMA type 2 (IP31) and suitable for wall mounting. Wall mounting lugs shall be provided. The enclosure shall incorporate a bottom entry gland plate for power and or engine connection entrance. The gland plate shall be field removable and meet the same NEMA rating of the enclosure. Lifting lugs shall be provided.

e. The diesel engine driven fire pump controller shall be supplied with a ‘Hand’-‘OFF’-‘Auto’ selector switch installed behind a lockable breakable cover.

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f. The controller shall include a motor rated combination isolating disconnect switch/circuit breaker, mechanically interlocked and operated with a single, externally mounted handle. The isolating disconnect switch/circuit breaker shall be mechanically interlocked so that the enclosure door cannot be opened with the handle in the ON position except by a hidden tool operated defeater mechanism.

g. The fire pump controller operator interface shall be capable of displaying true RMS digital motor voltage and current measurements for all three phases simultaneously.

h. Diesel Engine and Electrical Motor Fire Pump Controller screen operator interface shall visually indicate the following alarms and differentiate the criticalness:

Engine run

Main switch in Hand, Off or Auto  

AC present / failure

Battery #1 and battery #2 failure

Battery charger #1 and battery charger #2 failure

Low oil pressure

High engine temperature

Over-speed Fail to start

Fail when running

Periodic test

System overpressure  

Water reservoir low

Low system (discharge) pressure

Periodic test cut-in not reached  

Run test solenoid valve check  

Faulty pressure transducer  

Pump on demand

Over pressure and Under pressure  

Low pump room temperature

Low fuel level

Power Available

Alarm

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System Pressure Low

Remote Start

Transfer Switch Normal

Transfer Switch Emergency

Phase Failure

Phase Reversal

Interlock On

Fail To Start

Motor Overload Emerg. Iso. Switch Off

Automatic Shutdown Disabled

Overvoltage and Undervoltage

i. The controller shall feature a RS485 serial communications port for use with 2 or 4 wire Modbus RTU communications.

j. The controller shall not start the fire pump motor under a single-phase condition.

k. A 4” alarm bell rated for 85dB at 10ft (3m) shall sound during boot up and internal communication error.

9.0 LPG FILLING PUMP DESIGN REQUIREMENTS

9.1 General

a. All centrifugal pumps shall be met with the PTM standard design amended in accordance with the additional requirements called for by this specification.

b. LPG Filling pumps shall be design, manufactured, tested and installed as per API 610 latest edition. The pumps shall be design for minimum 20 years of service life and at least 3 years of uninterrupted operation.

c. Preference will be given to pumps running close to the best efficiency point at the design conditions.

d. Pumps shall be designed to minimize wear of components in contact with the fluid and to resist the chemical environment described on the data sheets.

e. All pumps shall be self-venting without the need for external bleed valves.

f. The pumps shall not be selected to operate at the fastest speed of the pump impeller range, not shall the smallest or largest impeller diameters be used.

g. All bolts & nuts, shafts, screw on rotating parts shall be correctly tightened and locked in position with the appropriate tools and parts or product.

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h. All pump casings and their components shall be furnished with corrosion resistant bolts, nuts and washers.

i. Pumps shall be suitable for uncovered outdoors installation under the specified ambient conditions.

j. Materials shall conform to appropriate standards for chemical analysis and mechanical properties.

k. All exposed moving parts shall be fitted with appropriately painted guards to prevent contact, by accident or intent, of personnel with the moving parts. The seal space shall be covered to prevent accidental splashing of harmful fluids in the event of seal failure.

l. All safety guards shall be fully removable during maintenance activities.

m.Electrical components and installation shall be suitable for the area classification and grouping specified in the Data Sheets.

n. All pumps shall be have a stabile curve (the head and capacity curve) with continue increment until the pump is shut off.

o. Pressure design of casing shall be design for at least 10% bigger than maximum discharge pressure.

p. Alarm and shutdown of pumps are happen in case of condition:

- The inlet pressure is too low.- Excessive motor power (overload)

9.2 Design

a. The impeller diameter selected to meet the specified duty point shall be no more than 90% of the maximum impeller size of the pump. Where this requirement is deemed impractical, full details shall be provided in the proposal and PTM approval obtained prior to award purchase order.

b. The pump shaft shall be machined all over with fine finish ground surfaces and large radius fillets. Shaft deflection shall not exceed the more stringent of either 0.05 mm at the shaft seal or the seal manufacturer’s requirement. Locking of impeller to shaft shall tighten with normal pump rotation.

c. A renewable shaft sleeve shall be provided. The sleeve shall be positively fastened to the shaft with expansion provision to cater for any temperature variations.

d. Ball or roller type anti-friction bearings shall be provided. These shall have a L10 service life of not less than 50,000 hours.

e. Bearings shall be sealed against entry of foreign matter or moisture, but with provision for lubrication. Rolling element bearings shall not have plastic

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cages. Bearing temperatures shall not exceed the bearing manufacturer’s requirements.

f. The end-suction nozzle shall be on the pump centre line. The discharge nozzle shall be designed to be self venting.

g. Flanged connections rated for the operating conditions and conforming to ASME B16.5 shall be provided for all process connections. Otherwise, an adaptor piece or mating flange shall be provided to suit the connecting piping.

h. Internal and external threads shall conform to ASME B2.1 tapered threads. Drain and vent connections shall be at least 15 mm (1/2 inch) nominal size.

i. API Pumps shall be capable of operating continuously up to 150% of rated speed.

9.3 Mechanical Shaft Seal

a. The selection of the seal shall be compatible with the rigidity of the assembly, the flexibility of the shaft and the temperature, pressure and composition of duty fluid.

b. Unless otherwise specified, all standard mechanical seals shall be a cartridge design. The seal cartridge shall be removable without disturbing the driver.

c. When the barrier fluid requires cooling, an air cooled finned tube cooler is to be used.

d. The standard un-pressurized dual mechanical seal shall be a balanced seal.

e. Mechanical seal sleeves shall meet the following criteria:

Be of wear, corrosion and erosion resistant material.

Be sealed at one end.

Extend beyond the outer face of the seal gland.

The shaft sleeve shall have at least two “O” rings to seal against the shaft to prevent dust ingress and fluid escape.

The seal shall be fitted with a pumping ring to assist in circulating the barrier fluid

f. Unless otherwise specified, seal chambers and seal glands shall be designed for the same pressure and temperature as the pump casing and shall have sufficient rigidity to avoid distortion that may occur during tightening of the bolts to set gasket.

g. Seal Chambers and Seal Glands shall be designed for same pressure and temperature as the casing.

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h. Where applicable, a shoulder at least 0.125 inch wide shall be provided in the seal gland to prevent the stationary element of the mechanical seal from dislodging as a result of chamber pressure.

i. Specified seal and pump connections shall be identified by symbols permanently marked into the components (such as stamped, cast, or chemically etched) and shown on the seal drawing.

j. Mechanical seals and glands for all pumps shall be installed in the pump before shipment and shall be clean and ready for initial service. On pumps whose seals require final adjustment or installation in the field, the Vendor shall attach a tag warning of this requirement.

k. The seal gland plates shall have a throttle bushing (0.125 inch thickness) to restrict the flow to atmosphere in the event of seal failure. The throttle bushing shall be of non-sparking material, and shall be shouldered to prevent blowout. Seal glands plates shall be provided with quench and drain connections (1/2 inch diameter NPT minimum).

l. Special tools and accessories required for mechanical seal servicing shall be supplied by the Vendor.

m.The Vendor shall nominate a seal liquid system and the PTM shall confirm the system suitability for the given application.

n. Seal fluid inlet and outlet connections shall be located in the seal cartridge housing, with the outlet connection above the upper seal face for proper venting of seal cavity air.

o. Unless otherwise noted, “O” rings shall be used to seal the shaft sleeve to the shaft. The “O” rings shall be located so as to minimize the effects of heat from the duty fluid.

9.4 Vibration

All pumps shall be designed not to produce excessive vibrations that would be harmful to the equipment as a whole and surrounding and supporting, as a result of hydrodynamic forces, both:

a. In operation, during opening and closing of flow and for all flow rates up to and including maximum flow, and

b. When stationary including partial opening position.

c. Vibration limits for overhung and between-bearings API 610 pumps are specified as :

Measured Overall velocity < 3,0 mm/sec Root Mean Square (RMS)

Discrete frequently velocity (measured with Fast Fourier Transform) < 2.0 mm/sec RMS.

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9.5 Base Plate

a. The pump, driver and electric motor shall be mounted on a rigid base plate suitable for full grout support.

b. Grouting holes of 4 inch in diameter with raised edges shall be provided.

c. A pan under the pump shall drain leakage to a 1 inch diameter flange connection at the pump end of the base plate, as well as a 1 inch drip rim around the skid.

d. Jacking bolts shall be provided for all motors 45 kW and greater, to enable axial and transverse positioning. Stainless steel shims shall be provided for height adjustment.

e. Lifting lugs shall be provided on the base plate.

9.6 Lubrication

a. Pump bearings shall preferably be lubricated by a rotary flinger picking up oil from below bearing level. A sight glass and fill cap shall be provided. Oil lubricated components shall be sealed to prevent both leakage of oil and entry of fumes and dust. Lip seals are not preferred and the option of rotating labyrinth or magnetic seals shall be provided. Where a breather is fitted, it shall be designed to prevent spray water ingress.

b. The Vendor shall lubricate all components requiring lubrication prior to testing and delivery.

9.7 Electric Motor & Drive

a. All motors and their auxiliaries for LPG Filling Pumps shall be suitable for use in either a zone 1 Hazardous area, group D, Temperatures class T3 as per Hazardous Area Layout, CLP-DWG-030-002-A3.

b. Electric motor for LPG Filling pumps shall be Explosion Proof Motor type and ingress protection shall be IP 55.

c. Zone 1 Low voltage motors shall be either EEx “d” or EEx“ e”.

d. Zone 2 Low voltage motors shall be either EEx “ e”, EEx “nA” to IEC 60079-15, or Ex”N” to BS5000 (part 16 of the publication).

e. Low voltage motors shall be the same types as for zone 2, for standardization purpose.

f. Type of construction, dimensions shall be in accordance with IEC60072. Preference is given to motors with one end shaft (B3 and V1 type). If not, they shall be provided with a permanent and dismountable guard on the non-driving end.

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g. Enclosure, motor shall be of the totally enclosed fan cooled (TEFC) type and the enclosure shall be cast iron up to frame 315 or welded steel corrosion resistant.

h. All motors over than 20 kgs, shall have adequate lifting and hoisting provisions.

i. Drivers shall be foot mounted, refer to PTM’s specification CLP-PSP-030-006-A4, Specification for Induction Motor

j. The Vendor shall supply a flexible coupling, selected to suit the power output of the motor and able to transmit the design starting torque with a service factor of 1.2, in accordance with the coupling manufacturer’s recommendations.

k. Couplings shall be manufactured from materials such that the coupling is classified as non-sparking.

l. Drivers shall have a continuous rating at least equal to the most stringent of:

The highest power requirement along the pump characteristic curve containing the specified operating conditions.

9.8 Performance

a. Selection of pumps shall be in accordance with the specified LPG Filling Pump Data Sheets. All flow and pressure conditions influencing reliability shall be nominated by the Vendor in the proposal submission. This shall include the conditions to avoid suction recirculation and cavitation, the minimum flow conditions and any specific installation requirements (e.g. piping and valve).

b. Standard NPSHReq data provided by the Vendor shall be presumed to be for 3% head drop and this shall be at least 1.0 m less than the available NPSH at the maximum specified flow at the highest specified temperature.

c. Balancing of pump rotating parts shall be in accordance with grade G2.5 of ISO 1940. Vibration of the bearing housing at design conditions shall not exceed 2.8 mm/s RMS at 1800 rpm and 4.5 mm/s RMS at 3600 rpm.

d. The pump and drive components shall be selected so that the pump cannot be run at a speed more than 80% of the first critical speed of the pump rotating assembly.

e. To improve reliability, the value of L3 / D4 shall not exceed 2 mm-1, where L is the length from the bearing centre to the impeller centreline, and D is the solid shaft diameter (under sleeve) at the seal.

9.9 Noise

a. Noise limitations shall comply with requirements of IEC 60034-9.

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b. Combined pump and driver noise at all operating conditions shall not exceed a sound pressure level of 85 dB(A) at 1 meter periphery from the surface of the equipment.

c. When equipment has a noise level expectation above this, attenuation devices including shields or enclosures shall be offered as an option. Low noise fans shall be fitted to motors if the standard fans do not meet the noise specification.

d. An acoustic enclosure, where required, shall be suitable for outdoor installation in the specified environmental condition.

e. The Vendor shall provide all additional ancillary equipment necessary to ensure the efficient operation of the pump within the enclosure under the specified environmental conditions. These may include ventilation fan, temperature gauges and instrumentation as recommended by the Vendor.

f. The enclosure shall incorporate a sufficient number of hinged or readily removable access panels to provide convenient access for inspection and maintenance.

g. The enclosure shall also be designed so that it can be readily removed. Lifting lugs shall be provided for this purpose.

h. All grease lubrication points shall be extended to externally mounted grease nipples and all pressure and temperature gauges shall be mounted external to the enclosure.

9.10 Material

The materials shall be new, free from defects and in accordance with the following:

a. Pump casing, impeller, wear ring, and mechanical seal parts shall be in accordance with LPG Filling Pump Data Sheet, CLP-DSH-020-005-A4

b. Seal flush lines shall be 316 stainless steel tubing and tubing fittings.

c. Pump/motor skid shall be in accordance with CLP-PSP-030-006-A4, Specification for Induction Motor.

d. All wetted pump parts must be inert to the process fluids. No corrosion / erosion products are permitted to enter the product stream. Materials offered by the Vendor to perform the stated duty shall be clearly defined in the proposal.

e. Pump materials must have a proven history in process duties similar to those specified in the Data Sheet.

f. Viton elastomers shall not be used. AFLAS is considered an acceptable alternative.

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g. Asbestos materials shall not be used.

h. Exposed aluminium and copper - alloyed materials shall not be used.

i. Galling material combinations shall not be used.

j. Cast iron pump casings are not permitted for applications involving flammable or combustible fluids.

10.0 SPARE PARTS FOR THE PUMP ORDERED

The following minimum spares required shall be offered:

a. For Commissioning and Start-up: one (1) set of gaskets/packing ring/O ring

b. For two years operation:

- One (1) set mechanical seal, if applicable

- Other parts such as coupling bushing, shaft keys, coupling, etc.

11.0 SPARE PARTS FOR ENGINE ORDERED

The following spare parts shall be offered for each of the diesel engines.

a. Two (2) sets of fuel filters, elements and seals,

b. Two (2) sets of lubricating oil filters, elements and seals,

c. Two (2) sets of belts (where used)

d. One (1) complete set of engine-joints, gaskets and hoses,

e. One (1) No. of Inlet and Exhaust Valve each

f. One (1) set of piston ring and 2 Nos injector nozzle

g. One (1) solenoid valve

12.0 INSPECTION AND TESTING

12.1 Fire Pump

a. The equipment shall be inspected by the Contractor at manufacturer’s works prior to dispatch. The equipment will be inspected as per the tests pre-identified in the approved Quality Assurance Plan (QAP), relevant approved drawings, specifications, data sheet etc.

b. The Contractor shall finalize the QAP within two weeks after placement of order with the PTM.

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c. PTM shall have free access to the manufacturer’s works to carry out any stage inspection to ensure the quality of the equipment being manufactured.

d. The inspection call shall be accompanied by internal inspection/test reports by the manufacturer ensuring that the equipment has been manufactured and tested as per the requirement/approved QAP. In case of any subcontracting, only the main Contractor shall give inspection call enclosing internal inspection report by the main Contractor.

e. The manufacturer shall furnish all relevant documents and test certificates as required by the inspection agency during inspection. Materials shall be tested only in recognized test houses.

12.2 LPG Filling Pump

a. Hydrostatic Test

Each pump casing shall be hydrostatically tested with water to a minimum of 1.5 times the design pressure. Hydrostatic tests shall be considered satisfactory when no material or joint see page or leaks are observed for a minimum of 30 minutes.

Any leak age shall be cause for rejection. Repairs shall be subject to prior approval by the PTM and shall be carried out in accordance with agreed procedures. Repairs shall be subject to approval by the PTM's inspector before a second or subsequent hydrostatic test is commenced.

b. Performance Test

The pump Vendor or Manufacturer shall operate the pump in the shop for a period sufficient to produce at least six (6) points of complete test data, including head, capacity, and power. These (6) six data points are subject to negotiation between the PTM and the Vendor but will normally be shut off, minimum continuous stable flow, midway between minimum and rated flows, rated flow, 110% of rated flow and 125% of rated flow. The test speed shall be within 3 percent of the rated speed shown on the certified outline drawing. Test results shall be converted to the rated speed.

The pump may be shortened to suit the Supplier's test facility. Appropriate corrections shall be made in the head produced due to the reduced length and friction losses.

When operated at rated speed and rated capacity, pumps shall be in accordance with the guaranteed characteristics within the tolerances defined below.

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If it is necessary to dismantle any pump after the shop test for the sole purpose of machining impellers to meet the tolerances on differential head, no retest shall be required unless the reduction in diameter exceeds 5% of the original diameter. The diameter of the impeller at the shop test, together with the final diameter of the impeller, shall be recorded on a certified shop test curve sheet showing the operating characteristics on test and the calculated characteristic after the diameter of the impeller has been reduced.

If it is necessary to dismantle the pump because of some other correction, such as improvement of efficiency, NPSH, or mechanical operation, a further performance test shall be run after corrections are made.

Following the performance test each pump and motor unit shall be run continuously for four hours under full load conditions.

c. NPSH Test

This test is optional and is only required if specified in the requisition.

Testing by vacuum tank suppression test is preferred; however an arrangement where the pump is installed above a suction pit in which the level can be lowered is also acceptable. The Manufacturer shall state the method of NPSH testing (if specified) in the proposal.

Data shall be taken at the same points as the performance test. The NPSH test shall be subject to the approval of the Principal.

A drop in head of 3% at the first-stage shall be interpreted as an indication of performance impairment. Where identical impellers are installed the total head rise shall be divided by the number of stages to approximate the first-stage head rise. Where a different impeller is used for the First stage, the head rise of the first stage shall be similarly estimated from the total head rise by proportioning the theoretical relative impeller head rises for each stage accordingly.

d. Motor Test

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Conventional motors shall be tested in accordance with project specification No. CLP-PSP-030-006-A4, Specification for Induction Motor. The final procedure and test parameters shall be agreed by the PTM.

13.0 PERFORMANCE GUARANTEE

The Contractor shall indicate guaranteed performance parameters for the pump, such as rate of flow, delivery pressure, efficiency, specific power consumption etc. The Contractor shall also indicate guaranteed performance parameters for the diesel engine such as BHP, specific fuel consumption etc. as per NFPA 20 standard for fire pump and API 610 standard for LPG Filling Pump.

14.0 NAME PLATE

A nameplate of 18Cr-8Ni stainless steel or Monel type material shall be furnished, securely attached by stainless steel pins to the discharge head. The nameplate shall be stamped with the following information in the English language.

In addition to being stamped on the nameplate, the pump serial number shall be plainly stamped on the bowl assembly. For LPG Filling pumps, a plate of 18Cr-8Ni stainless steel or Monel type material, showing the direction of rotation, shall be furnished, secure to the motor by stainless steel pins.

a. Pump.

Manufacturer

Equipment Tag Number

Model and Type

Serial Number

Date of Manufacture

Purchase Order Number

Rated capacity, horsepower, pressure, temperature

Total package weight

b. Motor

See CLP-PSP-030-006-A4 Specification for Induction Motor, for motor tagging requirements.

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15.0 PREPARATION FOR SHIPMENT

Equipment preservation and protection shall be suitable for a minimum period of 12 months outdoors or as otherwise as stated on the data sheet.

The Manufacturer/Vendor shall produce a detailed preservation and protection procedurefor each item of equipment or packaged unit for PTM's approval