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ANNEXURE – A

Technical Specification for Stainless Steel Chemical Process Pumps

Design, Procurement of requisite materials, manufacture, assembly, inspection, shop testing, packing, supply, arranging transport and delivery to FRZ stores, BARC, Trombay and guarantee of Centrifugal type Chemical Process pumps complete in stainless steel construction with all accessories and auxiliaries including Prime mover for each unit ready to use of pump details as below.

1. Detail scope of supply: Centrifugal, single stage, horizontal, one piece self venting volute casing in rugged construction, back pull out design, end suction and top discharge complete in stainless steel construction unless and otherwise specified and each pump shall have following installed/assembled accessories:

1.1 In standard construction i.e., All Stainless steel construction including base plate and distance piece/adaptor and foundation bolts etc.

1.2 Each pump shall be supplied with 3-phase, T.E.F.C, squirrel cage induction motor for continuous duty, conforming to IS: 325 with class ‘F’ insulation temperature rise limited to Class ‘B’, IP-55 enclosure and protection, suitable for DOL starting with power supply of 415 volts ±10% and frequency 50 Hz ± 5%. Make of motor shall be Siemens/Kirloskar/ABB.

1.3 Each pump complete in all respect shall be supplied in fully assembled and coupled condition with motor on common base plate/bed plate. Coupling and coupling guard shall be provided. Pump shall be supplied with mechanical seal installed in pump on shaft/shaft sleeve and impeller on shaft.

1.4 Each pump shall be supplied with stainless steel AISI 304L slip on type companion flanges and stainless steel nuts and bolts AISI 304/316 on suction and discharge along with 3mm thk. PTFE gaskets.

1.5 Each pump shall be supplied with foundation bolts S.S. 304/316. 1.6 If any item is not mentioned but required for ready use of the pump shall be supplied with the pump. 2. Terminating point schedule:

2.1 Pump suction and discharge flanges with Stainless steel AISI 304L counter flanges and nuts and bolts in Stainless steel AISI 304 construction respectively along with 3mm thk. PTFE gaskets.

2.2 Terminal boxes shall be suitable to terminating Al-conductor cables of appropriate size. 3. Standards and applicable codes:

The design, manufacture, inspection, assembly and testing of the equipment’s covered by the specification shall unless specifically stated otherwise conform to the latest editions of all standards and codes (along with addend mentioned below. In case of conflict between two different classes of specifications the requirements of the more stringent the two shall govern.

3.1 ISO 2858 : specification for Back pull out pumps. 3.2 ANSI B73.1 : Specification for process pumps 3.3 IS 5120 : Technical requirements for pumps. 3.4 A.S.M.E. : boiler and pressure vessel codes Section VIII Div-1

3.5 A.N.S.I. B16.5 : codes for steel flanges and flanged fittings. 3.6 A.S.T.M./ IS : standards for various tests and materials.

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3.7 IS 325 : three phase induction motors. 3.8 IS 4029 :guide for testing three phase induction motors. 3.9 ISO 2372 : Vibration level for rotating equipment

4. OPERATING CONDITIONS 4.1 Site Condition

a) Elevation at ground level: 10 MSL b) Wet bulb temperature: 28.40C c) Dry bulb temperature: 350C

4.2 Power Supply 0 a) 415 Volts ± 10%, 3-Phase, A.C. supply

b) 50Hz ± 5% 4.3 Performance:

The centrifugal pumps as per subject tender are required for pumping process solutions of acidic nature ( upto 55 to 60 % (by weight) HNO3), All the centrifugal pump sets shall be designed to operate continuously at designed efficiency under following conditions consistent with good operating characteristics and shall have continuously rising head characteristics from the design point to shut-off. This point shall be clearly mentioned in the quotation.

5. REQUIREMENT:

Sr. No. Flow rate, M3/Hr Head, MLC Required Quantity

1. 1.2 20 15 nos.

Note1: pump shall be continuously operated with variable head and therefore motor selection shall be based on high flow rate when operating with lower head. For pump Sr.No.1 (1.2 M3/Hr and 20 MLC) shall also operated continuously at differential head of 8 MWC with high flow rate and hence motor selection shall be corresponding to 8 MLC of the model offer for pump Sr.No.1 with 25 % additional safety margin Corresponding to head 8 MLC and high flow while handling the concentrated acid as per details given in Technical fluid data TECHNICAL FLUID DATA:

1. Fluid handled : Clear Concentrated Nitric acid solution 2. Molarity : Upto 14 M 3. Density : Upto 1.45 g/cc 4. Viscosity: Upto 3 CP 5. Temperature: 500C 6. Suction Condition : Flooded 7. Service : Continuous

5.1 GENERAL DESIGN REQUIREMENTS:

5.1.1 The pump shall be designed to permit maximum interchangeability of parts for shaft assembly including bearings, sleeves and mechanical seal components. Casing and impeller shall be made by investment casting method.

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5.1.2 All pumps shall be robust in construction. The pumps shall run free from undue vibration; vibration velocity shall not exceed as per the standard.

5.1.3 The pumps shall be fitted with renewable wearing parts such as wearing ring, if required and shaft sleeve etc.

5.1.4 All pressure containing components including the pump casing, nozzles and mechanical seal housing shall be designed, fabricated and tested as per ASME Boiler and Pressure vessel code section VIII Div.1. The casing design pressure shall not be less than suction pressure plus shut off pressure of the pump.

5.1.5 The pump casing should be integral & shall not be provided with any venting and draining provisions.

5.1.6 Jacking bolts of suitable size for dismantling the pump shall be provided if required. 5.1.7 The motor selected shall be to suit the pump’s operation requirement. The motor

selected KW rating shall be such that it should able to operate the pump continuously at differential pressure of 8 MLC for pump of 20 MLC X 1.2 M3/hr for said liquid.

5.1.8 Each pump shall be designed to operate continuously at designed efficiency with the specified liquid under specified conditions. The pump shall be non-overloading type with continuous rising head characteristic from design point to shut off. The preferable operating speed for 20 M head pump shall be 2900 RPM.

5.1.9 NPSH: The NPSHR of the pump shall not be more than 1.2 Metres of Liquid column for head at 20 Metre.

5.1.10 The first critical speed of the rotating assembly shall be at least 30% above the operating speed. The run away speed shall be less than the first critical speed.

5.1.11 Pumps that handle liquids more viscous and specific gravity than water shall have their water performance corrected in accordance with the Centrifugal pump section of the Hydraulic Institute Standards.

5.1.13 IMPELLER

5.1.13.1 The impeller shall be closed/semi closed/open, backward curved and floating/hydraulically balanced with provision of back vanes and holes to relieve pressure on stuffing box if required.

5.1.13.2 The impeller shall be dynamically balanced as per ISO 1940 grade 2.5 and to good engineering practice. The impeller selected shall have high efficiency and low NPSH requirement.

5.1.13.3 The impeller shall be keyed to the shaft and proper lock nut provision or threaded to shaft shall be made to prevent loosening of impeller in case of reverse rotation etc.

5.1.13.4 The impeller shall be investment casted. 5.1.13.5 All internal surface of casing and impeller surface shall be smooth and free from any

surface flaws and irregularities. 5.1.13.6 The shaft shall be preferably be machined from bar forging and ground finished. It should be adequately sized so that maximum deflection of shaft at stuffing box face

under worst condition of loading shall not exceed 0.05mm. The surface finish in critical areas of stuffing box shall be as per std industrial practice and code.

5.1.13.7 The shaft sleeves and wearing ring shall be replaceable with suitable surface hardness. The shaft sleeves shall be positively driven, Clamped and scaled at impeller ends but free to expand at other end if required. The surface finish shall be as per std industry practice and applicable code.

5.1.13.8 All bearings used for pumps and motors shall be precision and reputed makes like SKF/FAG and shall be subject to purchaser’s approval. The make should be indicated while quoting. The bearings should be selected in such way that shaft

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endplay should be less than 0.025mm for maximum seal load. Bearings should be sized for trouble free operation for minimum 2 years and B10 average life.

5.1.13.9 The bearings shall be oil lubricated. The bearing housing shall house oil seals and shall be easily replaceable. The in board bearing housing shall have a S.S. deflector mounted on shaft to protect the seals and bearing housing.

5.1.13.10 The bearing housing shall have a breather, oil level indicator and drain plug. 5.1.13.11 The base plate should be rigid and with provision of drain lips and necessary

draining connections. The base plate shall be Cast stainless steel construction or shall be fabricated type with fine finish.

5.1.13.12 The pumps shall have provision of S.S. drip plate just below stuffing box gland to contain the drips to avoid splashing and guiding it downwards.

5.1.13.14 The pumps suction and discharge nozzles shall be with flanges with provision of stainless steel companion flanges and stainless steel bolts unless and otherwise specified. The flanges shall conform to and drilled as per ANSI 150 lbs class. The companion flanges shall accompany with 3mm thick PTFE gaskets.

5.1.13.15 The stuffing box shall be extra deep and with ground inside surface finish for minimum leakage and ease of maintenance.

5.1.14 MECHANICAL SEALS (Minimum Requirement):

Each pump will be fitted with mechanical seal of flowserve sanmar seal/leakproof/Eagle burgman seal with minimum following requirements.

5.1.14.1 The mechanical seals shall be single, internal, unbalanced, dry running capability and shall be design for with safety margin at shutoff pressure.

5.1.14.2 The mating surfaces shall be Solid Silicone carbide Vs Solid Silicone carbide. The surface shall be hard with surface flatness equal to or better than 3 light band.

5.1.14.3 The secondary seals and gasket of mechanical seal shall be Teflon (PTFE). 5.1.14.4 Mechanical seal gland plate/ring (SS316) if any, springs(Hastelloy C276) and other

metal parts in SS316/SS304/Hastelloy and shall be compatible with the process liquid being handled.

5.1.15 ADAPTOR PIECE 5.1.15.1 The adapter piece/distance piece if any between pump and bearing bracket shall be

of cast stainless steel construction. 5.1.15.2 The adapter piece shall have stainless steel drip pan at the bottom to collect drips.

The drip pan shall have provision of outlet connection. 5.1.15.3 The support plate provided for bearing bracket that is resting on bedplate shall be of

stainless steel and shall be in rigid construction. 5.1.15.4 Impeller seals, stuffing box cover gasket and other soft gasket of sealing material on

pump shall be of Teflon only. 5.1.16 COUPLING:

The pump shall be directly coupled with the electric motor through suitable flexible spacer type coupling of fenner / lovejoy to take care of usual shaft misalignment, shaft expansion and ease of dismantling during maintenance of pumps, Couplings should be guarded. The spacer shall have a suitable length so that it shall permit removal of the coupling, bearings, seal and rotor as applicable, without disturbing the driver or the suction and discharge piping.

5.1.17 Suitable lifting arrangement such as eyebolts of S.S.etc., shall be provided to pumps and accessories for ease of handling.

5.1.18 MATERIAL OF CONSTRUCTION: The following materials shall be used for construction of various parts unless and otherwise stated specifically.

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Sr No. PARTS Material-Standard Construction

1 Casing with supporting foot Stainless Steel casting to ASTM-A351 Grade CF-8 /CF-8M 2 Stuffing box cover/casing cover

3 Stuffing box, gland, quench gland if any

4 Bearing housing/bracket and Bearing bracket foot piece

5 Impeller

6 Impeller/casing wearing rings SS 316/SS304

7 Shaft sleeves

8 Shaft SS AISI 316

9 All screws bolts, nuts, plugs coming on casing stuffing box cover and gland and companion flange nuts and bolts on pump suction and discharge

Stainless Steel AISI 316

10 Adapter/distance piece if any Cast Stainless steel CF8M/CF8 grade

11 Base plate Cast Stainless steel CF8M/CF8.

12 Deflector plate, drip plate and drip pan Stainless Steel 304

13 Name plate Pump

14 Companion flanges on pump suction and discharge

Stainless steel 304L

15 Bearings, oil seals etc. FAG/ SKF , reputed make

Bearing end covers SS304/316

16 All non metallic parts like gaskets etc., Teflon

17 All pump metallic part not mentioned which come in contact with liquid or leakage will cause dripping on thatcomponent

S.S. 304/316

6. Inspection & Testing (General)

6.1 The minimum inspection requirement of all components/equipment shall conform to the

specification and reference codes standards and approved drawings. 6.2 All tests and test procedures along with the time schedule proposed by manufacturer

shall be submitted for purchaser’s approval. 6.3 The purchaser or his representative will carry out inspection, who should be informed at

least 20 days prior to vendor schedule inspection dates. 6.4 The contractor or his subcontractor should allow access at all reasonable time during

manufacture, assembly, testing and inspection to the premises where work is being

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carried out and shall provide all gauges, instruments, testing facilities required for inspection and testing of components/equipment.

6.5 All material used for manufacture of the equipment should be new and conforming to

specific standards and of tested quality. Relevant mill test certificates for major components shall be made available to the purchaser before the final shop inspection. In case, relevant test certificates are not available the supplier shall arrange to carry out the necessary tests required by the code at his own cost.

6.6 Unless otherwise stated, inspection/test shall be conducted in the presence of purchaser and/or his representative. The purchaser reserves the right to waive the requirement of his engineer’s presence during any or all of the stage inspections.

7. Inspection & Testing at Manufacture’s works 7.1 Casting shall conform to relevant specifications. 7.2 Casting shall be sound, clean and free from porosity, blowholes, hard spots, cold shuts,

distortion and other harmful defects. All casting shall be examined by liquid dye penetrant inspection in accordance with ASTM E-165. Inspection shall be carried out

after rough machining operation. Any indication that is not removed during finial machining shall be gouged out and repaired using approved procedure and by approved welder. No repair shall be carried out unless approved by the purchaser.

7.3 All shafts shall be ultrasonically tested and shall meet the material requirement of relevant ASTM or IS specifications and relevant test certificates shall be provided.

7.4 Pump casing shall be hydrostatically tested in the shop to a pressure of one and a half times the respective maximum discharge pressure or twice the operating pressure whichever is higher relevant to design fluid. Minimum thickness shall be checked as per data. All pumps shall be tested for mechanical running to check the soundness and vibrations within limits.

7.5 Performance test shall be conducted for each of the pump in accordance with relevant code/standard to demonstrate the specific performance requirements. Tender shall submit with his bid the details of facility available with him along with the procedure for test. The vendor shall make all arrangements for testing pumps. The purchaser or his representative shall witness the test. Test procedure shall be subject to Purchaser’s approval. Pump shall be tested with its respective motor.

7.5.1 All pumps shall be tested for plotting the characteristic curves i.e. capacity against head, power and efficiency. At least five readings shall be taken. The pump shall also be tested for low head and high flow requirement to check selection of Motor for the application for one hour minimum (for minimum one number) or 20 % of the ordered quantity for each size which ever is maximum.

7.5.2 NPSH test : Minimum one pump shall be tested for NPSH for each size. Sufficient

number of readings (at least five) shall be taken. 7.6 Vibration Test: The vibration measured during the performance test in velocity shall not

exceed as per ISO2372 at any pump’s preferred operating region. 7.7 Bearing Oil temperature test: During the performance test of the pump the oil sump

temperature shall not exceed 300C above ambient temperature for splash lubrication system of bearing housing.

7.8 Strip down test shall be carried out on the one pump of each size in the presence of purchaser or his authorized representative.

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7.9 All motors routine test shall be as per IS: 325 and routine and type test certificate shall be submitted for review.

7.10 The impeller shall be dynamically balanced as per ISO 1940 Gr 2.5 and test certificate shall be provided. Test will be witness by purchaser.

7.11 Material test certificate shall be provided for major components like casing, casing cover, impeller, shaft etc. and for other components material compliance shall be submitted. Manufacture’s certificate shall be provided for mechanical seals.

7.12 Should purchaser waive inspection of equipment or even though the purchaser carries out the inspection. Such inspection shall however not relieve the vendor of all the responsibility for furnishing equipment conforming to the requirements of contract for satisfactory performance after commissioning.

8. PERFORMANCE GUARANTEE

Each equipment shall be guaranteed to meet the performance requirements of this specification for design fluid. If the equipment fails to meet the guarantee in any respect for any reason whatsoever and it is necessary for the supplier to make alternations for the purpose of meeting the guarantee. The alterations shall be made and additional tests required showing the effects of such alterations shall be performed by the supplier at no expense to the purchaser.

9. Drawings Performance Curves to be submitted With Offer

9.1 one copy of offer along with following drawings shall be submitted for evaluation for each type of pump. 0 a) General arrangement drawing of pumps and motor with coupling arrangement for

all types. b) Sectional assembly drawing of the pumps showing part list and material of

construction. c) Component Drawings:- Details of stuffing box with normal packing arrangement

and mechanical seal. d) Foundation detail drawings for all types of pumps e) Dimensional drawings of motor showing terminal boxes and method of

termination of purchaser’s cables. 9.2 one set of following supporting documents shall be submitted for detail evaluation of bid

with quotation for each type of equipment. 0 a) Complete description, illustrated literature/catalogue of equipment offered in

specific (Pumps/Mechanical seal) b) Characteristic curves of pumps showing capacity against head, power efficiency

and NPSH pump for design fluid c) Description of shop inspection testing and quality control facilities and quality

assurance plan proposed. d) Speed Vs Torque, Speed Vs Current Load characteristics and starting current Vs

Time characteristics for motors.

9.3 Annexure – B duly filled

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10. Documentation 1 The supplier shall two sets of bound volume consisting of 2 a) Approved final drawings consisting all details of pump

b) All relevant material tests reports, manufacture’s test certificates, hydrostatic test certificates, performance test certificates etc. as asked in the specification for inspections and testing. c) Instructional manuals for each type of pump for installation operation and maintenance of the equipment furnished by him. The manuals should include drawings and performance curves, assembly and disassembly procedure, parts replacement, etc. the manual shall be got approved by the purchaser before full supply is made.

11. Cleaning Protection & Painting (Pump & Motor assembly) 11.1 All equipment shall be neatly finished in workman like manner exposed metal surface

shall be smooth and free from burrs. Finished surface shall be protected against corrosion and mechanical damage.

11.2 All steel and casting surface shall be thoroughly cleaned and removed off mill scale, rust etc. Exterior surfaces shall be given one coat of epoxy primer and minimum two coats of finial epoxy paint for the motor, the colour of which shall be approved by the purchaser.

11.3 After cleaning all interiors, all openings shall be properly closed with blank flanges caps etc. to prevent entry of water dirt, etc.

11.4 All parts shall be properly covered in PVC sheet, boxed and protected to prevent all possible damage during transportation.

12.0 Packaging and Shipment:

Each pump set shall be packed separately and secured properly to avoid damage during the transit. The whole responsible will rest with the supplier till the pumps sets received at the destination.

13.0 Delivery time schedule:

Vendor shall clearly mention time schedule for supply of items under this specification

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ANNEXURE -B

Technical Particulars for Annexure - A Pumps Specification:

1.0 Description To be filled by vendor with remarks

1.1 Manufacture Name

1.2 Model No.

1.3 Type of pump and description

1.4 Nos. of pump offered

1.5 Capacity m3/hr.

1.6 Total head MLC

1.7 Shut off head MLC

1.8 Overall efficiency of pump at best efficiency point ( BEP ) in %

1.9 Overall efficiency of pump at rated/design condition in %

1.10 NPSH required at BEP MWC

1.11 NPSH required at rated condition MWC

1.12 Pump speed in rpm

1.13 Kw required at ;

1.13.1 i) 100 % design capacity flow

1.13.2 ii) 8 MLC head/4 MLC Head as per the pump rating with higher flow of the model offered

1.14 Minimum recommended flow rate m3/h

1.15 Design pressure for the pump casing in Kg/cm2g

1.16 Hydrostatic test pressure in Kg/cm2g

1.17 Casing thickness in mm

1.18 Corrosion allowance for casing

1.19 Pump BKW

1.20 Motor rating in KW

1.21 Impeller shall be investment casting (yes/no)

1.22 Casing shall be investment casting (yes/no)

2. Pump rotating assembly

2.1 Direction of rotation viewed from driver end

2.2 Diameter of impeller selected for rated

condition mm

2.3 Maximum dia. Of impeller for the selected

casing mm

2.4 Impeller radial clearance in mm

2.5 Moment of inertia of rotating assembly including pump and motor

2.6 Sleeve surface finish in micron

3. Nozzle size and rating

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3.1 Suction flanges size and rating

3.2 Discharge flanges size and rating

3.3 Counter flanges & bolts provided

4. Bearings

4.1 Make and designation for inboard bearing

4.2 Make and designation for outboard bearing

4.3 Design life in hours at rated condition

4.4 Radial load on impeller in Kilo Newton

4.5 Axial load on impeller in Kilo Newton

4.6 Weight of impeller in Kg

5. Coupling

5.1 Type & Make

5.2 Coupling Guard provided and its material SS 304/316

6. Stuffing Box and Mechanical seal

6.1 Bore & Depth (mm x mm) of box

6.2 Type and description of mechanical seal

6.3 Make of Mechanical seal

6.4 Size of Mechanical seal

6.5 Is it shaft mounted or sleeve mounted

6.6 Materials of face combination

6.7 Material of elastomers like O- rings

6.8 Materials of hardwere

6.9 Materials of spring

6.10 Materials of gland plate if any

6.11 Material of sleeve for seal if any

7. Material of Construction for pump parts

7.1 Impeller

7.2 Shaft

7.3 Casing

7.4 Casing cover

7.5 Shaft sleeve if any

7.6 Impeller wear ring if any

7.7 Casings wear ring if any

7.8 Counter flanges

7.9 Nuts and bolts

7.10 Base Plate/bed plate

7.11 Adapter/distance piece if any

7.12 Bearing housing/bracket

7.13 Bearing end covers

7.14 Deflector plate, drip plate and drip pan

7.15 Name plate for Pump

7.16 Any material not mentioned and selected by manufacturer for the application shall be

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metals parts in SS304/316 and elastomers in PTFE/Viton when components expected to come in contact of Acid .

8. Drive Motors

8.1 Make of Motor

8.2 Type of motor

8.3 Rated Power

8.4 Suitable for DOL starter

8.5 Class of insulation and temp. rise limited to

8.6 Ingress of protection

8.7 RPM of motor

8.8 Rating

9.0 Inspection and testing of pump and motor

9.1 Review of material test certificates for chemical and mechanical where ever applicable

9.2 DP test report shall be review and random check shall be carried out.

9.3 Each pump shall be Hydro-tested.

9.4 Each pump shall be performance tested for flow, head, power and efficiency. Before carrying out this test each pump shall be run tested for minimum one hour.

9.5 Minimum one pump shall be tested for NPSH for each size.

9.6 Pump noise and vibration level shall be monitored and measured.

9.7 Routine test of each motor shall be carried out. Type test certificate shall be reviewed.

10.0 General

10.1 Complete pump set including base/bed plate weight in Kg

10.2 Rotating assembly weight in Kg

10.3 Motor weight in Kg

10.4 Overall dimensions (length x width x height) mm x mm x mm

10.5 Base/bed plate (length x width) mm x mm

10.6 Weight of base/bed plate in Kg

11. Documents &Literature with the offer

11.1 GA drawing

11.2 Cross sectional drawing showing MOC

11.3 Performance curves (Flow Vs. head, efficiency, power and NPSHR )

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11.4 Experience in manufacturing and supplying of same model pumps along with details to whom, when and how many pumps have been supplied during last five years.

11.5 Speed Vs torque and Current characteristic curve for motor

11.6 Speed Vs torque curve for pump

11.7 Literature and catalogue for pump and motor

11.8 Shop inspection & testing facility documents

12. Others

12.1 Impeller balancing grade G2.5 ( yes /no )

12.2 Vibration Level in mm/sec.

12.3 Noise Level in dBA@1Metre

12.4 Any deviation from specification shall be clearly mentioned in your offer

Signature of bidder