PDRP-8410-SP-0018_Rev_F1.pdf

PARADIP REFINERY PROJECTPROJECT SPEC. A

CENTRIFUGAL PUMPS FOR GENERAL DUTY SERVICES

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CONTENTS

(INDEX OF ISO 5199 SECTIONS REFERRED TO IN THIS SPEC.)

SECTION SUBJECT PAGE NO

1 SCOPE ---------------------------------------------------------------------------3

2 NORMATIVE REFERENCES------------------------------------------------3

4 DESIGN -------------------------------------------------------------------- 4

5 MATERIALS -------------------------------------------------------------------16

6 SHOP INSPECTION AND TESTS-----------------------------------------18

7 PREPARATION FOR DISPATCH------------------------------------------22

8 SPECIAL TOOLS---------------------------------------------------------------22



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ISO 5199 second edition 2002 Technical Spec. s for centrifugal pumps - Class II" is an integral part of this Specification. The numbering of sections and paragraphs is the same as in ISO 5199. The type of change e.g. addition, deletion, modification, substitution or new, is noted in parenthesis for each item.

1 SCOPE

1.1 (mod) This Specification covers the minimum requirements for centrifugal pumps intended primarily for chemical plants and general utility applications with pumping temperatures between -29 to 177 DEG C (-20 to 350 DEG F), for non-flammable services and when it is not necessary to use API Std. 610. Project Spec No. PDRP-8410-SP-0001 Centrifugal Pumps for Heavy Duty Services. shall apply where API 610 is to be used.

1.4 (new) Compliance with this Spec. does not relieve the vendor of the responsibility for supplying equipment of proper design and construction and fully suitable for all specified operating conditions.

1.5 (new) Equipment offered by vendor shall satisfy the following minimum service and manufacturing experience requirements:

The equipment shall be identical or validly similar in frame, power rating, speed, discharge pressure, differential pressure, mechanical design and materials, as compared with at least TWO units produced by the vendor at the proposed manufacturing plant of which at least one unit must have had at least one year's satisfactory operation at the time of enquiry issue.

2 NORMATIVE REFERENCES

(mod) The latest revisions of the following Paradip Project Spec. s form part of this Spec. and take precedence over those listed in ISO 5199 paragraph 2.



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Project Spec. No. Title

PDRP-8410-SP-0007 Induction Motors

PDRP-8410-SP-0011 Guards for Machinery

PDRP-8820-SP-0001 Basic Engineering and Design data

PDRP-8440-SP-0013 Equipment Noise Control Spec.

PDRP-8410-SP-0021 Loading and Penalty Criteria for Rotating Equipment

2.1 (new) The vendor shall ensure that all equipment in his scope of supply complies with all applicable statutory requirements, local rules and regulations.

4. DESIGN

4.1 General

4.1.1 Documents

(mod) The order of precedence of this Spec. is between b) data sheets and c) ISO 5099:2002.

4.1.2 Pump H(Q) curve (characteristic curve)

(add) All pumps shall have a continuously rising head/capacity curve. The shutoff head at rated speed shall be at least 110 per cent of the head

of rated capacity. The maximum shutoff head at rated speed, on test, shall not exceed 125 per cent of the head at rated capacity, inclusive of all tolerances, except for mixed-flow and axial-flow type pumps or unless approved by the IOCL.

4.1.3 (add) Pumps with Inducers are not acceptable.

4.1.4 Outdoor Installation

(add) Ambient and environment conditions are as per the Project Spec. No. PDRP-8820-SP-0001 Basic Engineering Design data.



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4.1.5 (new) Suction Specific Speed

For pumps handling liquids other than water, with driver power of 75 kW, and above, and for water pumps with driver power of 55 kW and above:

1. The suction specific speed shall not exceed 12,780 at the best efficiency point for the maximum diameter impeller.

2. For pumps operating at 30% of pump peak efficiency capacity, or below, the suction specific speed shall not exceed 11,620.

Note: a) For pumps using an inducer, the criteria of item 1 and 2 above apply to the pump impeller and not the inducer.

b) Suction specific speed is expressed by:

S = N (Q)0.5 / (NPSHR)0.75

Where =S = suction specific speed

N = rotative speed in r.p.m,Q = flow per impeller eye in m3/hNPSHR = net positive suction head required in m.

4.1.6 (new) Pumps that handle liquids more viscous than water shall have their performance corrected in accordance with the Centrifugal Pump

Section of the Hydraulic Institute Standards.

4.1.7 (new) Vertical Pumps

1. Vertical pumps that could be damaged by reverse rotation shall be provided with a nonreverse ratchet.

2. For all vertical pumps the Vendor shall supply, shop mount, align and be responsible for all vertical drive components (including

motor, gear and couplings). Vendor's responsibilities shall cover freedom from harmful effects of torsional and/or lateral critical

speeds and vibrations of the entire unit.

3. For vertical sump pumps Vendor shall state the minimum submergence required and the minimum clearance from the sump bottom.

4.1.8 (new) The noise level for the pump set shall not exceed the values specified in Project Spec. No. PDRP-8440-SP-0013 Equipment Noise Control Specification.



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4.1.9 (new) Vendor to note that the efficiency of offered equipment will be assessed during the selection and performance testing of the pump in accordance with Project Spec. No. PDRP-8410-SP-0021 Loading and Penalty Criteria for Rotating Equipment.

4.2 Prime Movers

4.2.1 (new) The type of prime mover shall be specified by IOCL and be in accordance with the relevant project Spec. . The prime mover shall be sized to meet the maximum specified operating conditions, including external gear and/or coupling losses. Prime movers, other than electric motors, shall have rated output power in accordance with

Fig2 but never less than 1.0 kW.

Electric motors shall have power ratings, at least equal to the following percentage of pump rated power:

Motor Nameplate Percentage of RatedRating Power

18.5 kW and less 12522 kW 55 kW 115

75 kW and more 110

For electric motors required as drivers for pumps operating in parallel service or for fire water pumps, the nameplate rating shall be at least

equal to the pump maximum brake absorbed power or the above percentage rating whichever is the larger.

4.2.2 (new) Electric motor Vendor shall be from an IOCL approved Vendor list. The intent of this requirement is to select motors from a single motor

Vendor to the greatest extent possible for this project.

4.2.3 (new) Motors for vertical pumps shall have the thrust bearing at the top. This requirement is not mandatory for vertical in-line pumps. Unless

otherwise approved by IOCL, prime movers, or gear drivers for vertical pumps, including in-line vertical pumps, shall be designed to carry double the maximum thrust (up and down) the pump may develop while starting, stopping, or operating at any capacity. The maximum thrust load shall be determined at double the initial internal clearances.



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4.3 Critical Speed, Balance and Vibration

4.3.1 Critical Speed

(add) When specified by IOCL, the calculations detailed in Items (a) and (b) below shall be provided by the Vendor.

(a) A lateral critical speed analysis to determine that the critical speeds of the prime mover are compatible with the critical speeds of the pump and that the combination is suitable for the specified operating speed range.

(b) A torsional vibration analysis of the pump-driver system. The Vendor shall be responsible for the satisfactory performance of the system.

4.3.1.1 (new) Torsional modes of the complete unit shall be at least 10 per cent removed from any operating speed up to the trip speed.

4.3.1.2 (new) The support and bearing housing resonances of the prime mover and driven equipment shall not occur within the specified operating speed

range or the specified separation margins.

4.3.2 Balance and Vibration

4.3.2.1 General

(add) All major rotating components, such as impellers and balancing drums, shall be dynamically balanced. When specified by IOCL, the assembled rotors shall be dynamically balanced.

4.3.2 Balance and vibration

(add) All major rotating components, such as impellers and balancing drums, shall be dynamically balanced. When specified by IOCL, the assembled rotors shall be dynamically balanced.

The unfiltered vibration for all pumps with rolling bearing, when measured on the bearing housing during the shop test at rated speed and at rated capacity, midway capacity, minimum continuous stable flow and 110 per cent of rated flow, shall not exceed the values listed in the table.



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4.3.2 (contd.) The unfiltered vibration of all sleeve-bearing pumps, measured on the shaft during the shop test at rated speed and at rated capacity, midway capacity, minimum continuous stable flow and 110 per cent of rated flow shall not exceed a velocity of 10.2 millimetres (0.40 inches) per second peak nor exceed a displacement of 50.8 micrometers (2.0 mils) peak to peak (including shaft runout). The filtered vibration at running speed frequency, blade passing frequency or frequencies, and other frequencies specified by IOCL shall not exceed a velocity of 7.6 millimetres (0.30 inches) per second peak (see Figure A).

Vibration readings shall be taken on the upper bearing housing of the driver for vertical pumps with rigid couplings and next to the top pump bearing for vertical pumps with flexible couplings.

Pumps shall operate smoothly throughout their speed range in reaching rated speed.

4.4 Pressure - Containing Parts

4.4.4.1 Dismantling

(sub) Horizontal pumps and vertical in-line type pumps shall be designed to permit removal of the impeller, shaft, seal and bearing assembly without disturbing the inlet and outlet flange connections.



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4.5 Branches (nozzles) and Miscellaneous Connections

4.5.3 Vent Pressure-Gauge and Drain

(add) 1. When pump casing vents and drains are required to be valved, the valves shall be gate type.

2. All valved vent and drain connections shall be suitably braced, details of the bracing shall be approved by IOCL.

4.5.5 Auxiliary Pipe Connections

(add) To withstand vibration, auxiliary connections shall be at least 1/2 inch (15 mm) nominal pipe size (NPS) for pumps with discharge openings of 2

inches (50 mm) NPS and smaller. Connections shall be at least 3/4 inch (20 mm) NPS for pumps with discharge openings of 3 inches (80 mm) NPS and larger, except that connections for seal flush piping and lantern rings may be 1/2 inch (15 mm) NPS without regard to pump size. Threaded connections shall conform to ANSI B1.20.1.

4.5.7 (new) Auxiliary Piping and Appurtenances

4.5.7.1 (new) General

1.Auxiliary piping systems, including all accessories such as gauges and valves, shall be furnished by the Vendor fully assembled and installed on horizontal pumps, and on vertical pumps where practical.

2. Pipe threads shall be taper type in accordance with ANSI B1.20.1 or equivalent. Flanges shall be in accordance with ANSI B16.5.

3. Minimum requirements for carbon steel pipe wall thickness shall be schedule 80 or equivalent for nominal pipe sizes 1/2 inch (15 mm) through 11/2 inches (40 mm) and schedule 40 or equivalent for nominal pipe sizes 2 inches (50 mm) and larger.

4. Minimum requirements for stainless steel pipe wall thickness shall be schedule 40 or equivalent for nominal pipe sizes 1/2 inch (15 mm)

through 11/2 inches (40 mm) and schedule 10 or equivalent for nominal pipe sizes 2 inches (50 mm) and larger.

5.On pumps handling toxic fluids all threaded process piping connections shall be seal-welded except when the connection is required for dismantling. Seal-welded connections shall be made up

without thread lubricants or compounds. The seal weld shall consist of at least two passes, the throat of the finished weld being a maximum of 3/8 inch (9.5 millimetres) and shall cover all exposed



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threads. No undercutting is permitted.

4.5.7.2 (new) Auxiliary Piping

1. Auxiliary piping includes vents and drains, balance lines, product flushing lines, lines for injection of external fluid into stuffing boxes

and cooling water. Where IOCL makes connection the vendor shall terminate the piping at the edge of the baseplate.

2. Auxiliary piping shall be 1/2 inch (15 mm) nominal pipe size minimum.

3. Piping components subject to the process fluid shall have a pressure- temperature rating at least equal to the maximum

discharge pressure and temperature of the pump casing.

4. When the pump casing is of alloy material, all piping components subject to the process fluid shall be equal to or better than the casing

material. Otherwise, all components shall be steel.

5. Seamless 18Cr - 8Ni stainless steel tubing, ASTM A 269, Type 304 or equivalent, may be used for process fluid to mechanical seals. Stainless steel tubing shall have a minimum wall thickness of

0.065 inch (1.65 millimetres) for 1/2-inch and 5/8-inch sizes and a minimum wall thickness of 0.095 inch (2.413 millimetres) for 3/4-inch

tubing. Tubing fittings may be the Vendor's standard.

4.7 Branch (nozzle) Flanges

(add) Unless specified otherwise flanges shall conform to ANSI B16.1, 16.5

or 16.42 as applicable, except as specified in Items 1 through to 3 below.

1.Cast iron flanges shall be flat faced and shall be ANSI B16.5 Class 250 minimum thickness for sizes 8 inches (200 mm) and smaller.

2.Flat-faced flanges with full raised-face thickness are acceptable on casings other than cast iron.

3.Flanges that are thicker or have a larger outside diameter than required by ANSI are acceptable.



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Openings for nominal pipe sizes of 1 3 inch (DN 32), 2 2 inch (DN 65), 3 2 inch (90mm), 5 inch (DN 125), 7 inch (175mm) and 9 inch (225mm) shall not be used.

Flanges shall be full or spot faced on the back and shall be designed for through bolting.

Suction flanges shall be designed for the same pressure rating as the discharge flanges.

Notes:

a. Both ISO 2084 and 2229 are superseded by ISO 7005.

b. ANSI Class ratings are included in ISO 7005, eg. ISO 7005-1, steel flanges, Class 150 is equivalent to PN20, Class 300 equivalent to PN 50, Class 600 equivalent to PN110; ISO 7005-2, CI flanges, Class

125 is equivalent to PN20 and Class 250 equivalent to PN50.

4.9 Wear Rings or Equivalent Components

(add) Renewable wear rings furnished on both the casing and the impeller are preferred.

Pumps handling slurry or fluids containing abrasive solids shall be provided with wear rings equipped for injection of clean flushing liquid to prevent the ingress of abrasive particles.

Mating wear surfaces of hardenable materials shall have a difference in Brinell hardness number of at least 50, unless both the stationary and rotating wear surfaces have Brinell hardness numbers of at least 400.

Renewable wear rings shall be held in place by a press fit with locking pins or threaded dowels (axial or radial) or by flanged and screwed methods. Other methods, including tack welding at three or more points, require IOCL's approval.

4.11 Shafts and Shaft Sleeves

4.11.1 General

(add) Preferably, shafts shall be provided with sleeves. The sleeve material shall be resistant to wear, corrosion, and erosion.



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4.11.3 Shaft deflection

(add) The 50 micrometer shaft deflection limit shall apply to all one and two stage horizontal and to vertical in-line pumps and is not confined to ISO 2858 type pumps.

In addition to condition (a) the requirement shall also apply to conditions (b) and (c).

4.12 Bearings

4.12.1 General

Radial bearings shall be of the standard available design (ball, roller, sleeve, or pivoted shoe) unless otherwise specified by IOCL. Thrust bearings shall be either rolling type or hydrodynamic, as required.

Thrust bearings shall be sized for continuous operation under all specified conditions, including conditions such as maximum differential pressure. Normal loads shall be determined at design internal clearances and maximum load at two times design internal clearances.

4.12.4 (add) Lubrication

Provision for oil mist lubrication shall be provided as follows :

1. An oil mist inlet connection, 1/4 inch nominal pipe size, shall be provided in the top half of bearing housing. The pure-or-purge-oil mist fitting connections shall be located so that oil mist will flow through rolling bearings. There shall be no internal passages to short-circuit oil mist from inlet to vent.

2.A vent connection, 1/4 inch nominal pipe size, shall be provided on the housing or end cover for each of the spaces between the rolling bearings and the housing shaft closures. Alternatively, where oil mist connections are between each housing shaft closure and the bearings, one vent central to the housing shall be supplied.

Housings with only sleeve-type bearings shall have the vent located near the end of the housing.

3.Shielded or sealed bearings shall not be used.

4.When pure-oil mist lubrication is specified, oil rings or flingers (if any) and constant-level oilers shall not be provided and a mark indicating the oil level is not required. When purge-oil mist lubrication is

specified, these items shall be provided and the oiler shall be piped



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so that it is maintained at the internal pressure of the bearing housing.

5. The oil mist supply and drain fittings will be provided by IOCL.

4.12.5 (add) Bearing Housing Design

1. Housings for oil lubricated non-pressure fed bearings shall be provided with 1/2 inch minimum plugged fill and drain openings, threads conforming to ANSI B1.20.1 or equivalent. They shall be equipped with constant-level sight-feed oilers (4 ounces minimum size) with mechanically lockable adjustment, with transparent

containers (not subject to sunlight or heat induced opacity or deterioration), and with protecting wire cages. A permanent indication of proper oil level shall be accurately located and clearly marked on the outside of the bearing housing with permanent

metal tags, marks inscribed in the castings, or other durable means.

2. Bearing housings shall be equipped with labyrinth-type end seals and deflectors where the shaft passes through the housing; lip- type seals shall not be used.

3. Bearing housings for sleeve or pivoted shoe type bearings shall be provided with the facility for fitting non-contacting type vibration probes to API Standard 670; two radial 90 Deg at each other, two

axial position at thrust bearing end of the pump and a one-event- per revolution probe. The material requisition/data sheet will specify the extent of supply of the vibration detection equipment.

4.13 Shaft Sealing

4.13.1 General

(add) Mechanical seals shall be furnished, unless otherwise specified. Specified gland connections shall be identified by stamping on the seal gland as follows: Q for quench, F for flush, D for drain, and V for vent. When a steam quench is specified by IOCL, the inlet connection shall be located at the top quadrant of the seal gland and the outlet connection shall be located at the bottom position of the seal gland to prevent the formation of water pockets.



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4.13.1.1 (new) Stuffing Box

Stuffing boxes shall be provided with a lantern ring for the introduction of a cooling medium directly into the packing. Inlet and outlet connections shall be provided with connections conforming to para

4.5.5. Lantern rings shall be equipped with threaded holes to facilitate their removal.

A drain shall be provided on vertical pumps so that no liquid can collect in the driver support piece.

Pump packing shall be furnished by Vendor unless otherwise agreed; it shall be shipped separately, for installation in the field. Two complete sets of packing shall be provided for each stuffing box.

4.13.3 Mechanical Seals

4.13.3.1 (mod) Type and Arrangement

Where the type has not been specified on the data sheet the Vendor shall make recommendations and submit full details with his quotation.

4.13.3.3 (add) Construction Features

When an auxiliary sealing device is not specified a spark-resistant throttle bushing, pressed into the seal gland against an outside shoulder, shall be provided.

A deflector shall be provided on vertical pumps not equipped with auxiliary packing or closure to prevent foreign materials from entering the space between the seal and the shaft.

4.13.5 (add) Auxiliary Piping for stuffing box and mechanical seal

See also new paragraph 4.5.7.

4.13.6 (add) Mechanical design of auxiliary piping

See also new paragraph 4.5.7.



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4.14 Labelling

4.14.1 (add) Nameplates

In addition the nameplate shall be stamped with the following information, with units as specified in the project Spec. No. PDRP-8820-SP-0001 Basic Engineering and Design Data.

- IOCLs order number - IOCLs item number

- Rated capacity - Rated pumping head- Motor kW - Casing hydrostatic test pressure - Bearing manufacturer's identity Nos.

In addition to being stamped on the nameplate, the pump serial number shall be plainly stamped-on the pump casing.

4.15 Couplings

(add) Unless specified otherwise, couplings shall be dry, non-lubricated multiple-disc flexible type, all metal with stainless steel discs.

Couplings shall be rated for at least 1.5 times the maximum driver torque.

For glandless pumps, magnetic type coupling, eddy current type or magnet to magnet type, shall be used as specified. Sealing shroud enclosing the shaft and the inner magnet ring, shall be non-magnetic and have high electrical resistivity. Any cooling liquid shall be fed via an in-line filter.

If solid-shaft drivers are used on vertical pumps without integral thrust bearings, the couplings shall be all steel and of the rigid adjustable type. When a solid-shaft driver is used on vertical pumps equipped with mechanical seals, the coupling shall be spacer type. The spacer shall be of sufficient length to permit replacement of the seal assembly, including the sleeve, without removing the driver. The pump half-coupling shall be designed so that it can be removed without the use of heat.

Where the pump Vendor is not required to mount the driver, he shall deliver the fully machined half-coupling to the driver Vendor's plant or any other designated location, together with the necessary instructions for mounting the half-coupling on the driver shaft.



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Removable coupling guards shall be supplied. They shall comply with the requirements of Project Spec. No. PDRP-8410-SP-0011 Guards for Machinery.

4.16 Baseplate

(add) All horizontal pump baseplates shall be designed for the future filling with grout but stiff enough without being filled to withstand the forces and moments described in para 4.6. Such baseplates shall be

provided with at least one grouting opening, minimum 4 inch (100 mm) dia. in each bulkhead section. These holes shall be located to permit filling the entire cavity under the baseplate without creating air pockets. Vent holes, 1/2 inch (13 millimetres) minimum size, shall be provided for each bulkhead compartment.

4.16.4 Baseplate Design

(add) Normally, drain-rim or drain-pan baseplates shall be furnished for horizontal pumps and shall have a raised lip. Connections for a drain shall be tapped (1 inch ANSI B1.20.1 minimum) in the raised lip at the

pump end and shall be located to effect complete drainage.

The baseplate shall extend under the pump and drive train components.

For driver trains over 75 kilowatts, alignment positioning screws shall be provided for each drive element to facilitate longitudinal and transverse horizontal adjustments. The lugs holding these positioning screws shall be attached to the baseplate so that they do not interfere with the installation or removal of the drive element.

Vertical pumps shall have the vendor's standard mounting arrangement with a minimum of four alignment positioning screws provided for drive elements 50kW or more to facilitate horizontal adjustments.

5. MATERIALS

5.1 (add) Selection of Materials

Materials for pump parts shall be in accordance with those specified on the data sheet. Where these have not been specified the Vendor

shall make recommendations for IOCL approval.

Pressure-casing parts of pumps that are to handle toxic liquids shall be of carbon steel or alloy steel.



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Asbestos shall not be used in any form as material of construction.

Materials shall be identified in the proposal with applicable International Standards, grade and equivalent.

5.2 (add) Material Composition and Quality

When radiography, magnetic particle, or dye penetrant inspection of welds or materials is required or specified by IOCL, radiography

shall be in accordance with Paragraph UW-52; magnetic particle inspection shall be in accordance with Appendix 6 and dye penetrant inspection shall be in accordance with Appendix 8, all of the Section VIII of ASME Code. Other equivalent National Codes may be used.

If parts made from 18Cr - 8Ni stainless steel are exposed to the liquid pumped and are to be fabricated or hard surfaced by welding,

stabilised or extra-low-carbon grades are required. For example, for Type 304, use Type 304L or 347; for Type 316, use Type 316L or

318.

5.3 (add) Repairs

Weld repairs for all major repair welding on pressure containing parts shall be submitted to IOCL for approval prior to commencement of the repair work.

Welded or brazed repairs on iron castings are not acceptable.

5.4 (new) Welding

5.4.1 (new) Piping connections to pressure casings shall be installed as follows:-

Auxiliary piping welded to alloy steel casings shall be of material with the same nominal properties as the casing or shall be low-carbon austenitic stainless steel. Other materials compatible with the casing material and intended service may be used with IOCL's approval. All weldments shall be heat treated in accordance with the ASME Code, Section VIII, Division 1, Paragraph UW-40 or equivalent. Auxiliary piping welded to the casing shall terminate with a flange.

5.4.2 (new) All welding of piping and pressure-casing parts shall be performed by operators and procedures qualified in accordance with the welding qualifications of Section IX of the ASME Code or equivalent.

Weld repairs are covered in Paragraph 5.3.



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6. SHOP INSPECTION AND TESTS

6.1 General

(add) The Vendor shall provide IOCL with advance notification of certain shop inspections and tests as outlined in the purchase order, requisition or data sheet or other agreement. IOCLs representative shall have entry, after prior notification by IOCL, to all Vendor and sub-vendor plants where work upon or testing of the equipment is in progress. It shall be the responsibility of the Vendor to notify sub-vendor of IOCL's inspection requirements.

The pump data sheet states which test shall be "witnessed" or "observed"; these are defined as follows:-

'Witnessed' means that a hold shall be applied to the production schedule and the test carried out with IOCL in attendance. It usually implies a double test.

'Observed' means that IOCL requires notification of the test's timing. However, the test if performed as scheduled, and if the

IOCL is not present the Vendor may proceed to the next step. Since only one test is scheduled, IOCL should expect to be in

the factory longer than for a witnessed test.

For purchase order of large value and/or critical items, a meeting between IOCL and the Vendor may be requested to co-ordinate manufacturing hold points and inspector's visits. Prior to the

meeting, the Vendor shall provide a quality control plan showing the proposed programme of inspection and testing and which items are to be witnessed or observed. This plan will be reviewed by IOCL who will advise any required amendments. When required, the Vendor shall provide a copy of his quality control procedures for IOCL's review.

Acceptance of shop tests shall not constitute a waiver of requirements to meet field tests under the specified operating conditions, nor does inspection relieve the Vendor of his

responsibilities in any way whatsoever.

All equipment shall be subject to inspection by IOCL or his representative, in accordance with the purchase order requirements.

As a minimum, the scope of IOCL's inspection shall include sub-orders, materials, welding, heat treatment, non-destructive testing of materials and welds, repairs, rotor balancing, dimensional



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checks, hydrostatic and running tests, checks after testing and final inspection prior to shipment.

It is intended that IOCL's inspection work will be reduced to a minimum by assigning to the vendor the responsibility for

providing the inspector with all specified certification of materials and shop test data to verify that the requirements of the

Spec. s and contract are being met.

IOCL's inspector shall be informed of any defects noticed during manufacture. Vendor shall also inform IOCL and

obtain his permission before proceeding with any repairs which may affect equipment operation, integrity or interchangeability.

Procedures for major repairs shall be approved by IOCL before rectification. The procedures shall include a sketch showing

the size and location of the defect, the post weld heat treatment and non-destructive tests to be carried out. Rejection by IOCL shall be final.

6.3 Tests

(add) The extent of testing and IOCL's participation in the testing shall be in accordance with the purchase order and requisition/data sheet.

Vertical pumps are to be tested as complete assemblies. Tests using only bowls and impellers are not acceptable. In cases where

assembly testing is impractical because of pump length, the pump Vendor shall submit alternative testing procedures with the proposal.

6.3.3 Hydrostatic Test

(add) Cooling passages and jackets for bearings, stuffing boxes, oil coolers, and so forth, shall be tested to at least 7.9 bar gauge.

All hydrostatic tests shall be maintained for a sufficient period of time to permit complete examination of parts under pressure. The hydrostatic test shall be considered satisfactory when no casing or casing joint seepage or leaks are observed for a minimum of 30 minutes.

6.3.4 Performance Test

6.3.4.2 (mod) Performance test shall be carried out in accordance with ISO 9906, Rotor dynamic pumps-Hydraulic performance acceptance tests

Grades 1 and 2 unless otherwise specified, the Vendor shall operate the pump in the shop for a sufficient period for him to



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obtain at least five points of complete test data, including head, capacity, and power. These five data points shall normally be shutoff, minimum continuous stable flow, midway between minimum and rated flows, rated flow, and 110 per cent of rated flow.

The Vendor shall maintain a complete detailed log of all final tests and shall prepare the required number of copies, including test curves and data, certified as to correctness. All running tests and mechanical checks shall be completed by the Vendor prior to the final inspection.

Unless otherwise mutually agreed upon, the test speed shall be within 3 per cent of the rated speed. Test results shall be converted

to the rated speed.

Pumps shall be tested with all seals installed. Pumps with double or tandem seals shall have a clean hydrocarbon oil seal fluid

supplied between the two seals.

When operated at rated speed and rated capacity, pumps shall be within the following tolerances of the guaranteed characteristics or the test equivalent (on both regular and suppression tests).

Tolerances of Guarantee Characteristics:

CONDITION GUARANTEE POINTS

(PER CENT) SHUTOFF (a) (PER CENT)

Rated Differential Head

Rated Power

NPSHR

-2, +5

+4 (b)

+0

+10, -10

Note: Rated efficiency = minus 1/2 point of efficiency.

a) The as tested shut off head shall comply with the requirements of par 4.1.2. The negative tolerance specified shall be allowed only if the test curve still shows a continuously rising characteristic.



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b) Under any combination of the above. Also refer to Project Spec. No. PDRP-8410-SP-0021 Loading and Penalty Criteria for Rotating Equipment. for penalty on power tolerance.

6.3.4.3 (mod) If the NPSH available exceeds the NPSH required by 1 m or less, at any specified duty point, an NPSH test shall be carried out. In such cases, both the NPSH and the performance test shall be witnessed. The NPSH test shall be in accordance with ISO 9906

(Rotor dynamic pumps-Hydraulic performance acceptance tests Grades 1 and 2).

NPSHR data shall be taken at the following four points: minimum continuous stable flow, midway between minimum and rated flows, rated flow, and 110 per cent of rated flow.

A vacuum tank suppression test is preferred; NPSH testing by suction valve throttling may be used when mutually agreed upon.

If the NPSHA exceeds the NPSHR by 0.5 meters or less the pump will be rejected.

6.3.4.4 (add) The pump shall operate with no undue heating of bearings or

other display of unfavourable operation, such as noise caused by cavitation.

Vibration measurements shall be made and results recorded on the test log at various capacities. Values shall not exceed those given in 4.3.2.

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 will be required unless the reduction in diameter exceeds 5 per cent 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 characteristics after the diameter of the impeller has been reduced.

6.4 Final Inspection

(add) This inspection is subject to witness inspection at the discretion of IOCL's inspector (e.g. an "observed" test).



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DSN 1836

7. PREPARATION FOR DISPATCH

(add) Preparation for dispatch shall be in accordance with the purchase order. It shall be made after all testing and inspection of the equipment has been accomplished and approved by IOCL.

The paint for all exterior surfaces shall be suitable for the environment specified. The paint, preparation and painting

procedures shall be approved by IOCL.

8. (new) SPECIAL TOOLS

Pumps shall be supplied with all special tools necessary to dismantle and assemble the unit.

ANNEX C - Enquiry, Proposal, Purchase Order

C.1 Enquiry

(add) IOCL's data sheet may differ from Annex A.

C.2 Proposals

(add) The vendor's proposal shall include the information listed below:

Evidence of satisfactory experience requirements required by paragraph 1.5.

Brochures.

Copies of IOCL's data sheet(s) with complete vendor's information entered thereon.

Performance curves, which include differential head, efficiency, water NPSHR, and absorbed power, all expressed as functions

of capacity. These curves shall be extended to at least 125 per cent of capacity at peak efficiency. In addition, the head curve for maximum and minimum impeller diameters shall be shown. These curves shall indicate viscosity corrections if applicable.

The eye area of the first-stage impeller and the impeller identification number shall be shown on the curve.

Predicted and guaranteed noise levels.

Preliminary outline and arrangement drawings.



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Typical cross-sectional drawings and literature to describe fully details of the offerings

For vertical sump pumps, the minimum submergence and minimum clearance from sump bottom.

Seal recommendations.

Prime mover details and manufacturer.

Coupling make and model.

A specific statement that the system and all components are in strict accordance with IOCL's Spec. s. (If they are not in strict accordance with the Spec. s, the Vendor shall include a specific list detailing and explaining every deviation. Deviations may include alternative designs or systems equivalent to and guaranteed for the specified duties). The specific statement shall also cover requirements of IOCL's requisition, all specified standards and enquiry documents.

An explicit statement of any deviations from the specified guarantee and warranty (see Section 9).

A specific statement of the fixed number of weeks to effect delivery after receipt of the written order and the complete information.

ANNEX D - Documentation After Purchase Order

D1 (add) After receipt of the written order, the Vendor shall supply IOCL with certified dimensional installation drawings of the complete assembled units. The Vendor's certified drawing shall

show (for the pump, coupling, and driver) identification data, rotation, weight, and adequate dimension data to permit the design of foundation, piping, and wiring connections. All auxiliary piping connections shall be identified with terminations located and sizes indicated. The drawings shall indicate the disassembly clearance.

Vendor's drawings shall be reviewed by IOCL; such review shall not constitute permission to deviate from any requirements in the order unless specifically agreed upon in writing. After the drawings have been reviewed, the Vendor

shall furnish certified copies in the quantity specified.



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DSN 1836

D.2 (add) In addition the information listed below shall be submitted at dates agreed prior to order placement.

1. Analyses as required by para 4.3.1.

2. Major repair procedures (if applicable).

3. Test schedule.

4. Quality control plan.

5. Surface preparation and painting procedure.

6. A drawing showing mechanical seal installation and setting dimensions.

7. Certified hydrostatic test data.

8. Certified performance test curves and data, including head, input power recalculated to the proper specific gravity, and efficiency plotted against capacity. If a NPSH test has not been carried out the water NPSH curve shall be included, drawn from previous test data, for an impeller of the same pattern. The

curve sheet shall include the maximum and minimum diameters of the impeller supplied, the eye area of the first-stage impeller, the identification number of the impeller, and the pump serial number. Viscosity corrections, if applicable, shall be indicated. The certified copies of test curves and data shall be submitted

to IOCL prior to shipment

PDRP-8410-SP-0018_Rev_F1.pdf

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