DOCUMENT NO:ESS-001

DOCUMENT TITLE : ENGINEERING SPECIFICATION SHEET FOR LALITPUR 3 X 660 MW

1.0 GENERAL

This Engineering Selection Sheet provides required Design and Performance Parameters for the LP
Startup Condensate Pumps for Lalitpur Super Critical TPP (3x660 MW) situated in Uttar pradesh. This
has to be read along with pump Technical Specification No:PC:TSP:LPSS: CON-PUMP:001

2.0 EQUIPMENT
2.1 The pumps covered by this specification are identified in the following table.(per boiler)

QTY. DESCRIPTION TAG NOs.

Unit -1 Unit -2 Unit -3

1 CONDENSATE PUMP “A” CPA-01 CPA-02 CPA-03

1 CONDENSATE PUMP “B” CPB-01 CPB-02 CPB-03

3.0 DESIGN AND PERFORMANCE PARAMETERS

Name LP Startup Condensate Pump

Type Horizontal, Centrifugal, Double Suction

Location Out door

Tag Number(s) See section 2.1.

Number of Pumps Required per boiler Two (2)

Number of pumps per project Six (6)

Liquid to be Pumped Condensate Water

Specific Gravity 1.0

pH 8.5 – 9.6

Fluid Temperature Range 10 – 100 oC

Maximum Operating (Design Point)
100 oC
Temperature
Design Fluid Temperature 135 oC
Design Maximum Supply Cooling Water
Fluid Temperature (for Seal Cooling Heat 38oC
Exchanger)
Design Maximum Supply Cooling Water
Fluid Pressure (for Seal Cooling Heat 12 kg/cm2(g)
Exchanger)

Rated Conditions – For Each Pump (Guarantee Case)

Design Flow rate, m³/hr 446

Design Total Developed Head, m Bidder to specify

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DOCUMENT TITLE : ENGINEERING SPECIFICATION SHEET FOR LALITPUR 3 X 660 MW

(Measured at pump discharge flange,

two pumps operating, not including
pump internal suction & discharge
losses)
NPSH avail, m @ design flow rate 5.2

Run-out Conditions – For Each Pump

Flow rate, m³/hr 760

Design Total Developed Head, m.
(Measured at pump discharge flange,
one pump operating, not including 21
pump internal suction & discharge
losses)
NPSH avail, m@ Run-out flow rate 4.9

Suction pipe size ODxTHK in mm 406.4x9.53

Discharge pipe size ODxTHK in mm 323.9x9.53

Construction

Pump materials shall meet or exceed the strength

Materials and corrosion-erosion resistance of the
following listed materials:

Casing Carbon Steel

Impeller 316 Stainless Steel

Shaft 316 Stainless Steel

Seals 316 Stainless Steel

Casing wear rings Nitronic 60

Impeller wear rings 316 Stainless Steel

Base plate Fabricated Steel

4.0 CONDENSATE PUMPS TECHNICAL DATASHEET(To be filled by vendor)

* Items with Asterisk are to be guaranteed by the Supplier.
Name of Pump LP Startup Condensate Pump

Number of pumps offered

Pump Type

Pump Model

Make

Liquid to be pumped

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DOCUMENT TITLE : ENGINEERING SPECIFICATION SHEET FOR LALITPUR 3 X 660 MW

Specific gravity

PH

Service

Fluid Temperature, ºC

Capacity (m3/hr)

At Design Point *

Maximum Flow

Minimum Flow

At Runout Flow *

Total developed head (mlc)

At Design Point *

Maximum Flow

Minimum Flow

At Runout Flow *

NPSH required (mlc)

At Design Point *

Maximum Flow

Minimum Flow

At Runout Flow *

Number of Pump Stages

Pump speed (rpm) at Design Point

Pump speed (rpm) at Runout Flow

Pump Critical Speed (rpm)

Efficiency at Design Point (%) *

Motor Size (kW) *

Brake Horsepower Required (KW)

At Design Point

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At Maximum Flow
Suction weld neck flange
SIZE/RATING/MATL
Discharge weld neck flange
SIZE/RATING/MATL
Impeller diameter for design conditions, mm.

Maximum impeller diameter, mm.

Minimum impeller diameter, mm.

Minimum recirculation flow required for safe
operation (m3/hr / temp. rise oC)

Type of Pump Bearing Lubrication

Is Water Cooling Required for Motor
Bearings? (m3/hr)/temp./max. particle size
Type Radial Bearings

Type Thrust Bearing - Make

Type Couplings - Make

Suction and Discharge Nozzles

Suction Pump Nozzle Size/Rating

Discharge Pump Nozzle Size/Rating

Length x Width of Base Plate, (mm.) (Common

base plate)

Weight of Pump Unit. (kg.)

Total Weight of Pump and Motor, incl.
Baseplate (kg)
Overall sound pressure level for pump/motor
unit without attenuation measured at one
meter from pump unit, dB(A)
Maximum Permissible Change of Design
Point TDH and Capacity from the Specified
Values Without Additional Cost to the Owner
Casing design/hydro pressure (bar)

Shaft diameter, in.

Rotation (looking down from motor end)

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CONTENTS

1.0 GENERAL

2.0 SCOPE OF SUPPLY

3.0 APPLICABLE CODES & STANDARDS

4.0 DESIGN REQUIREMENTS

5.0 EQUIPMENT REQUIREMENTS

6.0 DRAWING REQUIREMENTS

7.0 PAINTING AND SHIPPING REQUIREMENTS

8.0 EXCEPTIONS

APPENDIX A ENGINEERING SELECTION SHEET DOCUMENT [Link]-001 (PROJECT

SPECIFIC)

MOTOR DATA SHEET: PC: TSP: 81059 / Rev 02

PREPARED REVIEWED APPROVED

[Link] [Link] [Link]

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1.0 GENERAL

1.1 These specifications cover the design, engineering, performance, manufacturing and
testing requirements for complete 100% capacity, centrifugal, horizontal, double suction,
pump assemblies with electric motors for the LP start up system condensate pumps.

1.1 The following terms used herein with initial capitalization, whether singular or plural
shall have the following defined meanings:

Customer / Project As specified in Purchase Document

Purchaser BHEL

Supplier To be selected by BHEL

1.2 The specification is intended to cover all of the work. Unless expressly excluded, any and
all equipment, labor, material and services not indicated therein but which may be
necessary to complete any part of the work in a proper, substantial and workmanlike
manner shall be furnished by the Seller without additional cost to the Purchaser. Any
intended omission or exceptions to the requirements of this Specification are included in
the “EXCEPTIONS TO THE SEPCIFICATIONS” sheet.

1.3 These specifications establish the requirements for the condensate pumps and
appurtenances, as specified therein. The requirements of these specifications are the
minimum for the equipment and are to be supplemented by the Supplier’s own
requirements.

1.4 The Supplier shall comply with all of the requirements of these specifications. Approval
of any drawings and/or test results shall in no way relieve the Supplier from these
responsibilities.

2.0 SCOPE OF SUPPLY

2.1 BY SUPPLIER

2.1.1 It is the intent to have the Supplier provides each pump and driver
mounted on a common base plate, designed for minimum field
installation and assembly.
2.1.2 Equipment tag nos. for each pump / motor – As specified in data
sheet
2.1.3 The equipment, material and services to be supplied by the Supplier
shall consist of the following:
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a. The scope shall include each pump unit with all equipment, such
as motors, coupling with guard, mechanical seal, seal cooling
plan, base plate companion flanges with fasteners, anchor bolts
with fasteners and auxiliaries fully assembled and wired,
requiring only connection to BHEL piping, electrical and
control systems. Final alignment will be performed during pump
installation.
b. All equipment shop tests as specified herein.
c. Expedited schedules, drawings, procedures, pump and motor
curves, test reports and other documents and information
specified herein.
d. List of commissioning/mandatory spare parts for the pumps,
motors and accessories.

2.2 EXCLUSIONS

2.2.1 The following items are not covered

a. Civil foundation
b. Grouting for attaching the pump/driver common base plate to the
foundation
c. Piping and accessories not specified herein.
d. Erection/Installation of equipment
e. Instruments and controls, unless otherwise specified herein.
f. External electrical wiring and conduit.
g. Motor starting equipment.

3.0 APPLICABLE CODES AND STANDARDS

3.1 The publications listed below form a part of these specifications as applicable.
This publication listing is intended to identify the codes and standards applicable
to the design, fabrication and erection of the condensate pumps, but may not be
all inclusive. The seller shall comply with all applicable codes and standards,
whether or not identified in this listing. The text refers to these publications by
the basic designation only. When specific requirements are stated in these
specifications conflict with those required by codes and standards listed herein,
the more stringent requirement, as interpreted by the Purchaser, shall govern.
Such conflict shall be brought to the Purchaser’s attention in writing for
disposition.

3.2 The design, materials, manufacturing, fabrication, inspection, testing and

documentation of all equipment shall be in strict accordance with the latest
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edition and revision, in force as of the date of the purchase order, of the
following codes and standards.

a. American National Standards Institute (ANSI)

b. American Society for testing and materials (ASTM)
c. American society of Mechanical Engineers (ASME)
d. American Institute of Steel construction (AISC)
e. American welding society (AWS)
f. Anti friction bearing manufacturer’s Association (AFBMA)
g. Heat exchanger institute (HEI)
h. Hydraulic institute (ANSI/HI)
i. International Building code (IBC)
j. International Electro technical Commission (IEC)
k. Instrument Society of America (ISA)
l. Institute of Electrical and Electronics Engineers (IEEE)
m. National Electric Code (NEC)
n. National Electrical Manufacturers Association (NEMA)
o. Steel Structure’s Painting Council (SSPC)
p. Tubular Exchange Manufacturer’s Association (TEMA)
q. Indian Standard IS5120, Technical requirements for Roto dynamic
special purpose pumps.

3.3 Additionally, the pumps shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment will be installed.

3.4 The seller shall indicate the standards and codes to be used and shall list all
differences.

3.5 All drawings and data sheets shall be in Metric units / SI units. All words shall be
in the English language.

4.0 DESIGN REQUIREMENTS

4.1 General

4.1.1 The condensate pumps will be used to transfer hot condensate water
from the Flash tank Drain tank (FTDT) to the main steam turbine
condenser hotwell for reuse. Operation of the pumps will be
intermittent, used during plant start up and shut down operations, and
may be used on a more continuous basis during normal plant
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operations. In case of one pump failure, the other pump should have
the capability to deliver the runout flow as indicated in the datasheet.

4.1.2 Each pump shall be designed for operation using the criteria
specified in Document [Link]-001 “Engineering selection sheet for
condensate pumps”.

4.1.3 The supplier/manufacturer’s standard methods of construction and

pump design for the requested service conditions shall be provided
unless specifically excluded by these specifications.

4.2 Materials

4.2.1 Pump materials required are identified in Document no. ESS-001

“Engineering selection sheet for condensate pumps”.

4.2.2 Material options with pricing may be provided by the seller, along
with an explanation of the material options advantages,
disadvantages, costs and/or other benefits.

4.3 It is the intent to have the seller provides the pumps complete with drivers, with
each pump/motor combination mounted on a common base plate, designed for
minimum field installation and assembly.

4.4 The equipment specified herein will be installed outdoors at the site located in
India. Design data for this facility is provided in Selection sheet [Link]-001
“Site location information”.

4.5 Type &Arrangement

4.5.1 Each condensate pump shall be a 100% capacity, centrifugal,

horizontal, double suction type pump.

4.5.2 The pumps will be arranged in parallel and will take suction from the
bottom of the flash tank drain tank.

4.5.3 The condensate pumps shall be “Identical” as defined b ANSI/HI

standards for centrifugal pumps.
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4.6 Performance requirements

4.6.1 The performance requirements shall be as per Document [Link]-001

“Engineering selection sheet for condensate pumps”

4.6.2 Each pump shall be designed to meet the following performance:

[Link] The net positive suction head required (NPSHR) shall be

lower than the net positive suction head available (NPSHA)
and must be based on water at guarantee case conditions
listed in document no. ESS-001 “Engineering selection sheet
for condensate pumps”. Net positive suction head correction
factors shall not be applied.

[Link] The pump shall be designed to ensure that there is adequate

margin between the NPSHR and the NPSHA for operation at
run out conditions without pump cavitations at the pump run
out condition.

[Link] The guarantee point total developed head listed in

“Document no. ESS-001 “Engineering selection sheet for
condensate pumps” shall use the discharge connection
centerline as the reference point. Head losses through the
pump, including suction inlet losses and pump casing
friction losses, are not included in the total developed head
listed. Allowance for these losses shall be in addition to the
NPSHA listed.

[Link] The pumps shall be selected and designed to use as much as

possible the seller’s standard production models for
maximum interchangeability of parts between pumps and
ease of maintenance and accessibility.

[Link] The pumps shall be designed for suitable outdoor locations.

[Link] The pump shall be suitable for direct connection to an

electric motor driver.

[Link] The wetted parts of the pump shall be suitable for the fluid
handled by the pump (hot condensate).
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4.7 Operational requirements.

4.7.1 Two (2) or more pumps will be aligned / piped in parallel and will
operate independently from each other.

4.7.2 The pumps shall be capable of operating satisfactorily at flows

ranging from minimum flow to the guarantee case design flow, and
minimum flow to single pump operation maximum (run out) flow
specified in document no. ESS-001 “Engineering selection sheet for
condensate pumps”, without damage to the pumping equipment. The
seller shall specify the minimum flow requirements in ESS-001.

4.7.3 The pumps shall be designed to pump condensate water ranging

from 10 Deg C to 108.3 Deg C without thermal stresses causing
warping, buckling, misalignment, rubbing or other damaging effects.

4.7.4 Internal design clearances shall be adequate to account for pump

shaft deflection.

4.7.5 The pumps shall be designed for intermittent duty and shall be
designed to accommodate the quantity of starts & stops as
recommended by the ANSI / NEMA MG-1.

4.7.6 The pumps shall be designed to operate satisfactorily up to and

including 110% of design speed.

4.8 Pump characteristics

4.8.1 The pump shall be designed with a head capacity characteristic

which rises steadily from pump maximum (run out) capacity to
minimum flow. The pump head at shutoff shall be a minimum of
110% of the design head capacity.

4.8.2 The manufacturer shall indicate the specific speed of his design at
the best efficiency point and the specific speed limitation as imposed
by ANSI/HI.

4.8.3 Pump vibration shall not exceed the acceptable limits for centrifugal
pumps given by ANSI/HI at all discharge rates from minimum flow
to pump maximum flow (run out). The maximum net positive
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suction head required by the pump shall be at least 1.0 meter less
than the NPSH available at the design point.

4.8.4 The pumps shall operate without vapor binding or cavitation at all
operating conditions.

4.8.5 Each pump shall be capable of continuous operation at maximum

flow (run out capacity), minimum flow and minimum NPSHA
without sustaining mechanical damage.

4.9 Characteristic curves

4.9.1 The seller shall submit pump characteristic curves. Preliminary

pump characteristic curves shall be submitted with seller’s proposal.
Curves shall indicate total head, efficiency, brake horsepower, and
required net positive suction head, (basis 3% reduction in pump
head) as ordinates, with capacity in cubic meters per hour as the
abscissa. Final pump characteristic curves are required after award.

4.9.2 These curves shall be submitted for maximum and minimum

impeller designs, which may be fitted to the pump casing and for the
actual impeller design being provided.

4.9.3 The characteristic curves shall indicate pump performance from zero
capacity to the pump run out capacity during single pump operation
and during two pump parallel operation while switching operation
from one pump to the other.

4.9.4 Speed torque and motor performance curves shall also be submitted.

4.10 Testing

4.10.1 The seller shall perform a shop hydrostatic test and non cavitating
performance test.

4.10.2 Additional inspection and testing requirements are defined in the

manufacturing quality plan provided separately

4.10.3 The pumps shall be tested in accordance with HI standards (Level A)

and IS (Indian standard) 5120 at rated speed at the seller’s facility.
Tests shall measure capacity, total head, efficiency and power.
These tests shall form the basis for acceptance of the pumps except
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for vibration and noise. The pumps shall be tested over the range
from shut off head to maximum flow. The duration of the test shall
be minimum one (1) hour. A minimum of five (5) readings,
approximately equidistant shall be taken for plotting the performance
curves.
Note: the negative tolerance on efficiency shall be limited to 2.5%
and not 5% as indicated in Indian standard 5120.

4.10.4 The hydro test pressure on the casing shall be 1.5 times maximum
discharge head or twice the differential head, whichever is higher.
Maximum discharge head is defined as the sum of the shutoff head
and the maximum suction head. The duration of the test shall be
minimum thirty (30) minutes.

4.10.5 In the event of leakage, the procedure for repairs shall be subject to
review by the Purchaser. After the repair, the pump(s) shall be
successfully hydrostatically re-tested at 1.5 times (minimum) the
shut off discharge pressure.

4.10.6 The pump efficiency shall be calculated using the motor

manufacturer’s guaranteed efficiency. The test shall be made with
the motor to be supplied to the customer for the actual pump.

4.10.7 If the shop performance tests indicate the tested pump fails to meet
the guarantees stated herein, the other pump shall be shop tested in
accordance with the stated requirements specified herein.

4.10.8 Any pump not meeting the guarantees shall receive all adjustments,
repairs, additions, or replacements as required at the seller’s expense
for it to meet the guarantees.

4.10.9 Retesting and modifications will be repeated until all performance

guarantees are met or until arrangements are made which are
acceptable to the purchaser. All additional testing will be done at the
seller expense.

4.10.10 Certified test reports containing all test data, pump performance
curves and head capacity curves shall be submitted by the pump
supplier to BHEL.

4.10.11 After the pumps/drivers have been installed at the site, they shall be
subjected to testing. If the site performance is found not to meet the
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requirements regarding vibration and noise as specified the

equipment shall be rectified or replaced by the vendor at no extra
cost to the purchaser.

4.11 Guarantees

4.11.1 The pumps shall be guaranteed to perform at the design point as

indicated in this specification and on the seller’s supplied
performance curves and data sheets. The pumps shall be guaranteed
to operate satisfactorily without pitting, cavitation, excessive
vibration, or excessive noise.

4.11.2 The following parameters shall be guaranteed:

a. Capacity at the design point

b. Total developed head at the design point.
c. Pump speed at design point
d. Pump efficiency at design point without negative tolerance
e. Horsepower required at the design point
f. Maximum shut off head at pump discharge flange
g. No critical speed at or near pump operating speed. All critical
speeds shall be at least 25% greater than the highest operating
speed.
h. A satisfactory test in accordance with the “testing” section of this
specification.

5.0 EQUIPMENT REQUIREMENTS

5.1 Pump construction

5.1.1 A fabricated steel base plate shall be provided which is to be
installed on the customer’s concrete foundation. Each base plate
shall support the pump and its drive assembly. Base plates shall be
provided with a raised lip all around and shall have a threaded drain
connection. Motor mounting provisions shall be acceptable to the
motor manufacturer.

5.1.2 Base plates shall be designed to adequately support the equipment

under all conditions and reaction forces. Equipment bases shall be
designed to accept a connection to the plant grounding system.

5.1.3 Permanently installed lifting eyes or lugs shall be provided for each
pump and motor assembly to facilitate installation and maintenance.
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5.2 Shaft

5.2.1 The pump shaft shall be sized to transmit the power requirements of
the pump during all modes of operation without distortion or
excessive vibration.

5.2.2 The shaft shall be ground and polished over its entire length.

5.2.3 The impeller shall be firmly keyed and secured to the shaft in proper
axial position. It shall be cast in one piece, accurately machined,
finished all over and the water passages finished to the proper
contour. The impellers shall be balanced in two planes to ISO Grade
G6.3, as a minimum and comply with the vibration limits of the
hydraulic institute. In addition to static balancing, impeller and
balancing drum shall be balanced dynamically at or near operating
speed.

5.2.4 Each shaft shall be designed so that no critical speed will occur
within a 25 percent margin of the operating speed of the pump. It is
preferred that the first critical speed of the pump shall occur above
the pump operating speed.

5.3 Shaft couplings

5.3.1 The coupling shall be easily removed for equipment inspection or

maintenance.

5.3.2 Screwed, shrink, or press fits on the shafts are not acceptable
coupling attachment configurations.

5.3.3 The shaft coupling shall be sized to transmit the maximum brake
horsepower requirements of the driven equipment with a service
factor of not less than 2.

5.3.4 Shaft couplings shall be used between all drives and driven
equipment. Couplings shall be attached to driver and driven shafts
by keys. Couplings shall be of the non lubricated, all metal (stainless
steel) flexible disk type. Couplings for motors with ratings less than
250 hp shall have elastomeric elements.

5.4 Shaft sleeves and seals

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5.4.1 Pumps shall be furnished with removable shaft sleeves as required

by system design. Where required, the shaft shall be completely
protected and isolated from the pumped fluid by incorporating
gasketed or similarly sealed joints between the sleeve and the shaft.

5.4.2 Access shall be provided for dismantling the drive shaft coupling and
for maintenance and inspection of the pump seal. The coupling
guard shall be the removable type.

5.4.3 All pumps shall be provided with mechanical shaft seals.

Mechanical shaft seals shall be of the john crane type or equivalent.
Mechanical shaft seals shall be furnished with a complete flushing
system, including interconnecting piping, isolation valves, strainer
and orifice. The flushing system shall be (equal to or better than) an
API flush plan best suited for the single seal system provided with
the pump and utilize the pumped fluid unless otherwise required.

5.5 Casing

5.5.1 The pump casing, including suction connection shall be rated for the
design conditions of the pumping system. Suction and discharge
connections shall be raised faced flanged (ANSI Class 150). The
casing shall be drilled and tapped for venting and draining and
pressure connections with threaded plugs provided. Flange drilling
shall comply with the provisions of ANSI B16.5.

5.5.2 The Pump supplier shall supply one companion suction flange and
one companion discharge flange for each pump. Flanges shall be
ASME Class 150, raised face, weld neck type.

5.5.3 Allowable loads on the pump nozzles shall be provided to BHEL.

The base plate shall be designed to accommodate these loads.

5.5.4 The pumps shall be provided with replaceable front and back wear
rings for casings. Rings utilizing threads are unacceptable.

5.5.5 The pumps shall be supported between bearings with horizontally

split casings. The Pump supplier shall locate the suction and
discharge nozzles in the lower half of the casing to permit rotor
removal without disturbing the connected piping and shall supply
heavy duty carbon steel casings.
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5.5.6 The corrosion allowance for all pump pressure parts shall be a
minimum of 3 mm.

5.6 Bearings

5.6.1 Pump bearings shall be of the anti-friction type with regreasable type
bearing lubrication. Anti-friction bearings shall be designed for
AFBMA L-10 life rating of not less than 40000 hrs at the design
point. Pumps shall be provided with thrust bearings as required by
the system designed to prevent thrust loads from being imposed on
the drive motor bearings.

5.7 Pump accessories

5.7.1 Safety guards shall be provided for protection of personnel from all
exposed moving and/or rotating machine elements. Each guard shall
be fabricated from 20 gauge sheet steel and designed for easy
installation and removal. Necessary supports and accessories shall
be furnished with each guard. Safety guards for horizontal shafts,
shaft couplings etc shall be an OSHA approved design.

5.7.2 Miscellaneous trim: All piping and valves required for seal or
stuffing box injection water, air vent valves, oil level indicators,
grease lubricators and other miscellaneous accessories shall be
furnished by the pump manufacturer. All wetted parts (valve, tubing
etc) shall equal or exceed the corrosion characteristics of the casing
materials.

5.7.3 All fasteners shall be of domestic origin.

5.8 Driver

5.8.1 Each pump shall be supplied with one electric motor each. The type
of electric motor shall be specified in the Technical data sheet
5.8.2 The rating of the pump driver shall be the larger of the following:

a. The maximum power required by the pump from zero discharge

to pump run out discharge at site climatic conditions.

b. 110% of the power required at the duty point at site climatic

conditions.
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5.8.3 Electric motor drivers shall be furnished in accordance with BHEL

motor requirements (see listing in Appendix A).

5.8.4 Normal supply conditions at the Power plant are 415V/3PH/50 Hz (3

wire solidly earthed). The thrust bearings shall be ball type. The
total hydraulic thrust shall be incorporated in the thrust bearing
design capacity.

5.8.5 Bearing lubricating system shall lubricate satisfactorily at 14.6 to

42.5 Deg ambient site temperature range.

5.8.6 Electric motors shall be selected so that their rating will not be
exceeded by the brake horsepower of the pump over its entire
operating range.

5.8.7 Pump supplier shall complete the Motor data sheet in BHEL format
and also indicate rated current, locked rotor current and space heater
power.

5.9 Welding

5.9.1 The welding of pumps shall be in accordance with the Pump

manufacturer’s weld procedures.

5.9.2 Permitted welding processes shall be as specified in the ASME codes

referenced herein and shall include the restrictions and limitations
applicable to those processes as specified.

5.9.3 Preheat and inter pass temperature shall be performed in accordance

with the WPS for dynamic components.

5.9.4 The minimum preheat temperature and maximum inter pass

temperature shall be specified in the WPS.

5.9.5 When weld joint details are specified by the design documents, they
shall be prepared in accordance with the design documents.

5.9.6 Required NDE of welds or components shall be performed in

accordance with the Manufacturer’s Quality Plan.
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[Link] Visual examination of welds may begin immediately after

the completed welds have cooled to near ambient
temperature. However magnetic particle, liquid penetrant
and ultrasonic examinations shall be performed no less than
48 hrs after completion of the welds on quenched and
tempered steels (i.e. ASTM A514 and A517)
5.10 Base plate

5.10.1 Pump supplier shall provide a common fabricated steel base plate for
the pumps and drivers.

5.10.2 Base plate shall be sufficiently rigid to allow shipment with the
driver, mounted without the occurrence of any distortion to the base
plate.

5.10.3 Base plates shall be fabricated steel with integral drip lip or drip pan
and threaded drain connection and shall be designed to provide
common support and maintain proper alignment of the pump and the
motor.

5.11 Noise level and vibration

5.11.1 Pumps shall run smooth without noise and vibration. Noise level
produced individually or collectively (pump and motor) shall not
exceed 85 dB (A) measured at a distance of 1.5 meters from the
outline of equipment source in any direction.

5.11.2 The overall vibration level shall be as per hydraulic institute

standards.

5.12 Marking

5.12.1 A permanently attached corrosion resistant nameplate shall be

affixed at a prominent location on the outside of each condensate
pump and shall include the following information as a minimum.

a. Name of supplier/manufacturer

b. Equipment description (i.e. condensate pump) size, model

number and serial number.

c. Supplier’s shop order number

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d. BHEL’s purchase order number

e. Work order number

f. Conditions of service including service fluid pump capacity,

total head, minimum NPSH required, temperature, specific
gravity, efficiency, brake horsepower and speed.

5.12.2 A rotation arrow shall be permanently attached in a readily visible

area on the motor mounting bracket.

5.12.3 Component parts shall be clearly marked to assure proper assembly

in the field.

5.12.4 Nameplates mounted on equipment shall be attached with stainless

steel pinhead screws, rivets, drive screws or epoxy glue.

5.12.5 Name plates shall be 1/16” to 1.8” (2 mm to 4 mm) thick. The size
of nameplates shall be a minimum of ¾” by 3 inches and include the
tag numbers above. The text shall be sized as large as possible with
size constraints.

5.13 Spare parts

5.13.1 The Pump supplier shall submit a list of all recommended spare
parts. The list is to be based on requirements for normal continuous
operation of the pumps and motors as specified in these
specifications.

5.13.2 The Pump supplier shall submit a recommended spare parts list with
prices for both a three (3) and a five (5) year interval. Spare parts list
shall indicate a summary of the criticality of the various parts relative
to the expected life of the part before failure based on the supplier’s
experience. Spare parts list shall contain all drawing reference
numbers, item numbers, part numbers, a/or catalog numbers
necessary to identify spare parts.

5.13.3 The pump supplier shall quote price separately for mandatory spares
list (if applicable).
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6.0 DRAWING REQUIREMENTS

6.1 General

6.1.1 Fabrication of pumps shall be based on BHEL’s approval on

drawings.

6.1.2 Submitted documents shall reference to BHEL P.O Number.

6.1.3 Any drawings which reflect in attention to or noncompliance with

specification requirements, lacks certification for the specific project
or which is unchecked will be rejected by BHEL for proper
compliance, completion and/or checking.

6.1.4 Additional detailed drawings, where required for approval by BHEL

shall show all information necessary to assure complete knowledge
of the equipment and/or installation.
6.1.5 All drawings, data and documents submitted by the supplier shall be
in the English language system and metric units.

6.2 Documents to be submitted after P.O

6.2.1 Schedule of drawings and documents to be submitted for review,

approval and information with submission dates.

6.2.2 Quality Assurance Plan (QAP)

6.2.3 Detailed general arrangement drawing of pump and driver. This

drawing shall indicate all the design data and information furnished
in the document no. ESS-001 Data sheets.

6.2.4 Pump and driver with static and dynamic loads, details of fixing,
grouting and all base plate anchor bolt hole locations.

6.2.5 Cross section drawing of the pump with complete part list, materials
of construction and relevant standards for each part.

6.2.6 Pump performance curves flow rate versus head, break kilowatts,
efficiency, NPSHR from zero flow to maximum flow and torque-
speed curve.
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6.2.7 Scheme for pump sealing, lubrication and cooling.

6.2.8 Driver dimensional drawing.

6.2.9 Surface preparation and painting procedure.

6.2.10 Catalogues, data sheets and drawings for instruments.

6.2.11 Installation, operations and maintenance manual along with

lubrication schedule.

7.0 PAINTING AND SHIPPING REQUIREMENTS

7.1 Painting and coatings shall be as per QP.

8.0 EXCEPTIONS

8.1 Offer shall be submitted along with “EXCEPTIONS TO THE

SPECIFICATION” (Clause wise)

8.2 If there is no section with the header “Exceptions / Deviations to the

specification” enclosed along with the technical officer, it is interpreted that the
offer is strictly in accordance with the specification without any deviation.

8.3 Any exception / deviation listed and agreed by the purchaser shall become agreed
modification to the specification for that particular contract.
 DOCUMENT NO:ESS-002
DOCUMENT TITLE : ENGINEERING SPECIFICATION SHEET FOR MOUDA(2 X 660 MW)

1.0 GENERAL

This Engineering Selection Sheet provides required Design and Performance Parameters for the LP
Startup Condensate Pumps for Mouda Super Critical TPP (2x660 MW) situated in Mouda Tehsil,
Nagpur district, Maharashtra state. This has to be read along with pump Technical Specification No: PC:
TSP: LPSS: CON-PUMP: 002
2.0 EQUIPMENT
2.1 The pumps covered by this specification are identified in the following table.(per boiler)

QTY. DESCRIPTION TAG NOS.

Unit-1 Unit-2
1 CONDENSATE PUMP “A” 30LCL30AP001 40LCL30AP001
1 CONDENSATE PUMP “B” 30LCL30AP002 40LCL30AP002

3.0 DESIGN AND PERFORMANCE PARAMETERS

Name LP Startup Condensate Pump

Type Horizontal, Centrifugal, Double Suction

Location Out door

Tag Number(s) See section 2.1.
Number of Pumps Required per boiler Two (2)
Number of pumps per project Four (4)

Liquid to be Pumped Condensate Water

Specific Gravity 0.959

pH 6.8 – 7.2

Fluid Temperature Range 15 – 100 oC

Maximum Operating (Design Point)
100 oC
Temperature
Design Fluid Temperature 135 oC
Design Maximum Supply Cooling Water
Fluid Temperature (for Seal Cooling Heat 38oC
Exchanger)
Design Maximum Supply Cooling Water
Fluid Pressure (for Seal Cooling Heat 12 kg/cm2(g)
Exchanger)

Rated Conditions – For each pump (Guarantee Case)

Design Flow rate, m³/hr 500
Design Total Developed Head, m
(Measured at pump discharge flange,
two pumps operating, not including Bidder to Specify
pump internal suction & discharge
losses)

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 DOCUMENT NO:ESS-002
DOCUMENT TITLE : ENGINEERING SPECIFICATION SHEET FOR MOUDA(2 X 660 MW)

NPSH avail, m @ design flow rate 4.87

Run-out Conditions – for each pump

Flow rate, m³/hr 880
Design Total Developed Head, m.
(Measured at pump discharge flange,
one pump operating, not including 25
pump internal suction & discharge
losses)
NPSH avail, m@ Run-out flow rate 4.5

Suction pipe size ODxTHK in mm 406.4x9.53

Discharge pipe size ODxTHK in mm 323.9x9.53

Construction

Pump materials shall meet or exceed the

Materials strength and corrosion-erosion resistance of the
following listed materials:

Casing Carbon Steel

Impeller 316 Stainless Steel

Shaft 316 Stainless Steel

Seals 316 Stainless Steel

Casing wear rings Nitronic 60

Impeller wear rings 316 Stainless Steel
Base plate Fabricated Steel

4.0 CONDENSATE PUMPS TECHNICAL DATASHEET(To be filled by vendor)

* Items with Asterisk are to be guaranteed by the Supplier.
Name of Pump LP Startup Condensate Pump

Number of pumps offered

Pump Type

Pump Model

Make

Liquid to be pumped

Specific gravity

PH

Service

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 DOCUMENT NO:ESS-002
DOCUMENT TITLE : ENGINEERING SPECIFICATION SHEET FOR MOUDA(2 X 660 MW)

Fluid Temperature, ºC

Capacity (m3/hr)

At Design Point *

Maximum Flow

Minimum Flow

At Runout Flow *

Total developed head (mlc)

At Design Point *

Maximum Flow

Minimum Flow

At Runout Flow *

NPSH required (mlc)

At Design Point *

Maximum Flow

Minimum Flow

At Runout Flow *

Number of Pump Stages

Pump speed (rpm) at Design Point

Pump speed (rpm) at Runout Flow

Pump Critical Speed (rpm)

Efficiency at Design Point (%) *

Motor Size (kW) *

Brake Horsepower Required (KW)

At Design Point

At Maximum Flow
Suction weld neck flange
SIZE/RATING/MATL
Discharge weld neck flange
SIZE/RATING/MATL

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 DOCUMENT NO:ESS-002
DOCUMENT TITLE : ENGINEERING SPECIFICATION SHEET FOR MOUDA(2 X 660 MW)

Impeller diameter for design conditions, mm.

Maximum impeller diameter, mm.

Minimum impeller diameter, mm.

Minimum recirculation flow required for safe
operation (m3/hr / temp. rise oC)

Type of Pump Bearing Lubrication

Is Water Cooling Required for Motor
Bearings? (m3/hr)/temp./max. particle size
Type Radial Bearings

Type Thrust Bearing - Make

Type Couplings - Make

Suction and Discharge Nozzles

Suction Pump Nozzle Size/Rating

Discharge Pump Nozzle Size/Rating

Length x Width of Base Plate, (mm.) (Common

base plate)

Weight of Pump Unit. (kg.)

Total Weight of Pump and Motor, incl.

Baseplate (kg)
Overall sound pressure level for pump/motor
unit without attenuation measured at one
meter from pump unit, dB(A)
Maximum Permissible Change of Design
Point TDH and Capacity from the Specified
Values Without Additional Cost to the Owner
Casing design/hydro pressure (bar)

Shaft diameter, in.

Rotation (looking down from motor end)

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CONTENTS

1.0 GENERAL
2.0 SCOPE OF SUPPLY
3.0 APPLICABLE CODES & STANDARDS
4.0 DESIGN REQUIREMENTS
5.0 EQUIPMENT REQUIREMENTS
6.0 DRAWING REQUIREMENTS
7.0 PAINTING AND SHIPPING REQUIREMENTS
8.0 EXCEPTIONS

APPENDIX A ENGINEERING SELECTION SHEET DOCUMENT [Link]-002 (PROJECT

SPECIFIC)

MOTOR DATA SHEET PC: TSP: 81059 / Rev 02

PREPARED REVIEWED APPROVED

[Link] [Link] [Link]

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1.0 GENERAL

1.1 These specifications cover the design, engineering, performance, manufacturing and
testing requirements for complete 100% capacity, centrifugal, horizontal, double suction,
pump assemblies with electric motors for the LP start up system condensate pumps.

1.1 The following terms used herein with initial capitalization, whether singular or plural
shall have the following defined meanings:

Customer / Project As specified in Purchase Document

Purchaser BHEL

Supplier To be selected by BHEL

1.2 The specification is intended to cover all of the work. Unless expressly excluded, any and
all equipment, labor, material and services not indicated therein but which may be
necessary to complete any part of the work in a proper, substantial and workmanlike
manner shall be furnished by the Seller without additional cost to the Purchaser. Any
intended omission or exceptions to the requirements of this Specification are included in
the “EXCEPTIONS TO THE SEPCIFICATIONS” sheet.

1.3 These specifications establish the requirements for the condensate pumps and
appurtenances, as specified therein. The requirements of these specifications are the
minimum for the equipment and are to be supplemented by the Supplier’s own
requirements.

1.4 The Supplier shall comply with all of the requirements of these specifications. Approval
of any drawings and/or test results shall in no way relieve the Supplier from these
responsibilities.

1.5 All documents, drawings and attachments shall be submitted to the Purchaser using SI-
Metric Units and the English language.

2.0 SCOPE OF SUPPLY

2.1 BY SUPPLIER

2.1.1 It is the intent to have the Supplier provides each pump and driver
mounted on a common base plate, designed for minimum field
installation and assembly.
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2.1.2 Equipment tag nos. for each pump / motor – As specified in data
sheet
2.1.3 The equipment, material and services to be supplied by the Supplier
shall consist of the following:

a. The scope shall include each pump unit with all equipment, such
as motors, coupling with guard, mechanical seal, seal cooling
plan, base plate companion flanges with fasteners, anchor bolts
with fasteners and auxiliaries fully assembled and wired,
requiring only connection to BHEL piping, electrical and
control systems. Final alignment will be performed during pump
installation.
b. All equipment shop tests as specified herein.
c. Expedited schedules, drawings, procedures, pump and motor
curves, test reports and other documents and information
specified herein.
d. List of commissioning/mandatory spare parts for the pumps,
motors and accessories.
e. Insulation-if required to meet noise requirements.
f. One lot of any (unused) special tools required for installation and
maintenance, if required.

2.2 EXCLUSIONS

The following items are not covered

a. Civil foundation
b. Grouting for attaching the pump/driver common base plate to the
foundation
c. Piping and accessories not specified herein.
d. Erection/Installation of equipment
e. Instruments and controls, unless otherwise specified herein.
f. External electrical wiring and conduit.
g. Motor starting equipment.

3.0 APPLICABLE CODES AND STANDARDS

3.1 The publications listed below form a part of these specifications as applicable.
This publication listing is intended to identify the codes and standards applicable
to the design, fabrication and erection of the condensate pumps, but may not be
all inclusive. The seller shall comply with all applicable codes and standards,
whether or not identified in this listing. The text refers to these publications by
the basic designation only. When specific requirements are stated in these
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specifications conflict with those required by codes and standards listed herein,
the more stringent requirement, as interpreted by the Purchaser, shall govern.
Such conflict shall be brought to the Purchaser’s attention in writing for
disposition.

3.2 The design, materials, manufacturing, fabrication, inspection, testing and

documentation of all equipment shall be in strict accordance with the latest
edition and revision, in force as of the date of the purchase order, of the
following codes and standards.

a. American National Standards Institute (ANSI)

b. American Society for testing and materials (ASTM)
c. American society of Mechanical Engineers (ASME)
d. American Institute of Steel construction (AISC)
e. American welding society (AWS)
f. Anti friction bearing manufacturer’s Association (AFBMA)
g. Heat exchanger institute (HEI)
h. Hydraulic institute (ANSI/HI)
i. International Building code (IBC)
j. International Electro technical Commission (IEC)
k. Instrument Society of America (ISA)
l. Institute of Electrical and Electronics Engineers (IEEE)
m. National Electric Code (NEC)
n. National Electrical Manufacturers Association (NEMA)
o. Steel Structure’s Painting Council (SSPC)
p. Tubular Exchange Manufacturer’s Association (TEMA)
q. Indian Standard IS5120, Technical requirements for Roto dynamic
special purpose pumps.

3.3 Additionally, the pumps shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment will be installed.

3.4 The seller shall indicate the standards and codes to be used and shall list all
differences.

3.5 All drawings and data sheets shall be in Metric units / SI units. All words shall be
in the English language.
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4.0 DESIGN REQUIREMENTS

4.1 General

4.1.1 The condensate pumps will be used to transfer hot condensate water
from the Flash tank Drain tank (FTDT) to the main steam turbine
condenser hotwell for reuse. Operation of the pumps will be
intermittent, used during plant start up and shut down operations, and
may be used on a more continuous basis during normal plant
operations. In case of one pump failure, the other pump should have
the capability to deliver the runout flow as indicated in the datasheet.

4.1.2 Each pump shall be designed for operation using the criteria
specified in Document [Link]-002 “Engineering selection sheet for
condensate pumps”.

4.1.3 The supplier/manufacturer’s standard methods of construction and

pump design for the requested service conditions shall be provided
unless specifically excluded by these specifications.

4.2 Materials

4.2.1 Pump materials required are identified in Document no. ESS-002

“Engineering selection sheet for condensate pumps”.

4.2.2 Material options with pricing may be provided by the seller, along
with an explanation of the material options advantages,
disadvantages, costs and/or other benefits.

4.3 It is the intent to have the seller provides the pumps complete with drivers, with
each pump/motor combination mounted on a common base plate, designed for
minimum field installation and assembly.

4.4 The equipment specified herein will be installed outdoors at the site located in
India. Design data for this facility is provided in Selection sheet [Link]-002
“Site location information”.

4.5 Type &Arrangement

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4.5.1 Each condensate pump shall be a 100% capacity, centrifugal,

horizontal, double suction type pump.

4.5.2 The pumps will be arranged in parallel and will take suction from the
bottom of the flash tank drain tank.

4.5.3 The condensate pumps shall be “Identical” as defined by ANSI/HI

standards for centrifugal pumps.

4.5.4 Assembly and dismantling of each pump with the drive motor shall
be possible without disturbing the grouting base plate or alignment.

4.6 Performance requirements

4.6.1 The performance requirements shall be as per Document [Link]-002

“Engineering selection sheet for condensate pumps”

4.6.2 Each pump shall be designed to meet the following performance:

[Link] The net positive suction head required (NPSH R ) shall be

lower than the net positive suction head available (NPSH A )
and must be based on water at guarantee case conditions
listed in document no. ESS-002 “Engineering selection sheet
for condensate pumps”. Net positive suction head correction
factors shall not be applied.

[Link] The pump shall be designed to ensure that there is adequate

margin between the NPSH R and the NPSH A for operation at
run out conditions without pump cavitations at the pump run
out condition.

[Link] The guarantee point total developed head listed in

“Document no. ESS-002 “Engineering selection sheet for
condensate pumps” shall use the discharge connection
centerline as the reference point. Head losses through the
pump, including suction inlet losses and pump casing
friction losses, are not included in the total developed head
listed. Allowance for these losses shall be in addition to the
NPSH A listed.

[Link] The pumps shall be selected and designed to use as much as

possible the seller’s standard production models for
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maximum interchangeability of parts between pumps and

ease of maintenance and accessibility.

[Link] The pumps shall be designed for suitable outdoor locations.

[Link] The pump shall be suitable for direct connection to an

electric motor driver.

[Link] The wetted parts of the pump shall be suitable for the fluid
handled by the pump (hot condensate).

4.7 Operational requirements.

4.7.1 Two (2) or more pumps will be aligned / piped in parallel and will
operate independently from each other.

4.7.2 Normal operation will utilize one (1) pump providing rated capacity
with the remaining pump on standby. In case of high level in the
FTDT the second pump will start. Control and monitoring will be
done by a remote distributed control system. (DCS)

4.7.3 The pumps shall be capable of operating satisfactorily at flows

ranging from minimum flow to the guarantee case design flow, and
minimum flow to single pump operation maximum (run out) flow
specified in document no. ESS-002 “Engineering selection sheet for
condensate pumps”, without damage to the pumping equipment. The
seller shall specify the minimum flow requirements in ESS-002.

4.7.4 The pumps shall be designed to pump condensate water ranging

from 10 Deg C to 108.3 Deg C without thermal stresses causing
warping, buckling, misalignment, rubbing or other damaging effects.

4.7.5 Internal design clearances shall be adequate to account for pump

shaft deflection.

4.7.6 The pumps shall be designed for intermittent duty and shall be
designed to accommodate the quantity of starts & stops as
recommended by the ANSI / NEMA MG-1.

4.7.7 The pumps shall be designed to operate satisfactorily upto and

including 110% of design speed.
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4.8 Pump characteristics

4.8.1 The pump shall be designed with a head capacity characteristic

which rises steadily pump maximum (run out) capacity to minimum
flow. The pump head at shutoff shall be a minimum of 110% of the
design head capacity.

4.8.2 At the best efficiency flow condition, the impeller design shall not
exceed the specific speed limitation given by ANSI/HI. The
manufacturer shall indicate the specific speed of his design at the
best efficiency point and the specific speed limitation as imposed by
ANSI/HI.

4.8.3 Pump vibration shall not exceed the acceptable limits for centrifugal
pumps given by ANSI/HI at all discharge rates from minimum flow
to pump maximum flow (run out). The maximum net positive
suction head required by the pump shall be at least 1.0 meter less
than the NPSH available at the design point.

4.8.4 The pumps shall operate without vapor binding or cavitations at all
operating conditions.

4.8.5 Each pump shall be capable of continuous operation at maximum

flow (run out capacity), minimum flow and minimum NPSH A
without sustaining mechanical damage.

4.8.6 The pumps shall be capable of starting with discharge valve fully
open and closed condition.

4.8.7 Pumps shall be designed so that impellers and other accessories of

the pumps are not damaged due to flow reversal

4.8.8 Assembly and dismantling of each pump with drive motor shall be
possible without disturbing the grouting base plate or alignment.

4.9 Characteristic curves

4.9.1 The seller shall submit pump characteristic curves. Preliminary

pump characteristic curves shall be submitted with seller’s proposal.
Curves shall indicate total head, efficiency, brake horsepower, and
required net positive suction head, (basis 3% reduction in pump
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head) as ordinates, with capacity in cubic meters per hour as the

abscissa. Final pump characteristic curves are required after award.

4.9.2 These curves shall be submitted for maximum and minimum

impeller designs, which may be fitted to the pump casing and for the
actual impeller design being provided.

4.9.3 The characteristic curves shall indicate pump performance from zero
capacity to the pump run out capacity during single pump operation
and during two pump parallel operation while switching operation
from one pump to the other.

4.9.4 Speed torque and motor performance curves shall also be submitted.

4.10 Testing

4.10.1 The seller shall perform a shop hydrostatic test and non cavitating
performance test. These tests shall be in accordance with the Test
Code of the Hydraulic Institute Standards.

4.10.2 Additional inspection and testing requirements are defined in the

manufacturing quality plan provided separately

4.10.3 The pumps shall be tested in accordance with HI standards (Level A)

and IS (Indian standard) 5120 at rated speed at the seller’s facility.
Tests shall measure capacity, total head, efficiency and power.
These tests shall form the basis for acceptance of the pumps except
for vibration and noise. The pumps shall be tested over the range
from shut off head to maximum flow. The duration of the test shall
be minimum one (1) hour. A minimum of five (5) readings,
approximately equidistant shall be taken for plotting the performance
curves.
Note: the negative tolerance on efficiency shall be limited to 2.5%
and not 5% as indicated in Indian standard 5120.

4.10.4 The hydro test pressure on the casing shall be 1.5 times maximum
discharge head or twice the differential head, whichever is higher.
Maximum discharge head is defined as the sum of the shutoff head
and the maximum suction head. The duration of the test shall be
minimum thirty (30) minutes.
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4.10.5 In the event of leakage, the procedure for repairs shall be subject to
review by the Purchaser. After the repair, the pump(s) shall be
successfully hydrostatically re-tested at 1.5 times (minimum) the
shut off discharge pressure.

4.10.6 The pump efficiency shall be calculated using the motor

manufacturer’s guaranteed efficiency. The test shall be made with
the motor to be supplied to the customer for the actual pump.

4.10.7 If the shop performance tests indicate the tested pump fails to meet
the guarantees stated herein, the other pump shall be shop tested in
accordance with the stated requirements specified herein.

4.10.8 Any pump not meeting the guarantees shall receive all adjustments,
repairs, additions, or replacements as required at the seller’s expense
for it to meet the guarantees.

4.10.9 Retesting and modifications will be repeated until all performance

guarantees are met or until arrangements are made which are
acceptable to the purchaser. All additional testing will be done at the
seller expense.

4.10.10 Certified test reports containing all test data, pump performance
curves and head capacity curves shall be submitted by the pump
supplier to BHEL.

4.10.11 After the pumps/drivers have been installed at the site, they shall be
subjected to testing. If the site performance is found not to meet the
requirements regarding vibration and noise as specified the
equipment shall be rectified or replaced by the vendor at no extra
cost to the purchaser.

4.11 Guarantees

4.11.1 The pumps shall be guaranteed to perform at the design point as

indicated in this specification and on the seller’s supplied
performance curves and data sheets. The pumps shall be guaranteed
to operate satisfactorily without pitting, cavitation, excessive
vibration, or excessive noise in both single pump operation and
multiple pump parallel operation when pumping uncontrolled against
system head and when starting up or shutting down a pump with
another pump in operation on the header.
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4.11.2 The following parameters shall be guaranteed:

a. Capacity at the design point

b. Total developed head at the design point.
c. Pump speed at design point
d. Pump efficiency at design point without negative tolerance
e. Horsepower required at the design point
f. Maximum shut off head at pump discharge flange
g. No critical speed at or near pump operating speed. All critical
speeds shall be at least 25% greater than the highest operating
speed.
h. A satisfactory test in accordance with the “testing” section of this
specification.

5.0 EQUIPMENT REQUIREMENTS

5.1 Pump construction

5.1.1 A fabricated steel base plate shall be provided which is to be
installed on the customer’s concrete foundation. Each base plate
shall support the pump and its drive assembly. Base plates shall be
provided with a raised lip all around and shall have a threaded drain
connection. Motor mounting provisions shall be acceptable to the
motor manufacturer.

5.1.2 Base plates shall be designed to adequately support the equipment

under all conditions and reaction forces. Equipment bases shall be
designed to accept a connection to the plant grounding system.

5.1.3 Permanently installed lifting eyes or lugs shall be provided for each
pump and motor assembly to facilitate installation and maintenance.
5.2 Shaft

5.2.1 The pump shaft shall be sized to transmit the power requirements of
the pump during all modes of operation without distortion or
excessive vibration.

5.2.2 The shaft shall be ground and polished over its entire length and
shall be adequately sized to withstand all stresses from rotor weight,
hydraulic loads, vibration and torques coming in during operation.
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5.2.3 Each shaft shall be designed so that no critical speed will occur
within a 25 percent margin of the operating speed of the pump. It is
preferred that the first critical speed of the pump shall occur above
the pump operating speed.

5.3 Shaft couplings

5.3.1 The coupling for connecting the pump to the drive motor shall be of
sufficient length to permit installation of the mechanical seal without
disturbing the driver.
5.3.2 The coupling shall be easily removed for equipment inspection or
maintenance.

5.3.3 Screwed, shrink, or press fits on the shafts are not acceptable
coupling attachment configurations.

5.3.4 The shaft coupling shall be sized to transmit the maximum brake
horsepower requirements of the driven equipment with a service
factor of not less than 2.

5.3.5 Shaft couplings shall be used between all drives and driven
equipment. Couplings shall be attached to driver and driven shafts
by keys. Couplings shall be of the non lubricated, all metal (stainless
steel) flexible disk type. Couplings for motors with ratings less than
250 hp shall have elastomeric elements.

5.4 Shaft sleeves and seals

5.4.1 Pumps shall be furnished with removable shaft sleeves as required

by system design. Where required, the shaft shall be completely
protected and isolated from the pumped fluid by incorporating
gasketed or similarly sealed joints between the sleeve and the shaft.

5.4.2 Access shall be provided for dismantling the drive shaft coupling and
for maintenance and inspection of the pump seal. The coupling
guard shall be the removable type.

5.4.3 All pumps shall be provided with mechanical shaft seals.

Mechanical shaft seals shall be of the john crane type or equivalent.
Mechanical shaft seals shall be furnished with a complete flushing
system, including interconnecting piping, isolation valves, strainer
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and orifice. The flushing system shall be (equal to or better than) an

API flush plan best suited for the single seal system provided with
the pump and utilize the pumped fluid unless otherwise required.

5.4.4 Seal cooling water requirements shall be stated in the proposal.

Pumps shall be cooled by the pumped fluid where practicable. If not
practicable, provisions for bearing cooling from an external source of
cooling water shall be provided. Any external piping required shall
be furnished. Supplier to submit type plan proposed and required
cooling water flows and differential pressures based upon a cooling
water maximum supply temperature of 36 °C.

5.4.5 Renewable type fine finished shaft sleeves shall be provided at the
stuffing boxes/mechanical seals. Length of the shaft sleeves must
extend beyond the outer faces of gland packing of the seal and plates
so as to distinguish between the leakage between shaft and shaft
sleeve and that past the seals/gland.

5.4.6 Shaft sleeves shall be fastened to the shaft to prevent any leakage or
loosening. Shaft and shaft sleeve assembly should ensure concentric
rotation.

5.5 Casing

5.5.1 The pump casing, including suction connection shall be rated for the
design conditions of the pumping system. Suction and discharge
connections shall be raised faced flanged (ANSI Class 150). The
casing shall be drilled and tapped for venting and draining and
pressure connections with threaded plugs provided. Flange drilling
shall comply with the provisions of ANSI B16.5.

5.5.2 The Pump supplier shall supply one companion suction flange and
one companion discharge flange for each pump. Flanges shall be
ASME Class 150, raised face, weld neck type.

5.5.3 Allowable loads on the pump nozzles shall be provided to BHEL.

The base plate shall be designed to accommodate these loads.

5.5.4 The pumps shall be provided with replaceable front and back wear
rings for casings. Rings utilizing threads are unacceptable.
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5.5.5 The pumps shall be supported between bearing with horizontally

split casings. The Pump supplier shall locate the suction and
discharge nozzles in the lower half of the casing to permit rotor
removal without disturbing the connected piping and shall supply
heavy duty carbon steel casings.

5.5.6 The corrosion allowance for all pump pressure parts shall be a
minimum of 3 mm.

5.6 Bearings

5.6.1 Pump bearings shall be of the anti-friction type with regreasable type
bearing lubrication. Anti-friction bearings shall be designed for
AFBMA L-10 life rating of not less than 40000 hrs at the design
point. Pumps shall be provided with thrust bearings as required by
the system designed to prevent thrust loads from being imposed on
the drive motor bearings.

5.6.2 Proper lubricating arrangement for the bearings shall be provided.

The design shall be such that the bearing lubricating element does
not contaminate the liquid pumped. Where there is a possibility of
liquid entering the bearings suitable arrangement in the form of
deflectors or any other suitable arrangement must be provided ahead
of bearings assembly.

5.7 Pump accessories

5.7.1 Safety guards shall be provided for protection of personnel from all
exposed moving and/or rotating machine elements. Each guard shall
be fabricated from 20 gauge sheet steel and designed for easy
installation and removal. Necessary supports and accessories shall
be furnished with each guard. Safety guards for horizontal shafts,
shaft couplings etc shall be an OSHA approved design.

5.7.2 Miscellaneous trim: All piping and valves required for seal or
stuffing box injection water, air vent valves, oil level indicators,
grease lubricators and other miscellaneous accessories shall be
furnished by the pump manufacturer. All wetted parts (valve, tubing
etc) shall equal or exceed the corrosion characteristics of the casing
materials.

5.7.3 All fasteners shall be of domestic origin.

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5.8 Driver

5.8.1 Each pump shall be supplied with one electric motor each. The type
of electric motor shall be specified in the Technical data sheet

5.8.2 The rating of the pump driver shall be the larger of the following:

a. The maximum power required by the pump from zero discharge

to pump run out discharge at site climatic conditions.

b. 110% of the power required at the duty point at site climatic

conditions.

5.8.3 Electric motor drivers shall be furnished in accordance with BHEL

motor requirements (see listing in Appendix A).

5.8.4 Normal supply conditions at the Power plant are 415V/3PH/50 Hz (3

wire solidly earthed). The thrust bearings shall be ball type. The
total hydraulic thrust shall be incorporated in the thrust bearing
design capacity.

5.8.5 Bearing lubricating system shall lubricate satisfactorily at 14.6 to

42.5 Deg ambient site temperature range.

5.8.6 Electric motors shall be selected so that their rating will not be
exceeded by the brake horsepower of the pump over its entire
operating range.

5.8.7 Pump supplier shall complete the Motor data sheet in BHEL format
and also indicate rated current, locked rotor current and space heater
power.

5.9 Welding

5.9.1 The welding of pumps shall be in accordance with the Pump

manufacturer’s weld procedures.

5.9.2 Permitted welding processes shall be as specified in the ASME codes

referenced herein and shall include the restrictions and limitations
applicable to those processes as specified.
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5.9.3 Preheat and inter pass temperature shall be performed in accordance

with the WPS for dynamic components.

5.9.4 The minimum preheat temperature and maximum inter pass

temperature shall be specified in the WPS.

5.9.5 When weld joint details are specified by the design documents, they
shall be prepared in accordance with the design documents.

5.9.6 Required NDE of welds or components shall be performed in

accordance with the Manufacturer’s Quality Plan.

5.9.7 Visual examination of welds may begin immediately after the

completed welds have cooled to near ambient temperature. However
magnetic particle, liquid penetrant and ultrasonic examinations shall
be performed no less than 48 hrs after completion of the welds on
quenched and tempered steels (i.e. ASTM A514 and A517)

5.10 Base plate

5.10.1 Pump supplier shall provide a common fabricated steel base plate for
the pumps and drivers. Base plates shall be designed to adequately
support the equipment under all conditions and reaction forces.

5.10.2 Base plate shall be sufficiently rigid to allow shipment with the
driver, mounted without the occurrence of any distortion to the base
plate.

5.10.3 Base plates shall be fabricated steel with integral drip lip or drip pan
and threaded drain connection and shall be designed to provide
common support and maintain proper alignment of the pump and the
motor.

5.10.4 Base plate and pump supports shall be so constructed as to minimize

misalignment caused by mechanical forces such as normal piping
strain, internal differential thermal expansion and hydraulic piping
thrust.
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5.11 Impellers
5.11.1 The impeller shall be firmly keyed and secured to the shaft in proper
axial position. It shall be cast in one piece, accurately machined,
finished all over and the water passages finished to the proper
contour. The impellers shall be dynamically balanced, either
separately or as part of the shaft assembly.
5.11.2 Impeller shall be closed, semi-closed or open type and designed in
conformance with detailed analysis of the condensate being pumped.

5.11.3 The impeller shall be secured to the shaft, and shall be retained
against circumferential movement by keying, pining, or lock rings.

5.12 Impeller/casing Wear Rings

5.12.1 Replaceable type wear rings shall be provided at suitable locations of
pumps per manufacturer’s standard practice. Suitable method of
locking the wear ring shall be used.
5.12.2 The pumps shall be provided with replaceable front and back wear
rings for casings and impellers. Rings utilizing threads are
unacceptable. When impeller ring and impeller material are the
same, rings may be cast integral with impeller.

5.13 Noise level and vibration

5.13.1 Pumps shall run smooth without noise and vibration. Noise level
produced individually or collectively (pump and motor) shall not
exceed 85 dB (A) measured at a distance of 1.5 meters from the
outline of equipment source in any direction.

5.13.2 The overall vibration level shall be as per hydraulic institute

standards.

5.14 Marking

5.14.1 A permanently attached corrosion resistant nameplate shall be

affixed at a prominent location on the outside of each condensate
pump and shall include the following information as a minimum.

a. Name of supplier/manufacturer
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b. Equipment description (i.e. condensate pump) size, model

number and serial number.

c. Supplier’s shop order number

d. BHEL’s purchase order number

e. Work order number

f. Conditions of service including service fluid, pump capacity,

total head, minimum NPSH required, temperature, specific
gravity, efficiency, brake horsepower and speed.

5.14.2 A rotation arrow shall be permanently attached in a readily visible

area on the motor mounting bracket.

5.14.3 Component parts shall be clearly marked to assure proper assembly

in the field.

5.14.4 Nameplates mounted on equipment shall be attached with stainless

steel pinhead screws, rivets, drive screws or epoxy glue.

5.14.5 Name plates shall be 1/16” to 1.8” (2 mm to 4 mm) thick. The size
of nameplates shall be a minimum of ¾” by 3 inches and include the
tag numbers above. The text shall be sized as large as possible with
size constraints.

5.15 Spare parts

5.15.1 The Pump supplier shall submit a list of all recommended spare
parts. The list is to be based on requirements for normal continuous
operation of the pumps and motors as specified in these
specifications.

5.15.2 The Pump supplier shall submit a recommended spare parts list with
prices for both a three (3) and a five (5) year interval. Spare parts list
shall indicate a summary of the criticality of the various parts relative
to the expected life of the part before failure based on the supplier’s
experience. Spare parts list shall contain all drawing reference
numbers, item numbers, part numbers, a / or catalog numbers
necessary to identify spare parts.
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5.15.3 The pump supplier shall quote price separately for mandatory spares
list (if applicable).

6.0 DRAWING REQUIREMENTS

6.1 General

6.1.1 Fabrication of pumps shall be based on BHEL’s approval on

drawings.

6.1.2 Submitted documents shall reference to BHEL P.O Number.

6.1.3 Any drawings which reflect in attention to or noncompliance with

specification requirements, lacks certification for the specific project
or which is unchecked will be rejected by BHEL for proper
compliance, completion and/or checking.

6.1.4 Additional detailed drawings, where required for approval by BHEL

shall show all information necessary to assure complete knowledge
of the equipment and/or installation.
6.1.5 All drawings, data and documents submitted by the supplier shall be
in the English language system and metric units.

6.2 Documents to be submitted after P.O

6.2.1 Schedule of drawings and documents to be submitted for review,

approval and information with submission dates.

6.2.2 Quality Assurance Plan (QAP)

6.2.3 Detailed general arrangement drawing of pump and driver. This

drawing shall indicate all the design data and information furnished
in the document no. ESS-002 Data sheets.

6.2.4 Pump and driver with static and dynamic loads, details of fixing,
grouting and all base plate anchor bolt hole locations.

6.2.5 Cross section drawing of the pump with complete part list, materials
of construction and relevant standards for each part.
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6.2.6 Pump performance curves flow rate versus head, break kilowatts,
efficiency, NPSHR from zero flow to maximum flow and torque-
speed curve.

6.2.7 Scheme for pump sealing, lubrication and cooling.

6.2.8 Driver dimensional drawing.

6.2.9 Surface preparation and painting procedure.

6.2.10 Catalogues, data sheets and drawings for instruments.

6.2.11 Installation, operations and maintenance manual along with

lubrication schedule.

7.0 PAINTING AND SHIPPING REQUIREMENTS

7.1 Painting and coatings shall be as per QP.

8.0 EXCEPTIONS

8.1 Offer shall be submitted along with “EXCEPTIONS TO THE

SPECIFICATION” (Clause wise)

8.2 If there is no section with the header “Exceptions / Deviations to the

specification” enclosed along with the technical officer, it is interpreted that the
offer is strictly in accordance with the specification without any deviation.

8.3 Any exception / deviation listed and agreed by the purchaser shall become agreed
modification to the specification for that particular contract.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 1 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

09

08

07

06

05

04

03

02 07.11.13 Generally revised [Link] [Link] [Link]

01 15.07.03 Generally revised [Link] [Link] [Link]

00 03.06.02 Fresh issue -Sd- -Sd- -Sd-

[Link] [Link] [Link]

REV. DATE ALTERATION PREPARED CHECKED APPROVED

 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 2 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

1.0 SCOPE

1.1 This standards specifies the requirement of HT & LT MOTORS for use in
Utility/Captive Power Plants.

1.2 Wherever the specification requires information to be furnished by the tenderer /

supplier, the same shall be furnished in the offer.

2.0 CODES & STANDARDS

2.1 Three phase induction motors : IS :325

2.2 Single phase AC motors : IS : 996
2.3 Crane duty motors : IS : 3177
2.4 DC motors/generators : IS : 4722
2.5 Energy Efficient Motors : IS : 12615 02

Motors conforming to equivalent international standards shall also be considered,

provided the same ensures equal or better features compared to the standards
listed above.

3.0 TYPE

AC Motors : Squirrel cage induction motor suitable

for direct on line (DOL) starting
Continuous duty LT motors upto 160 kW
02 output rating (at 50 deg.C ambient
temperature) shall be energy efficient
motors, efficiency class-Eff 1, confirming to
IS 12615
: Crane duty motors shall be slip ring type
induction motor

DC Motors : Shunt wound

4.0 TEMPERATURE RISE

4.1 Air cooled motors : 70 Deg.C by resistance method, over an

ambient of 50 Deg.C (unless specified
otherwise in Project Synopsis) for both class
B& F Insulation.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 3 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

4.2 Water cooled motors with

maximum 38 Deg.C : 77 Deg.C by resistance method for
both cooling water temperature of
class B & F insulation.

5.0 RATING : Continuously rated (S1) unless specified

02 otherwise. Crane duty motors – S4, 40%
Cyclic duration factor.

5.1 Margin : Maximum continuous rating (MCR) shall

have atleast ten percent (10%)
margin over maximum load demand
including voltage and frequency variation.
MCR shall correspond to the above
Temperature rise, and supply variations
given in Annexure – A

6.0 SUPPLY CONDITIONS : Details given in Annexure – A. Motors shall

be capable of withstanding the thermal,
mechanical and electrical stresses when
starting at extreme supply voltage and
frequency limits.

6.1 Supply change over conditions : Motor shall be designed to withstand the
Voltage and torque stresses corresponding
to 150% of the rated voltage, during
change over of buses.

7.0 TORQUE REQUIREMENTS : Motors for reciprocating compressors shall

be designed to withstand the pulsating
torque of the driven equipments.

7.1 Accelerating torque at

minimum permissible voltage : Ten (10) percent in excess of the
driven equipment torque requirement at
any speed.

7.2 Pull out torque at rated

voltage : 205 percent of full load torque. For crane
duty minimum 275 percent of full load
torque.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 4 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

8.0 NUMBER OF STARTS : Two starts in succession under the

specified conditions of load, torque and
inertia with motor initially at it’s normal
running temperature.

9.0 STARTING CURRENT

The ratio of locked rotor KVA at rated voltage to rated KW (MCR corresponding to
the specified temperature rise) shall not exceed the following. No further tolerance
to be considered.

[Link]. MCR Starting KVA/Rated KW

(a) Up to 110 KW 6.0

(b) Above 110 KW 5.5

Starting current of DC motors shall be limited to 200% of the rated current with
starting resistors.

10.0 LOCKED ROTOR WITHSTAND TIME / STARTING TIME

Starting time at Up to 20 seconds More than 20 More than 45

minimum starting seconds but seconds
Voltage less than 45
seconds

Locked rotor with 2.5 seconds more 5 seconds more Ten (10) percent
stand time at than the starting than the starting more than the
highest permissible time time starting time.
voltage

Note: Where above requirements are not met, speed switches shall be mounted
on motor shaft, with prior consent of purchaser.

11 CONTROL

11.1 H T Motors : Any type of circuit breaker including

vacuum.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 5 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

11.2 L T Motors : Up to 160 KW contactor controlled.

Greater than 160 KW circuit breaker
controlled.

12 ENCLOSURE AND METHOD OF COOLING

Enclosure TEFC Enclosure Enclosure Enclosure Enclosure SPDP Method of

Method of CACA CACA CACW Cooling-ICO1
Cooling- Method of Method of Method of
ICO141 Cooling- Cooling- Cooling-ICW
ICO151 ICO161 37A 81

LT Motors HT Motors HT Motors This option is This option is acceptable for

acceptable for circulating water and cooling
HT Motors rated tower motors located
HT Motors above 3000 kw indoors

TEFC - Totally enclosed fan cooled

CACA - Closed air circuit air cooled
CACW - Closed air circuit water cooled
SPDP - Screen protected drip proof

13 ENCLOSURE DEGREE OF : IP 55 for Outdoors.

PROTECTION : IP 54 for Indoors.
: IP 23 for SPDP Motors.
: Flame proof as per relevant
IS & NEC for hazardous areas.

14 VIBRATION AT BEARINGS : Within limits specified in IS : 12705 / BS :

02 4999 rt –142. Motors shall be designed to
withstand the Vibration produced by the
driven equipment.

15 NOISE LEVEL : Within limits specified in IS : 12065

 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 6 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

16 CONSTRUCTIONAL FEATURES

16.1 Component interchangeability : To be ensured for motors of identical

rating & design

16.2 Drain holes : To be provided for totally enclosed motors.

16.3 Cooling Fans

(a) Type : Shaft driven
(b) Direction of rotation : Preferably in either direction. Particularly
where identical motors are used for
opposite direction of rotation.

16.4 Lifting Lug/eye bolts : To be provided.

16.5 Rotors : To be dynamically balanced. Combined

critical speed with driven equipment shall
be away from the running speed by at least
20%.

16.6 Brush : Electrographic or metal graphite type.

Brushes should run for three months with
out the need for replacement.

16.7 Commutator : Industrial Type

16.8 Space heater : Rated for 240 V AC, to be provided for

motors rated above 30 KW

17.0 WINDING AND INSULATION

17.1 (a) Insulation for LT & : Class B or better 02

DC Motors
(b) Insulation for HT motors : Non hygroscopic, preferably epoxy
impregnated type. Class – F.

(c) Stress control & anti- : To be provided for HT Motors.

corona protection
(d) Slot packing for HT Motors : To be impregnated with a conducting
material.
(e) Over hang winding support : Properly braced and blocked.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 7 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

(f) Cage winding : Joints to be braced or welded.

Thermal capacity should take care of
starting duty specified.

17.2 Winding Temperature detector for HT Motors

(a) Type : Platinum resistance temperature

detectors. resistance at Zero Degree C
shall be 100 ohms. Simplex or duplex
type.

(b) Numbers : Six - Evenly distributed around the

stator.

(c) Insulation class of Temp : Same as stator winding insulation

class. Detectors Protective covering
to be provided on leads external to slot.

17.3 All HT motors : To be suitable for VFD operation.

18 BEARINGS

18.1 Type : Roller or other type to suit application. For

vertical motors, thrust bearings may be
kings bury tilting Pad type.

18.2 Lubrication : Self lubricated/Sump oil lubricated/forced oil

lubricated.

18.3 Forced oil lubrication oil pumps : Two (2) numbers, each rated for100%
requirement. In case of failure of the forced
lubricated system, ring oil system shall
provide sufficient lubrication for coasting
down of motor along with driven
equipments.

18.4 Jacking oil pump : If provided , shall preferably meet jacking

oil requirement of motor and driven
equipment.

18.5 Bearing sump accessories : Drain plug, Filling hole and oil level
indicator.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 8 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

18.6 Lubricating oil temperature : 71 Degree C at bearing outlet.

18.7 Instrumentation (for HT motors) : Dial type thermometer with adjustable alarm
Contact & Resistance Temperature
Detectors. (RTD) for each bearing.

RTD type : Duplex, Three wire. Hundred ohms at

zero deg.C.

18.8 Prevention of Shaft Current : For motors above 1000 KW

(a) Bearing insulation : For pedestal mounted bearing, both

bearings to be insulated. Earth bonding link
at drive end bearing.

(b) other measures : Water /oil pipe connections etc. to be

insulated as necessary.
: Insulation to be meggered at 500 volts.

19.0 HEAT EXCHANGERS : To be provided with 15% excess tubes.

19.1 Air to air heat exchangers : For motors rated above 1000 KW, dial type
02 thermo meter with adjustable alarm
contacts shall be provided to measure
primary air inlet and outlet temperature.

19.2 Air to water heat exchanger : Cooler tubes of stainless steel 304 or
70/30 brass.
: Flow switch to be provided.
: Water leakage detector to be provided.
: Pipe flange connections, drain cock, air
release plug etc. shall be external to motor.

19.3 Hydraulic Pressure withstand : 1.5 times the maximum working pressure or
3.5 bar (g) whichever is higher.

20.0 TERMINAL BOX

20.1 General : Separate terminal box for power and

instrumentation.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 9 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

(a) Details of owner’s Cables : Copper/Aluminium conductors. Exact details

to be intimated to successful Bidder.

(b) Glands : Single compression nickeled chrome

finish brass.

(c) Lugs : Tinned copper lugs. For motors rated

higher than 160 KW lugs shall conform to
DIN 46329

20.2 For HT motors : Phase separated type, capable of being

turned through 180 degree. OR provided
with Elastimold-type termination kits.

(a) Distance between gland : Not less than 500 mm

Plate and terminal

(b) Accessories if Elastimold : Complete accessories along with heat

Offered shrinkable trifurcating sleeves for 3
core cable. Where two cables per phase is
envisaged, six sets of apparatus bushing
and elbow connectors are to be provided.

: Metal enclosure with open bottom.

20.3 (A) For LT motors : Terminal box capable of being turned

through 180 degree.

Distance between gland plate & : As follows

Terminals
Minimum distance between
Motor MCR in KW Cable Size center of stud and gland plate
in MM
1 2 3

Up to 3 KW 3Cx2.5 [Link] (Cu) As per manufacture’s practice.

PVC insulated
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 10 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

Above 3 KW – up to 7 KW 3Cx6 [Link] (Al) 85

PVC insulated

Above 7 KW – up to 13 KW 3Cx16 [Link] (Al) 115

PVC insulated

Above 24 KW – up to 37 KW 3Cx70 [Link] (Al) 196

PVC insulated

Above 37 KW – up to 55 KW 3Cx120 [Link] (Al) 249

PVC insulated

Above 55 KW – up to 90 KW 3Cx150 [Link] (Al) 277

XLPE insulated

Above 90 KW – up to 110 KW 3Cx240 [Link] (Al) 331 02

XLPE insulated

Above 110 KW – up to 200 KW 3-1/2Cx300 [Link] (Al) 203 02

XLPE insulated

(B) For HT Motors : At the time of PO

21.0 NEUTRAL CURRENT

TRANSFORMERS (CTs) : Neutral CTs of PS class shall be provided on
02 each phase, for motors rated 2000 kW and
above. These shall be star connected.

21.1 Star formation : In separate terminal box. Terminals to be

brought out through bushings.
21.2 Location of CTs : In above terminal box.

21.3 CT type : Epoxy cast resin class PS. Parameters

to be given to successful Bidder.

22.0 EARTHING TERMINALS : Two numbers, on opposite side

suitable for bolted connection.

23.0 RATING PLATE : To be provided indicating KW rating at

specified cooling medium with corresponding
temperature rise.
: Bearing identification number.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 11 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

: For ball/roller bearing, recommended

lubricant.

24.0 PAINT & FINISH : Minimum one coat of primer and two coats
of finished enamel paint. Paint shade – 692
for indoors. 631 for outdoors.
02 * Details will be confirmed to successful
bidder

25.0 FASTENERS : Corrosion resistant material or cadmium

plated.
: Current carrying fasteners shall be of
stainless steel/high tensile brass/copper.

26.0 QUALITY ASSURANCE

26.1 All materials, components and equipments covered under this specification shall
be procured. manufactured, erected, commissioned and tested as per a
comprehensive quality assurance program to be approved by the owner. A
complete quality plan shall be furnished for the motor rated above 50 KW. All
welding and brazing operation shall be carried out as per approved welding and
brazing procedure and by qualified welder/brazers.

26.2 The bidder shall also furnish copies of the reference documents/plant
standards/acceptance norms/ test and inspection procedure etc. for Owner’s
review/approval. In these approved quality plans, Owner shall identify customer
hold points(CHP), which shall be carried out in the presence of the Owner’s
representative and beyond which work shall not proceed with out the consent of
Owner’s representative in writing.

26.3 Owner reserves the right to witness any of the tests and verify the documents of
the contractor and his sub contractor. No materials/equipments shall be dispatched
from the manufacturer’s works before the same is duly cleared for dispatch by the
Owner.

26.4 All the sub vendors proposed by the Contractor for procurement of major bought
out items including raw materials, semi- finished components shall be subject to
Owner’s approval.

26.5 The Contractor shall carry out an inspection and testing program during
manufacture in his works, and that of his sub- contractor’s to ensure the
mechanical accuracy of components, compliance with drawings, conformance to
functional and performance requirements, identity and acceptability of all
materials,parts and equipments. He shall carry out all tests/ inspection required to
 Bharat Heavy Electricals Limited
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ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 12 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

establish that the items/equipments conform to requirements of the specification

and the relevant codes/standards specified in the specification , in addition to carry
out tests as per the approved Quality plan.

26.6 Quality audit/ surveillance/ approval of the results of the test and inspection will
not, however, exclude the right of the Owner to reject the equipment if it does not
comply with the specification when erected or does not give complete satisfaction
in service and the above shall in no way limit the liabilities, and responsibilities of
the contractor in ensuring complete conformance of the materials / equipments
supplied to relevant specification, standard, data sheets, drawing etc.

26.7 Indicating tests/checks to be carried out for the motors rated above 50 KW during
manufacturing are to be listed by manufacturer.

27.0 TESTS

(a) All motors shall be subjected to routine tests. All LT motors shall be of type
tested quality. For each type and rating of HT motor, type tests, shall be
carried out.

(b) The tests shall be carried out as per applicable standards including all
special tests. The list of routine tests and type tests are given below:

27.1 Induction motors

27.2 Routine Test

For all the motors:

(a) Visual check

(i) Marking on rating plates.

(ii) Appearance and painting
(iii) Location and details of terminal boxes and accessories
(iv) Check for phase sequence and terminal markings.

(b) Dimensional check

(c) Insulation resistance test for winding, space heater and RTD

(d) Measurement of resistance of windings, space heater and RTD

 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 13 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

(e) High voltage test on windings, space heater and RTD followed by insulation
resistance test.

(f) No load test.

(g) Locked rotor test (For all the ratings of motors as per IS 4029)

(h) Reduced voltage running test at no load.

(i) Over speed test.

(j) Vibration measurement at rated speed and rated voltage.

(k) Degree of protection test for IP 54 & IP 55 enclosure (It shall not be
possible to insert a feeler gauge of 0.1 mm thick in the enclosure or flange
faces)

Additional routine tests for HT motors only

(l) Shaft voltage measurement.

(m) Tan delta tests on windings and also on individual phases. 02

(n) Polarization index measurement (The PI value with 2.5 KV shall be not less
than 2.0)

(o) Measurement of bearing temperature during steady state conditions.

(p) Functional check on auxiliaries.

27.3 Type Tests

For all the motors.

(a) All the tests as listed under routine tests.

(b) Measurement of noise at no load.

(c) Momentary overload test.

(d) Full load test to determine efficiency, power factor and slip. 02

(e) Pull out torque measurement.

 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 14 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

(f) Temperature rise test During test winding temperature, bearing

temperature, core temperature, coolant flow and its temperature shall be
recorded at various intervals In case the test is carried out at other than
rated load specific approval for the test method and procedure shall be
obtained. Wherever ETD’s are provided the temperature shall be measured
by ETD also.

(g) Degree of protection test for the enclosure followed by IR, HV and no load
run test.

(h) Fault level withstand test for terminal box. (For breaker controlled motors
only).

(i) Measurement of no load starting time & starting current.

Additional type tests for HT motors only.

(j) No load saturation and loss curves (up to approximately 115% of rated
voltage)

(k) Surge withstand test for main insulation on a sample coil after placing it in
stator
Core with at least five impulses on 1.2/50 micro sec. Wave at test voltages
indicated in Annexure – A

(l) Surge withstand test for inter turn insulation on each type of motor coil
with at least five impulses of 0.3/3 micro sec. At test voltages indicated in
Annexure–A This test shall be followed by one minute power frequency
high voltage test on turn to turn insulation after cutting the coil and
bringing out turns suitably. The test voltage shall be mutually agreed upon.

(m) Determination of magnetic center (for pedestal mounted bearing motors

only.)

27.4 When tests to determine the break away starting current of cage induction motors
are taken at reduced voltage, due allowance shall be made for the effect of
saturation and the estimated value of break away starting current at rated voltage
shall be given on all test certificates.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 15 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

27.5 DC motors shall be subjected to all routine and type tests as per IS :4722. In
addition following tests shall be carried out.
(a) Noise level measurement as type test.

(b) Vibration measurement as routine test.

(c) Degree of protection test as per IS:4691 as type test.

28.0 COMMISSIONING CHECKS (If called for)

Commissioning checks should be carried out as per IS: 900 and other relevant
standards.

29.0 DOCUMENTS REQUIRED

29.1 With bid (3 sets)

(a) Filled in motor data sheet

(b) Catalogue
(c) Q.P
(d) Compliance / Deviation list

29.2 With supplies (15 Sets)

(a) Filled in motor data sheet

(b) Catalogue
(c) Q.P
(d) Test report.
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 16 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

ANNEXURE - A

TECHNICAL PARAMETERS FOR MOTORS

11KV SYSTEM 3.3/6.6 KV 415/380 V 220 V DC

SYSTEM SYSTEM

1.0 Supply system

a) Nominal system volt 11KV 3.3/6.6 KV 415/380/240 V 220 V
b) Voltage variation +/- 6% +/-10% +/-10% 190 to
c) Frequency 50 Hz 50 Hz 50 Hz 240V
d) Frequency variation + 5 to –5% + 5 to –5% +5 to –5%
e) Combined voltage and 10% 10% 10%
frequency variation

> 160 KW (for < 0.2 KW (for

2.0 Permissible rating in coal handling & 240 V)
each voltage level. ash conveyor
> 1500 KW > 200 KW and > 0.2 & up to
up to 1500 KW 200 KW (for
(for other 415/380 V)
motors.)

-
3.0 Fault Level 40 kA rms for 1 40 kA rms for 1 45 kA rms for 1
02
sec sec sec

4.0 Minimum starting 75% (for more 85% (for up to 80% (for more
voltage available than 4000 KW) 1000 KW) 80% than 110 KW)
80% (> 1500 (> 1000 KW & up 85% (for up to 190 V
KW & up to to 1500 KW 90% 110 KW)
4000 KW) (for coal mill
motor of < 1000
KW)

5.0 Class of insulation Class F with B Class F with B Class B Class B

limits. limits.

6.0 1.2/50 micro sec

impulse withstand 49 KV 19/36 KV -
level for main
insulation
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 17 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

7.0 0.3/3 micro sec

surge withstand level for 32.0 KV 12.0/24.0 KV -
interturn insulation

8.0 High frequency over 27 KV 8/16 KV

voltage test value

9.0 Terminal box

a) Fault withstand level 750 MVA 150/250 MVA 31 MVA (for >
for 0.12 sec. 125 KW)
b) Clearance between 130 mm 70/110 mm* 12.5 mm 02 10mm
bare live parts.
c) Clearance between 120 mm 60/100 mm* 12.5 mm 02
10 mm
bare live parts & earth
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 18 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

ANNEXURE – B

PROFORMA OF MOTOR INFORMATION

Bidder’s name :
1 GENERAL

(i) Manufacturer

(ii) Equipment driven by motor

(iii) Motor type

2 DESIGN AND PERFORMANCE DATA

(i) Frame size

(ii) Type of duty

(iii)Type of enclosure and

method of cooling

(iv) Applicable standard to which

motor generally conforms

(v) Type of mounting

(vi) Direction of rotation as viewed

from non-driving end

(vii) Standard continuous rating at

40deg.C ambient temperature
as per Indian standard (KW)

(viii) Derated rating for specified

normal condition ie. 50deg.C
ambient temperature (KW)

(ix) Rated voltage (Volts)

(x) Rated speed at rated voltage and

frequency (r.p.m)
 Bharat Heavy Electricals Limited
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ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 19 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

(xi) Full load current at rated voltage

and frequency (Amp)

(xii) Power factor at rated load

(xiii) Efficiency of motor at rated voltage and

frequency (without any tolerance) at

a) Design duty point (%)

b) 100% of full load (%)

(xiv) Starting current (amps) at

a) 100% voltage

b) 85% voltage

c) 80% voltage (for boiler feed-

pump only)

(xv) Torques at

a) Starting (Kg-metre)

b) Pull up (Kg-metre)

c) Pull out (Kg-metre)

(xvi) Stator winding insulation

a) Class & type

b) Tropicalised (Yes / No)

c) Temperature rise over specified

ambient of 50deg.C (deg)

(xvii) Stator winding connection

(xviii) Number of stator terminals

brought out
 Bharat Heavy Electricals Limited
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ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 20 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

(xix) Type of terminal box for

a) Stator leads

b) Space heater
c) Temperature detector

(xx) Space heaters

a) Number

b) Location

c) Power requirement (KW)

(xxi) Bearing type

a) Driving end

b) Non driving end

(xxii) Type of construction of rotor

(xxiii) Weight of

a) Motor stator (Kg)

b) Motor rotor (Kg)

c) Total weight (Kg)

(xxiv) Motor starting time (sec)

(xxv) Motor rated torque (Kg-met)

(xxvi) Motor accelerating torque (Kg-met)

NOTE: INDICATE TOLERANCE VALUES AGAINST EACH DATA

 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 21 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

ANNEXURE – C

PROFORMA OF DC MOTOR INFORMATION

Bidder’s name :
1 GENERAL

(i) Manufacturer

(ii) Equipment driven by motor

(iii) Motor type

(iv) Country of origin

2 DESIGN AND PERFORMANCE DATA

(i) Frame size

(ii) Type of duty

(iii) Type of enclosure and

method of cooling

(iv) Applicable standard to which

motor generally conforms

(v) Type of mounting

(vi) Standard continuous rating at

40deg.C ambient temperature
as per Indian standard (KW)

(vii) Derated rating for specified

normal condition ie. 50deg.C
ambient temperature (KW)

(viii) Rated voltage (Volts)

(ix) Range of voltage between which from

Volts to Volts the motor can develop
rated torque
 Bharat Heavy Electricals Limited
Piping Centre Chennai-17

ENGINEERING DEPARTMENT

Rev. No Specification No. Sheet No.

02 PC : TSP : 81059 22 of 22

TECHNICAL SPECIFICATION FOR HT & LT MOTORS

x) Minimum permissible voltage at

which motor can develop the
required starting torque

(xi) Current at

a) Starting at minimum permissible voltage

b) Rated load

(xii) Armature winding

a) Class & type of insulation

b) Tropicalised (Yes / No)

c) Commutator material

(xiii) Shunt winding

a) Class & type of insulation

b) Tropicalisted (Yes / No)

(xiv) Feature incorporated to ensure satisfactory

communication during operation

(xv) Type of terminal box

(xvi) Motor starter (for motor 10 KW above)

a) Type

b) Make

(xvii) Space heater (if provided)

a) Number

b) Location

c) Power requirement (KW)

(xviii) Weight of motor (Kg)

NOTE: INDICATE TOLERANCE VALUES AGAINST EACH DATA

 Bharat Heavy Electricals Limited
Piping Centre Chennai-17
Specification Number [Link]. Sheet Number
PC:TSP:LPSS:CON-PUMP:001 00 1 of 1
TECHNICAL SPECIFICATION FOR CENTRIFUGAL PUMPS-CONDENSATE PUMP FOR
LP STARTUP SYSTEM

ANNEXURE-B
MANDATORY SPARES

DESCRIPTION QTY

i. All Gaskets in one pump 2 set

ii. All O rings in one pump 2 set

iii. Gland packing in one pump 2 set

iv. Impeller 2nos

v. All Pump Bearings in one pump 2 set

vi. Shaft 2 no.

vii. Impeller Lock nut 2 no.

viii. Shaft Protection Sleeve 2 no.

ix. Pump Motor coupling complete 2 set

x. All Wearing rings in one pump 2 set

xi. All Motor Bearings 2 set

xii. Motor 2nos