O & M Manual For Boiler Circulation Pump (BCP)

2 × 660 MW KHARGONE SUPER THERMAL
POWER PROJECT
Owner:
NTPC LIMITED
(A GOVERNMENT OF INDIA ENTERPRISE)
Digitally signed by
EPC Contractor: SOUMYAJIT
MUKHERJEE
LARSEN & TOUBRO LIMITED DN: cn=SOUMYAJIT
MUKHERJEE, c=IN,
o=NTPC,
Architect Engineer: ou=KHARGONE TF,
email=soumyajitmuk
L&T – SARGENT & LUNDY LIMITED
harjee@ntpc.co.in
Reason: cat-IV
Date: 2017.12.27
Vendor: 10:33:14 +05'30'
L&T-MHPS BOILERS PRIVATE LIMITED
QSGM:
L&T – S&L Job No.: LD16005000

L&T Project No.: KHARGONE
Vendor Job No.: 51006
Title: O& M MANUAL FOR BOILER CIRCULATION PUMP (BCP)
Doc./Drg. No.: 51006-41400-1055 Rev No.: 02 Total No. of Pages : 245
NTPC Doc./Drg. No.: 9578-001-102-PVM-W-074 Rev No.: 02 Unit Designation: 1 & 2
Digitally signed
by Debabrata
STAMP: FOR INFORMATION Kundu L&T-S&L Date Name
Date: 2017.12.11
11:27:00 +05'30' Checked 11.12.2017 JB
REVISION STATUS
Rev Prepared Reviewed Approved
No. Name Date Name Date Name Date
0 ---- ----- PKS 06.10.2017 RP 06.10.2017
1 ---- ----- PKS 06.11.2017 RP 06.11.2017
2 ---- ----- PKS 11.12.2017 RP 11.12.2017
Digitally signed by P.Kandasamy Digitally signed by RAJARSHI
DN: cn=P.Kandasamy, o=L&T-MHPS Boilers PAUL
Pvt. Ltd, ou=Engineering, Date: 2017.12.11 10:13:30
email=p.kandasamy@lntmhps.com, c=IN
Date: 2017.12.11 10:09:12 +05'30'
+05'30'
POWER PROJECT
O&M MANUAL FOR Doc. No.: 9578-001-102-PVM-W-074
BOILER CIRCULATION PUMP (BCP) Rev. No.: 02
Larsen & Toubro Ltd. Date: 11.12.2017
REVISION SUMMARY SHEET
Rev
Details / Description Date
No.
00 First submission 06/10/2017
01 No changes in Document. Customer comments had been responded in CRS. 06/11/2017
02 No changes in Document. Customer comments had been responded in CRS. 11/12/2017
Page 2 of 245
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INDEX
Sl.No Doc. No. Description Page Doc. NTPC Transmittal No.

No. Rev. No.
1.0 SECTION-A O&M MANUAL 05 PAGES FROM 05 TO 63
INSTALLATION, 11
General
OPERATION &
12
MAINTENANCE MANUAL Safety precautions
1.1 – BCP Introduction 13
1.2 Description of pumping set 17
1.3 Delivery and Preservation 18
1.4 Installation of Pumping Set and 22
Operating
1.5 Preparation prior to 29 02
Commissioning
1.6 Commissioning and Start-Up 38
1.7 Supervision of Operation 41
1.8 Pump Operation for Boiler Clean up 47
1.9 Dismantling and Reassembly of 49
Pumping Set
1.10 Operational Conditions 58
1.11 Cause and Remedy of Operational 59
Trouble
2.0 SECTION-B CATALOGUE NA NA
- - -
3.0 SECTION-C DRAWINGS & DOCUMENTS 64 PAGES FROM 64 TO 245
3.1 9578-001-102-PVM-B-072 Boiler Start up and Recirculation 65 5 Reference:
(41400-1002) pump Arrangement drawing CC:PE:9578102:7840
3.2 9578-001-102-PVM-Y-016 Data sheet (For Boiler Start up 66 3
(41400-1040) Recirculation Pump including
Motor)
3.3 9578-001-102-PVM-Y-016 Pump Data sheet (Torishima 73 6
(41400-1005) format)
3.4 9578-001-102-PVM-Y-016 Pump performance curve 79 3
(41400-1004)
3.5 9578-001-102-PVM-Y-016 Motor data sheet (NTPC format) 83 4
Reference:
(41400-1006)
CC:PE:9578102:10325
3.6 9578-001-102-PVM-Y-016 Sectional Drawing of Pump/Motor 93 2
(41400-1018)
3.7 9578-001-102-PVM-Y-016 Sectional Dwg for Main Terminal 95 2
(41400-1019) Box
3.8 9578-001-102-PVM-Y-016 Motor Curves 96 1
(41400-1034)
3.9 9578-001-102-PVM-Y-016 Utility list 104 1
(41400-1010)
Page 3 of 245
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3.10 41400-1011 PID for Boiler circulation pump 115 4

3.11 41400-1012 Valves list 116 2
3.12 41400-1013 Instrument list including set points 120 5
3.13 41400-1014 Logic diagram / Control Philosophy 126 1
3.14 41400-1016 I/O List 130 3
3.15 41400-1017 Cable connection drawing 135 1
3.16 41400-1020 Detailed drawing for Motor cooler 136 3
3.17 41400-1021 Detailed drawing for Purge cooler 140 1
3.18 41400-1022 Detailed drawing of Strainer 145 1
3.19 41400-1023 Detailed drawing of Valves 149 2
3.20 41400-1024 Detailed drawing of Major pump 159 1
components
3.21 41400-1025 Drawing & Data sheet of 164 2
Instruments
3.22 41400-1030 Insulation recommendations 189 1
3.23 41400-1032 Terminal point drawing 190 1
3.24 41400-1033 Detail of Bolt heater & Switch box 191 1
3.25 9578-001-102-PVM-B-072 Lifting plan 198 1 Reference:
(41400-1041) CC:PE:9578102:7840
3.26 41400-1058 Special tools list 226 1
3.27 41400-1056 Detailed drawing of Carrier 232 3
3.28 41400-1054 Spares parts list (Commissioning) 233 1
3.29 41400-1053 Spares parts list (Recommended) 237 0
3.30 9578-001-102-PVM-B-067 Circulating water pump handling 245 2 Reference:
(97000-04-AD-0065) arrangement maintenance CC:PE:9578102:10712
information including write-up
procedure
Page 4 of 245
POWER PROJECT
SECTION – A
O&M MANUAL
Page 5 of 245
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
LARSEN & TOUBRO LIMITED
Architect Engineer:
Vendor:
Sub Vendor:
TORISHIMA PUMP MFG. CO., LTD.
L&T – S&L Job No.: LD16005000

Vendor Job No.: 51006 L&T Project No.: KHARGONE
Sub Vendor Job No.: PU0137910/28/36
Title: O & M Manual
NTPC Doc./Drg. No.: Unit Designation: 1 & 2

Stamp: Vendor Date Name Sign
Checked
This document is also applicable for

51006B Unit #2 also. L&T-S&L Date Name
Checked
REVISION STATUS
0 5/8/2016 5/8/2016 5/8/2016
1 9/9/2016 9/9/2016 9/9/2016
2 18/8/2017 18/8/2017 18/8/2017
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(FORMERLY KNOWN AS L&T-MHI BOILERS PRIVATE LIMITED)
Doc. No. 51006-41400-1055
O & M Manual Rev. No.: 2
Larsen & Toubro Ltd.
Date: 18/8/2017
Rev
No.
0 FIRST ISSUE 5/8/2016
1 REVISED 9/9/2016
2 REVISED 18/8/2016
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GLANDLESS HOT CIRCULATION PUMP TYPE
--H L A V-- WET MOTOR TYPE
BCP OPERATION AND MAINTENANCE MANUAL
PRODUCT. NO. PU0114243/PU0114251

PUMP TYPE HLAV 250-630/1K
IMPORTANT !
To assure safe and proper operation, be sure to read this
“INSTRUCTION MANUAL” and the annexed “SAFETY
PRECAUTIONS” prior to installing and using your pump.
TORISHIMA PUMP MFG. CO., LTD

HEAD OFFICE & WORKS : 1-1-8, MIYATA-CHOU, TAKATSUKI-SHI,
OSAKA, JAPAN
TEL : +81-72-695-0551
TELEFAX : +81-72-693-1288
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Contents
Page
GENERAL 6
SAFTY PRECAUTIONS 7
1. Introduction 8
1.1 Pumping Set 8
1.2 Pump 8
1.3 Motor 8
1.4 Motor Cooler 9
1.5 Purge Cooler 9
1.6 Secondary Cooling Water 10
1.7 Life Time of Major Part (for recommendation) 11
2. Description of Pumping Set 12
3. Delivery and Preservation 13

3.1 Condition of Set as Dispatched to Site 13
3.2 Preservation 14
3.3 Long Time Storage of a Motor 16
3.4 Replacement of Terminal Box Silica-gel 16
4. Installation of Pumping Set and Operation 17

4.1 General 17
4.2 Suction Line and Discharge Line 18
4.3 Motor Cooler and Heat Barrier 19
4.4 Filter (Interior) 20
4.5 Temperature Monitor 21
4.6 Cooling of Motor Cooler and of Heat Barrier 22
4.7 Motor Emergency Cooling 23
4.8 Motor Protection Cutout Switch 23
5. Preparation prior to Commissioning 24

5.1 Priming and Venting 24
5.2 Verification of Correct Direction of Motor Rotation 26
5.3 Insulation Test 27
5.4 Drainage of Pump and/or Motor 30
5.5 Motor Flushing 31
5.6 Cleaning of Insulation Bushing 32
6. Commissioning and Start-Up 33

6.1 Pre Operational Check Items 33
6.2 Frequency of Switching On and Off 34
6.3 Pump shutdown procedure 35
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Page
7. Supervision of Operation 36
7.1 Supervision during operation 36
7.2 Inspection Sheet 1. 38
8. Pump Operation for Boiler Clean Up 42
9. Dismantling and Reassembly of Pumping Set 44

9.1 Dismantling 45
9.2 Inspections 47
9.3 Parts Inspection and Re-Assembly 50
9.4 Assembly 52
10. Operational Conditions 53

10.1 “On” Criteria 53
10.2 “Off” Criteria 53
10.3 Alarm Annunciations 53
10.4 Necessary Measures according to the Conditions of the Plant Demand 53
11. Cause and Remedy of Operational Trouble 54

11.1 Instance of abnormality 54
11.2 Research and Remedy 55
2 ATTACHMENT 1. Queries related to erection and commissioning
2 ATTACHMENT 2. Annexure of Dwg For Khargone OM Manual
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General
●The Torishima boiler recirculation pumpset forms an integral part of the system in which
it is installed.
The following instructions should therefore be read in conjunction with the operation and
maintenance manual for the system.
●In order to ensure trouble-free operation of the pumpset, it shall be carefully installed and
properly maintained according to the relevant manuals and instructions.
●The pumpset must not be operated beyond the limit values for the medium handled, flow, speed,
pressure, temperature and motor rating specified in the technical documentation.
Make sure that operation is in accordance with the instructions in this manual and other contract
documents.
●Modifications or alterations of the equipment supplied shall not be made without prior permission
from the manufacturer. Original spare parts and accessories authorized by the manufacturer ensure
safety. The use of third party parts invalidates any liability of the manufacturer for the damage
caused.
●During the validity period of guarantee by Torishima, NO dismantling of the pump or its
individual components shall be carried out without obtaining Torishima’s consent in this respect.
●The pump name plate indicates pump type, main operating data, production No. and unit No.
Please quote this information in all queries, repeat orders and when ordering spare parts.
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SAFETY PRECAUTIONS
This manual contains fundamental information and instructions that must be complied with during
operation of the pumpset.
Non-compliance with the instructions can cause injury of operator, failure of unit functioning and
damage to the pumpset. Therefore, this manual must be read and understood by operators
prior to commissioning and operation.
This manual must always be kept close to the location of operation for easy access and
reference.
Safety Alerts and Warning Notes

The safety instructions and warning notes contained in this manual are marked by symbols as follows.
SYMBOL DESCRIPTION
Potential hazard that could result in death or serious injury
Potential hazard that could result in minor or moderate injury

Alert against unsafe practices
Potential hazard that could result in damage to the equipment
and/or equipment malfunction
Informational notes
Operator qualification
Never allow any person other than operators qualified to operate the pumpset to engage in the
operation of pump.
General safety instructions for operation

●Never touch the casing or other components of pump while it is hot.
●Never open the terminal cover of any electrical device when it is energized. There is a risk
of electric shock.
●Do not start dismantling of the motor until the water temperature in pump casing will be 50 degrees
or less.
●Wear helmet, safety goggles, ear plugs, safety shoes, etc before approaching the pumpset
under operation.
●Confirm there is no excessive leakage from cooling water pipework before approaching the
pumpset in operation.
●Always follow all the rules and regulations in relation to the safe operation of the pump.
Immediately shut down the pump if there is an abnormal noise or vibration.
The pump should be thoroughly inspected and/or serviced before resuming operation.
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1. Introduction
1.1 Pumping Set
- Designation Glandless Circulating Pump

- Service Boiler Recirculation Pump
- Number of sets per unit 1
- Design pressure 315.6 kg/cm2g
- Design temperature
- Pump 345 deg C
- Motor 345 deg C
- Hydrostatic test pressure 473.4 kg/cm2g
1.2 Pump
- Type HLAV250-630/1K
- Fluid pumped Boiler water
- Operating temperature 303.6 deg C
- Capacity 830 m3/h
- Total head 120 m
- NPSHr 5.5 m
- Minimum flow 90 m3/h
- Nominal size
- Suction nozzle OD508 mm X ID382.9 mm
- Discharge nozzle OD406.4mm X ID306.3 mm
1.3 Motor
- Type HLV55/4FQ45-335
- Nominal rating 450 kW
- Nominal speed 1460 rpm
- Frequency 50 Hz
- Voltage 3300 V
- Nominal current 118.2 A
- Starting current 709 A
- Insulation of motor winding Cu-VPE
- Motor trip temp. 66 deg C (at upper motor cavity)
- Motor alarm temp. 63 deg C (at upper motor cavity)
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1.4 Motor Cooler
- Type Shell and Tube

Design conditions of primary side
- Cooled medium Boiler water
- Fouling factor 0.00005 m2Hdeg C/kcal
- Design temperature 345 deg C
Design conditions of secondary side

- Cooled medium Cooling water (Clean water)
- Design pressure 10 kg/cm2g
- Hydrostatic test pressure 15 kg/cm2g
1.5 Purge Cooler
- Type Shell and Tube

Design conditions of primary side
- Cooled medium Boiler water
Design conditions of secondary side

- Cooled medium Cooling water (Clean water)
- Design pressure 10 kg/cm2g
- Hydrostatic test pressure 15 kg/cm2g
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1.6 Secondary Cooling Water
The plant operator is responsible for the provision and monitoring of the secondary cooling water
supply in respect of temperature, quality and rate of flow.
- Heat Barrier
- cooling water quantity required 2.7 m3/h
- Inlet temperature 37.6 degC
- cooling water pressure loss 5 or less m
- emergency cooling water required 1.9 m3/h
- Motor Cooler
- inlet temperature 37.6 degC
- quantity of heat to be eliminated 189000 kJ/h
- cooling water quantity required 11.5 m3/h
- Purge Cooler
- inlet temperature 37.6 degC
- quantity of heat to be eliminated 311110 kJ/h
- cooling water quantity required 15 m3/h
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Cooling Water Quality
Clean, softened water should be provided as low-pressure cooling water. It should be free
from suspended matter, should not precipitate matter out of solution at the prevailing
operating temperatures, and should not be aggressive. pH value ≧ 8.5
Cooling Water Circuit Arrangement
The cooling water circuit between the motor cooler and the heat barrier, together with the
required monitoring devices, must be installed in accordance with the flow sheet attached.
During initial pump operation stages, strainer should be provided in front of flow switch to
protect flow switch from dirt.
1.7 Life Time of Major Part (for recommendation)
No Major Part Name Part No. Life year

1 Pump Casing compl. 1010 20
2 Motor Casing compl. 8110
3 Shaft 2100
4 Impeller 2300
5 Casing Wearing Ring 5020 5-10
6 Plain Bearing Compl. 3100.1, 2 (Please refer to table 9.2
7 Thrust Bearing Segment 3870.1, 2 "Clearance Measuring Record")
8 Bearing Sleeve 5290.1, 2
9 Thrust Bearing Plate 3840
10 Gaskets/O-Ring 4113, 4120 5-10(Shall be replaced with new one in every
11 Washers 5500 dismantling time)
12 Stator Coil 8140 10-15
13 Insulation Busing etc 5202
Note
The design life listed above is not guaranteed life but the expected life in case pump would be used in
general operating condition with appropriate regularly maintenance.
The actual life of parts should vary depending on each individual environment i.e. start-up frequency,
operating time, water quality or surrounding temperature etc.
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2. Description of Pumping Set

Refer to Sectional Drawing (41400-1018)
The pumping set consists mainly of the pump casing (1010), the motor (8110) and the
heat barrier (1520) situated between pump and motor. These components are bolted together
to form a pressure-tight assembly by means of the stud bolts (9020.1). The pump and the
motor are both subjected to the same system pressure. This pressure connection of the two
components is effected by means of a gap between the shaft (2100) and the heat barrier.
The pumped fluid flows axially into the pump through the suction nozzle. The pressure and
the kinetic energy levels of the fluid are raised in the impeller (2300), and a portion of the
kinetic energy is converted into pressure energy in the diffuser (1710). The discharge nozzle
diffuser (1710). The discharge nozzle (or nozzles) (7231) is/are arranged radially.
The heat barrier is provided to prevent the heat flow from the hot pump to the cold motor.
The motor is a submersible (wet) three-phase squirrel cage rotor motor. The stator winding is
plastic-insulated.
The shaft of the pumping set is guided in two water-lubricated radial plain bearings (3100.1
and 3100.2) and in a water-lubricated thrust bearing (3840,3870.1, 3870.2 and 3920). A motor
cooler attached to the pumping set and connected by piping to the motor is arranged to
dissipate the heat generated in the motor and in the bearings during operation of the pumping
set.
The thrust bearing plate (3840) arranged in the motor is shaped in the form of an auxiliary
impeller, and circulates the cold fluid from the motor cooler through the motor and back
to the motor cooler (high pressure cooling circuit). The fluid absorbs heat from the motor
during its passage through it, and delivers it to the motor cooler. The fluid in the high
pressure cooling circuit is at the same pressure as the fluid pumped in the pump
compartment, but is maintained within the temperature limits permissible for the
insulation material of the winding. The three phases of the stator winding of the motor are
led out individually through the wall of the motor casing via pressure-tight insulation bushings
into the terminal box. The power supply cable from the network is connected to the motor in
this terminal box.
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3. Delivery and Preservation

3.1 Condition of Set as Despatched to Site
For the hydrostatic pressure test and for the hydraulic trial runs, the pumping set is first of
all completely assembled at manufacturer's Workshop, in accordance with our Scope of Supply.
After completion of these tests, the set is dismantled and all components are thoroughly
cleaned.
The pump casing and studs are supplied as loose components whilst motor assembly is supplied
with heat barrier and complete motor unit. All the apertures and connections are sealed with
covers. The complete motor is filled with nitrogen gas.
The pump casing (1010) and the motor cooler also have all their apertures sealed with covers.
The components despatched to the site in the condition described above should be stored in a dry
room, in order to avoid any possible damage. The covers should only be removed immediately
before installation of the required components, in order to preserve the highest
possible degree of cleanliness. In addition, the relevant individual covers should only be
removed as required by the sequence of erection, i.e. immediately before connection of the
relevant pipeline or other item.
Despatch and packing of the pumping set components described above are effected in accordance
with the stipulations of the contract.
For hydrostatic pressure test at site of BRP, the following actions should be required.
・The erection of motor, motor cooler, HP piping, etc. should be completed.
・The test pressure should be less than the specified value. (See item 1)
・The water filling of the motor should be completed. (See item 5.1)
・The cold, clean water to motor should be filled. (See item 5.1)
・All wall surfaces and joints of each pressure parts should be cleaned.
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3.2 Preservation
3.2.1 General
Depending on plant specific situations and preservation time intervals, the following table applies
to pump motor preservation.
Hydrazine Preservation
No. Method Note
(ppm) time
In case 4 - 5 months preservation time
Normal boiler Max. 4 – 5
1 0-5 is exceeded, each pump should run for
water filled months
30 minutes, every 4 weeks.
In case 3 - 4 months preservation time
Max. 3 - 4
2 Ditto Max 500 is exceeded, each pump should run for
months
30 minutes, every 4 weeks.
In order to avoid local corrosion, each
Cold clean
3 0-5 Long time pump should run for 30 minutes, every
water filled
4 weeks.
Max. 3 - 4
4 Ditto Max 500 Ditto
months
Dry N２ Gas Long time Dry preservation procedure should be
5 -
filled (Item 3.2.2) observed.
If the pump can not be run each every 4 weeks, the water in motor should be replaced by
purge water.
N2 Gas
*Piping removed
(1)General No.1 to 4 (2)General No.5 (refer to 3.2.2)

Figure 3.1 Preservation
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3.2.2 Dry Preservation
For motor drain procedure, Item, 5.4 should be strictly observed. After completion of motor
drainage, N２ gas is filled according to the following procedure.
(1) Dry up pump motor internals by compressed dry air (max. 55℃).
(2) Close pump suction discharge valves and all other valves to isolate pump motor compartment
from the system.
(3) Supply N２ gas from high pressure cooling water inlet and outlet connections. During N２ gas
supply, keep open air vent valve of the suction pipe line.
(4) Continue N２ gas supply until N２ gas replaces air inside, by checking at air vent valve at the
suction pipe line.
(5) Close air vent valve. Stop N２ gas supply, when inner pressure reaches to 0.1 - 0.2 kg/cm2g
Leave 2 - 3 hours for O２ absorption.
(6) Repeat the above step (3), (4), (5), until O２ absorption is completed. Pump motor is ready for
preservation.
(7) Repeat the above step (3) - (6) once every 2 - 3 months.
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3.3 Long Time Storage of a Motor
3.3.1 Storage of a Motor before Motor installation
A motor is filled with nitrogen gas at manufacturer's Workshop, and all apertures will be sealed.
It should be kept either lying or standing, in a room .
The nitrogen gas fill should be renewed twice a year or more. The filling pressure should be 0.2 to
0.5 kg/cm2g.
When a motor is installed, the relevant instructions contained in this operating instruction manual
which relate to the connection of the motor cooler, to the monitoring instruments and the
commissioning of the motor should be carefully observed.
For tentative storage of all the delivered motors at site, the above storage instruction should be also
observed.
3.3.2 Preservation of a Motor after Motor installation
In case the motor inner room is expected to be frozen or to form dew condensation during storage
time, wet preservation(water + glycol anti-freezing agents)of the unit is recommended alternatively.
And in this case, prior to the initial pump operation, please replace the filled water (glycol solution)
by regular priming water acc. to Item 5.1.
3.4 Replacement of Terminal Box Silica-gel
In the case of opening the terminal box cover, if the silica-gel color has changed to pink or is
color-less, the silica-gel should be replaced by new charge before closing the terminal box cover.
Use silica-gel : PQ5up blue 500g (Fuji Gel Sangyo Ltd.) or equivalent.
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4. Installation of Pumping Set and Operation

4.1 General
A skilled erector should be entrusted with the installation of the pumping set. The set should
be installed vertically (as illustrated in outline drawing) with the motor below the pump.
As a general rule, no special or additional support is required for the set, which is suspended
freely in the pipeline. If an additional support is required for the set for any special reason, it
is absolutely essential that such a support should be elastic and free to move, to enable the
pumping set to freely follow the movements of the piping, despite the support. Such
arrangement of the support must receive manufacturer's prior approval before the set is
commissioned.
Use only the original Lifting Lugs of the motor casing when suspending the motor weight!
If it is intended to provide thermal lagging for the set, make sure that only the pump casing
(1010) is lagged. On no account should the motor (8110), the motor cooler, the connecting
piping to the motor cooler, the stud bolts (9020.1) and the heat barrier (1520) be lagged as well.
Prior to installation of pumping set, enable the supply of cold clean water for motor filling
(See Item 5.1).
The details are given in Lifting Plan Drawing (41400-1041).
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4.2 Suction Line and Discharge Line

(NPSH, Rate of Pressure Decrease)
The suction line is to be such as to promote favourable flow conditions, i.e. sharp bends,
abrupt changes in the cross sections and features likely to encourage the formation of air
pockets must be avoided.
In case of welded construction, the burrs and welding beads must be removed carefully.
In order to prevent evaporation in the pump, the value of NPSH (AV.)(static suction head
minus all losses in the suction line) must be at least as high as the value of NPSH (REQ.) as
prescribed by us, as, otherwise, this will result in reductions in pump performance and severe
damage by cavitation to the pump.
The NPSH (REQ.) as given by manufacture is to be understood for steady operating conditions
where there are only minor pressure variations.
Should there be, however, major rates of pressure decrease in the plant, the NPSH (AV.) must
be increased, or the suction flow must be subcooled, to avoid cavitation. Consequently, the
velocity of a pressure drop as incurring may, under any one phase of operation, not be
higher than the allowable rate of pressure decrease as established for the plant. Also, the
necessary minimum flow of the pumps may not drop below the admissible value specified by
manufacture. (Minimum flow : 90 m3/h)
Since the minimum flow rates of the plants are very different ones, these must always
be determined and are subject to our consent.
The discharge line must also be laid such as to ensure that the flow is not unnecessarily
impeded or restricted.
The suction and the discharge line must be suitably supported in the vicinity of the pump.
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4.3 Motor Cooler and Heat Barrier
The cooler and the motor of the pumping set should be primed with clean, cold water
immediately after erection of the cooler (See Item 5.1)
4.3.1 Motor Cooler (Refer to Dwg. No. 41400-1020)
As previously mentioned under item 2, it is necessary to provide a motor cooler for each of
the pumping sets, for the purpose of removing the heat generated in the motor and in the
bearings during operation of the set. The motor cooler is designed on the high pressure side
for the max. operating pressure of the pumping set. It is connected to the pumping set by
a short length of piping, as illustrated in our arrangement drawing. It must be bolted onto
the cooler retaining shackles arranged on the motor casing.
The arrangement of the motor cooler and of its connecting piping to the pumping set must be
such that the possibility of formation of air pockets is excluded anywhere within the cooler
itself or the piping during subsequent venting and priming operations.
The motor cooler and its connecting piping must be carefully cleaned before connection to
the pumping set, in view of the water-lubricated bearings.
Make sure that the regular gaskets are fitted and tightened securely.
4.3.2 Heat Barrier
In order to preclude the heat flow from the hot pump casing to the cold motor, it is absolutely
essential that the low pressure cooling water supply should remain switched on (e.g. in the
case of a stand-by pump or stopped pump kept "warm") for as long as the temperature in the
pump casing (or the temperature of the fluid) remains above 60℃.
The pressure of the cooling water at the inlet into the heat barrier should be at least
4 kg/cm2g.
2
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4.4 Filter (Interior)
In operation, the thrust bearing plate mounted within the motor assembly effects a continuous
circulation of the liquid in the HP cooling circuit, between the motor assembly and the cooling
water heat exchanger. The pollution, if any, contained in this circuit or forming there in the
course of the time, such as deposits from the water, corrosion products or small metal particles,
are, thus, partly circulated, too, and may, if entering the water-lubricated bearings, destroy
their contact face, no longer ensuring the formation of a very thin liquid film-necessary in view
of the lubrication by the water. Therefore, the thrust bearing case (3540) is fitted with a filter
the required cleanliness of the HP circulating water.
During the operation of the pump, the water within the HP cooling circuit of the motor
continuously flows through the filter.
4.4.1 Disassembly
After removal of socket head cap screw (9140.10), the filter set (7911) may be withdrawn from
the thrust bearing case (3540). By loosening the hex. nuts (9200.7), the screen (7931) may be
removed. The dismantled components of the filter set must be cleaned using gasoline used for
cleaning purposes; water is to be employed for cleaning the O-rings (4120.6).
The housing must equally be cleaned internally.
4.4.2 Maintenance
The filter set must be cleaned at the time of the routine maintenance of the boiler. The dirt collecting
chamber is of ample capacity. The routine maintenance is shown in Item 9.2.2.
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4.5 Temperature Monitor
The temperature of the high pressure cooling water (circulation water) at the outlet of the
motor should not exceed 50℃ approx. during normal operation. This temperature can be
regulated by the admission of a larger or smaller quantity of low pressure cooling water
through the motor cooler. On account of the plastic insulation of the motor winding and of the
cooling of the bearings, the max. temperature of the high pressure cooling water should not
2 exceed 66℃. Such a high temperature should, however, only occur in case of fouling of the
motor cooler or of an excessive temperature rise of the low pressure cooling water.
In order to protect the motor and the bearings against possible damage in such an eventuality, a temperature
monitor has been incorporated in the motor cavity. The sensors of these instruments protrude right into
the motor compartment and thus detect the highest motor temperature in the area
of the top winding end.
Temperature element (RTD) : 01HAG03CT031

Note : The first digit of Tag No. (i.e. “10”) is to be replaced by “20” for Unit 2.
The motor temperature monitored, on the one hand, can be read directly at the pump itself,
and on the other hand it can be transmitted to alarm, interlock trip system.
Set one switch to 63 ℃ max., in order to trigger an alarm.

The pump shall automatically be switched off via the other switch, set at 66 ℃ max.
When the alarm is triggered, steps should immediately be taken to find the reason of the
temperature rise and to lower the temperature, e.g.
(1) Check for possible leakage at the connection between the motor cooler and the motor in the
HP cooling system as well as all connections.
(2) Check the LP cooling system (rate of flow, temperature, leakages).
(3) Increase the flow of LP cooling water through the motor cooler or through the heat barrier.
(4) Switch over to another available cooling system if possible (emergency cooling system) in
case of cooling water failure.
If the above measures do not produce the desired result almost immediately, and if the motor
temperature should continue to rise, the pump must be switched off, or it will switch itself off
automatically when the limit temperature has been reached.
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4.6 Cooling of Motor Cooler and of Heat Barrier
See Item 1.4 for operating data and LP cooling water requirements and specification.
The operational safety of the pumping set is intimately related to the correct and reliable
operation of the low pressure cooling water system. If LP cooling water supply to the motor cooler
is interrupted for a few minutes during the motor running or LP cooling water supply to the heat
barrier is interrupted for a few minutes when the pump is hot condition and the motor is switched
off (e.g. in the case of a standby condition), motor temperature may be raised up and so the motor
may be alarmed at 63 deg. C or tripped at 66 deg. C. Eventually the insulation of the motor winding is
liable to suffer damage as a result of overheating.
Therefore an uninterrupted flow of LP cooling water must be maintained and
safeguarded under all circumstances.
In order to achieve this, it is necessary to incorporate a cooling water flow monitor in the
cooling water supply line to the motor cooler and to the heat barrier, which will trigger a pulse for
a visual or audible alarm signal immediately in case of the latter drops below 70% of the rate of flow
specified under Item 1.4. Thereupon when usual cooling line come to be unusable, the cooling water
supply should be switched over manually or automatically to another cooling water supply line (e.g.
from an emergency overhead water reservoir).
Being different of upper usual condition, in case of usual cooling water stopped during pump hot
condition, motor is surely maintained at a safe temperature in the condition that emergency cooling
water of heat barrier in secured. This emergency cooling water of heat barrier should be prepared
from water source not to break due to another power source, or, from head tank. A time required for
cooling water supplying to heat barrier is changed by pump operation temperature. Emergency
cooling water shall be continued to supply to heat barrier until the temperature of pump casing goes
down to 200 deg. C.
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4.7 Motor Emergency Cooling
In the case of the motor temperature rising and the alarm or the trip is triggered, the motor
may be temporarily cooled down by the purge water.
Purging of the motor should be carried out at a filling rate of 0.3 m3/h, at a temperature of max.
45℃ and at (pump system pressure) + (2～3 kg/cm2g)
4.8 Motor Protection Cutout Switch
To protect the motor against overload, it is necessary to provide a motor protection cutout
switch, in the same way as for conventional electric motors.
In addition, we recommend the provision of an earth leakage protective relay.
The permissible impulse voltage of the motor is max. 18.0kV – 1.2 x 50μs.
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5. Preparation prior to Commissioning

5.1 Priming and Venting
Immediately after erection, the complete pumping set (i.e. the motor and the pump, also the
motor cooler and its connecting piping) should be primed with cold, clean water to prevent
any hot water penetrating inside the motor compartment, when the set is subsequently
started up. The pumping set should be primed with pure water or cold, clean boiler feed
water.
If the above water could not be prepared immediately after erection, the drinking water may
be used to prime the motor, the pump, the motor cooler and connecting piping.
Water Quality: Halogen (specially Cl）≦ 50 ppm
PH ＞ 6.5 (at 25℃）
Solid content ≦ 5 ppm
Temperature ≦ 45℃
During the priming operation, the set should be vented at its apex, to prevent the formation
of air pockets inside the set.
Priming of the set and of the cooler should be carried out slowly, at a filling rate of max.
0.3 m3/h approx., until the water overflows at the vent aperture.
Priming must always be carried out from the bottom upwards.

One should never attempt to prime the motor via the pump.
If there is any danger of freezing, it will be necessary to protect the circulating pumps.
The air surrounding the set can for instance be warmed up by an external heat source
(e.g. a radiant heater).
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When the priming operation is completed,
(1) the high-pressure isolating valves in the priming line must be closed.
(2) the low-pressure cooling water supply for the motor cooler and for the heat barrier should
be turned on.
Thereafter, the pumping set can be pressurized. After checking the correct setting and
operation of the monitoring devices, the pumping set is ready for start-up.
Although the set should be filled carefully and slowly, complete venting cannot always be
ensured. In order to remove, nevertheless, the remaining air inclusions, it is necessary to start
the motor in a short time 1- or 2- times for approx. 5 - 10 seconds. The frequency of switching-
on as given in Item 6.2 may, however, not be exceeded.
It is, of course, unnecessary to prime the pumping set with cold water before every subsequent
start-up, because it remains filled with water when stopped. In case of doubt, however, the
water fill should be checked again before a renewed start-up.
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5.2 Verification of Correct Direction of Motor Rotation
To obtain the proper direction of rotation, the motors must be connected in compliance with
the information plate on the terminal box:
Cable phase " R" to be connected
to terminal phase " U" in the terminal box
Cable phase " S" to be connected
to terminal phase " V" in the terminal box
Cable phase " T" to be connected
to terminal phase " W" in the terminal box
Care must be taken to make sure that the time phase sequence - R, S, T - is available at
the end of the current supply cable.
Further check of the direction of rotation can be made by comparing the discharge shut off
head, and that at an operation under cold water (density = 1000 kg/m3 ).
For this purpose - after filling up and complete preparation of the pump for start-up - the
motor is to be switched on for a short period (approx. 2 ～3 sec.) and started against the
discharge valve closed.
If shut off head is considerably lower than the values given, the leads of the terminals must be
interchanged to suit the other direction of rotation.
The axial bearing (thrust bearing) is designed for a certain direction of rotation, so that
it will be damaged in case of improper direction of rotation during a major period,
resulting in a failure of the set.
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5.3 Insulation Test
The insulation resistance of the motor winding should be measured when the pumping set is
primed with water at a temperature of 20℃ (Max. 45℃).
This test should be carried out before the initial start-up of the set, and every time the
pumping set is subjected to a general inspection. The insulation test can be carried out
direct at the lead-out bushings, taking care to observe the following precautions:
(1) Disconnect the power supply cable from the cable lead-out bushings.
Do not touch bare live metal. Electric shock can be caused.
(2) If necessary, dry out the terminal box compartment.
(3) Connect the leads of the measuring instrument to U, V or W of the lead-out bushing and
to earth (casing) and carry out the measurement.
The insulation resistance under the conditions outlined above should be 200 megohms,
and in the case of a motor under hot running conditions (50℃) and under pressure, it
should be more than 3 megohms.
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<Note 1> The Insulation Resistance Criteria for BCP Motor
This measurement is effective on condition that the water pressure is atmospheric

and the water temperature is under 40℃. And test voltage is applied to DC1000V for
high voltage motor or DC500V for low voltage motor by Megger.
1) Operation limit (*1) 200ＭΩ
2) If long term operation is planned, motor insulation resistance should be

more than following value.
2000MΩ
3) From the point to be under 2000ＭΩ, the decline tendency of motor

insulation resistance should be observed and the usable period should be
judged. Concretely the motor insulation resistance should be recorded
periodically, and their data should be arranged along time, and re-winding
work should be planned adequately before it will reach to operation limit,
i.e.200MΩ. The frequency of measurement is recommended to one time a 2
weeks or a month.
(*1) Operation limit；This means if the value come to be under this

limit ,line-to-ground fault could occur. For safety, re-winding is necessary
immediately.
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<Note 2> Regarding High-voltage Test
Because each motor has been completed high-voltage test (2E+1000V・・・1 min.) at Works,
it is not necessary to apply the test again at Site.
After installation, if the test is attempted to carry out for some reasons, the following
apparatus should be provided.
(1) Test voltage＊ AC 5175 V (1.5 Eu, Eu = 3450 V)

(2) Motor charging current 0.47 A
(3) Transformer capacity 3 KVA or more (AC 6.6 kV)
＊Remark
Test voltage for aged or repaired motor
shall be decreased correspondingly.
・The above-mentioned numerical value is for a single motor (without power cables).
・Do not apply DC-voltage.
・Test shall be performed to the above-mentioned cold water filled motor.
・The cold water filled condition in the motor should be kept for 4 hours or more.
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5.4 Drainage of Pump and/or Motor
The water filling of the pump and/or from valve to valve is necessary for reasons of
preservation, and to prevent any particle entering into the motor.
The pump should only be drained and later refilled for the following purposed.
(1) Pump, Motor overhaul (See item 9.2)
(2) Partial dismantling (See item 9.1)
(3) Dismantling and Inspection of the Cooler H.P. side
(4) Inspection of the Filter
In order that the entire boiler water must not be led through the pump during every boiler
drainage - what will be the case more frequently during the first operating phase - the
following steps should be taken:
(1) Close the suction and discharge line valves, as far as such valve (s) is (are) provided.
(2) Separate boiler piping water drainage up to the pump valves.
(3) Separate pump casing water drainage via the discharge branch drainage
(with free inspectable outlet hopper).
Such a drainage should only be carried out when revisions will be necessary in this part of
the plant.
(4) After the above drainage has been completed, the motor should be rinsed via the motor
bottom feed line with approx. 3 - 5 m3/h clean, cold water. The rinsing procedure
shall be continued until the water will leave the discharge branch drainage clear and
drainage clear and colourless.
(5) Then, open drainage branch (7100.1) of pump casing, the water must also emerge clear
and colourless. If this is the case, the rinsing procedure is completed.
If it is not envisaged to remove the motor, the pump must, in order to avoid corrosion, be
refilled with water up to the boiler line valves after completion of the revision in this part
of the plant.
(6) If drainage of the motor is necessary because of revisions or removal of the motor,
the water emerging from the drainage branch of the motor must first of all be checked
with regard to its purity according to Item (4) and (5).
Then the residual water in the motor can be drained via the motor drainage.
As according to our experience abnormally high contamination in the motor part does derive
from irregular drainage procedures, please observe the above mentioned points, especially
during the first operating phase (pressure test, cleaning of boiler, starting operation).
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5.5 Motor Flushing
Recommendation is given below, for the following special pump operational modes;
(1) Pump motor filling after the pumping set installation (Item 5.1)
(2) Pump motor filling for hydrostatic pressure test (Item 5.1)
(3) Boiler clean up with pump operation (Item 8)
(4) Boiler clean up without pump operation (Item 8)
(5) Pump commissioning operation (Item 6)
(6) Pump re-start-up after boiler stand still (Item 6)
(7) Pump re-start-up after boiler inspection. (Item 6)
For the above special pump operational modes, there is a fear that boiler water dirty
particles can enter into the motor compartment. In such a case, the following provision
should be taken;
(1) Cold clean water should be flushed from motor filling connection at more than
(pump discharge pressure) + (2～3 kg/cm2g)
In order to avoid reversal flow of motor water, reliable check valve (with spring) should
be incorporated at each motor in the motor flushing water pipe line.
Especially for pump parallel operation, this check valve at each motor is of vital
importance. The motor priming valve for each of motors should be controlled to keep the
required flushing water pressure for the running pump.
(2) Flushing water temperature should be below 45℃.

(3) Flushing water quality should be similar to boiler feed water.
(4) Before start of flushing, please check flushing water quality.
(5) This motor flushing should be continued until pump draining water sampling shows
colourless, clear, and clean water.
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5.6 Cleaning of Insulation Bushing
Refer to Terminal Box Drawing (41400-1019).

If necessary, clean and dry out the insulation bushing.
Unscrew hex. nut (9200.21) , hex. nut (9200.20) and hex. nut (9200.25) and remove insulation
bushing (5202.1) .
The insulation bushing (5202.2) should be cleaned using a soft cloth and should be thoroughly
dried. The surface temperature of the insulation bushing should not be allowed to exceed 65℃.
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6. Commissioning and Start-Up

The initial start-up of the pump should be carried out by one of skilled engineer.
If this has not already been specifically agreed in the supply contract, we suggest that you
request us to supply the services of an erector for this purpose, who can also supervise the
operation of the pumps for a few days and train the operating staff.
6.1 Pre Operational Check Items
After the pumps have been prepared for service in accordance with Item 5, they can be started
up after making sure that the following conditions have been carried out:
(1) Is the pumping set primed with water? (See Item 5.1)
(2) Does the pump rotate in the correct direction? (See Item 5.2)
(3) Has the insulation resistance of the motor winding been measured? (See Item 5.3)
(4) Has an operational check of the temperature and cooling water flow monitors, ammeters
and motor protection cutout switches been carried out? (See Items 4.5, 4.6, 4.8)
(5) Is there a supply of LP cooling water available for the motor cooler and for the heat barrier?
(See 4.5)
(6) HP cooling water temperature ≦ 63 ℃ (See Item 4.5) 2
(7) Water level in suction vessel above, or at least as high as the minimum prescribed water
level.
(8) Is motor flushing cleaning completed, in case of special pump operation mode? (Item 5.5)
(9) Are pressure tight seals at motor cooler, valves and connecting pipes assured?
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If possible, the pumps should be started up against a closed isolating valve in the discharge
line, in order not to overload the motor too much during start-up. The valve should be opened
immediately after switching on the pump, in order to prevent excessive heating of the water
and the consequent dangers of dry running and cavitation.
Pumps operated at any capacity range (from 0 to design capacity) must be equipped with a
minimum flow recirculation control assembly and are only allowed to be started with the
flow line opened.
The pumps can be started up against an open valve in the discharge line. The automatically-
controlled pumps must, however, have been previously made ready for start-up at any time,
as described under Item 5.
The rate of flow should be adjusted solely by means of the valve in the discharge line.
The valve in the suction line must remain fully open all the time the pump is running.
In the case of routine starts, only Item 6.1, (5), (6), (7) and (8) above need to be checked.
The pump standby mode must be continuously warmed up by operating temperature.
6.2 Frequency of Switching On and Off
6.2.1 In case motor is in usual pattern of start-stop

during the commercial operation of power plant
Frequent start and stop may shorten the motor life time, then less than 750 times per year
is recommended. In the case of per one day, less than 2 times is recommended.
Less than 2 times starting per one day are permissible. Only two switchings-on in
immediate succession in cold condition, and one in hot condition are permissible.
Excessive frequent switching will damage the stator coil insulation.
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6.2.2 In case frequent switching on and off is required in a short term

(For example, plant commissioning stage etc.)
Please put the cooling-down period in the table below according to the state
immediately before.
Cooling-down period required for the motor to

restart after the Maximum allowable number of
Maximum allowable immediate switching on
Maximum allowable
number of
number of start per
immediate
Last operation is ... hour
switching on
Succeeded and
Failed
continuous running
from COLD 2
It's possible to restart It's possible to restart
condition(*1) times
only once after only once after
3 times
continuous running continuous stopping / hour
more than more than
from HOT 1
10 minutes. 30 minutes.
condition(*2) time
(*1) COLD condition : Internal temperature of the motor comes to be ambient temperature,
or the motor has been stopped for 6 hours or more.
(*2) HOT condition : Internal temperature of the motor is in operating temperature, or the
motor has been operated for a few minutes. And it is the condition
with the exception of COLD condition.
6.3 Pump shutdown procedure
Pump can be stopped without any procedure.
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7. Supervision of Operation
7.1 Supervision during operation
The following points should be observed while the pump is running:

(1) Water level in the suction vessel or steam drum.
(2) Pump differential pressure.
(3) Current absorbed by motor.
(4) Temperature of high-pressure cooling water at motor cavity.
(5) Flow rate of low-pressure cooling water for motor cooler and heat barrier.
(6) Temperature of low-pressure cooling water at motor cooler outlet and heat barrier outlet.
(7) Quiet and smooth running of pumping set.
After the pump has been switched off, the following points must be kept under observation for
as long as the temperature in the pump compartment exceeds 60 ℃.
(8) Flow rate of low-pressure cooling water to the heat barrier.

(9) Temperature of low-pressure cooling water at heat barrier outlet.
(10) Temperature of high pressure cooling water at motor cavity.
The above also applies to pump standby mode which are kept at operating temperature.
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In general, the leak-tightness of the entire high-pressure cooling circuit should be kept under
observation. And also it should be observed that the water leak has not occurred from the
detection hole (Fig 7.1).
Refer to Daily Check Sheet Item.9. If the water leak has occurred and is left as it is, it could cause
the insulation deterioration, line-to-ground fault or serious condition.
Any exposure to excessive heat or cold from the surrounding atmosphere must be
avoided.
Please refer to table 7.2 INSPECTION SHEET
Figure 7.1 Detection Hole for Water Leakage
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D A I LY C H E C K f o r P U M P I S I N S E R V I C E
Inspe ctio n She e t (1/4)
No. Inspect. Point Inspect. Item Inspect. Method Criteria Note

1 Suction tank Water level Level detector Min. water level Daily
2 Pump suc.& dis.pipes Pump differential press. Press. gauge Specified head Daily
7.2 Inspection sheet
3 Pump flow rate Flow rate Flow meter Specified flow Daily
4 Power supply Motor current Current meter Specified current Daily
5 Motor cavity HP cooling water temp. Temp.detector max. 63℃ Daily
Motor cooler LP cooling

6 LP cooling water temp. Temp.detector max. 40.6 ℃ Daily
water outlet
Heat barrier LP cooling
water outlet
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8 Pump motor Abnormal noise or vibration － No abnormality Daily

O & M Manual
Daily
9 HP cooling water lines Leak Visual No leak
(Important)
10 LP cooling water lines Leak Visual No leak Weekly
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DAILY CH ECK for PUMP IS IN STAND BY MODE
Insp ection Shee t (2/4)

1 Suction tank Water level Level detector Min. water level Daily
2 Motor cavity HP cooling water temp. Temp.detector max. 63℃ Daily

Motor cooler LP cooling
water outlet
Heat barrier LP cooling
water outlet
Daily
5 HP cooling water lines Leak Visual No leak
(Important)
6 LP cooling water lines Leak Visual No leak Weekly

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Rev. No.: 2
MO NTH LY CH EC K
Inspection She et (3/4)

1 Motor terminal box Insulation resistance Megger meter

Every 3-6
・At cold water filling 200MΩ or more
Months
(at approx. 20℃, Max. 45℃)
・At hot stand by 3 MΩ or more
(at approx. 50℃)

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Rev. No.: 2
AN N UA L C HE CK
Inspe ctio n Shee t (4/4)

Filter Clean and no abnormality

1 Disassembly inspection Visual (and then wash) Every year
HP cooling water No foreign matter
Clean
Through hand cover
2 Motor cooler (LP side) Inside inspection No abnormal deposit or Every year
Visual
corrosion
No abnormal wear or
3 Thrust bearing Disassembly inspection Visual Every year
score mark
No abnormal wear or
4 Lower plain bearing Disassembly inspection Visual Every year
score mark
No abnormality on coil,
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5 Stator coil end External Visual taping and binding Every year
O & M Manual
materials.
First 1 year and
Overhaul
6 Pump motor Overhaul Instruction manual thereafter every
at Maker's Works
4-5 year
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8. Pump Operation for Boiler Clean Up

The complete circulating water circuit of the plant must be cleaned out before installing the
pumps.
Generally, special pumps are used for this purpose.
Should the course of the piping require to mount the original pump casings, the motor should
be dismantled, together with the heat barrier and the impeller, and the casing opening plugged
by a pump casing cover.
The boiler circulating pumps may be used for the purpose of cleaning out the boiler, on condition that
they are correctly prepared for commissioning (Item 5) and that they can be properly supervised
during this duty (Item 7).
In addition, the following measures must be taken during the cleaning out of the boiler:
(1) If possible, the rate of flow needed for cleaning out the boiler should be selected in such a way
that one pump is operating only. Other pumps should be completely isolated from the boiler
piping and the system.
(2) In case chemical cleaning liquid is used for boiler clean up, the following points should be
observed;
(2.1) Not to use fluoric hydride acid as inhibitors of chemical cleaning liquid.
(2.2) When planning boiler chemical cleaning, chemical liquid suitable to the pump material
should be selected.
(2.3) Before chemical cleaning or before motor assembly, it is recommended to check that
thrust bearing is clean and without damage.
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(2.4) After completion of the boiler cleaning process, it is recommended to dismantle and
inspect the thrust bearing. The inspection is mainly concerned with dirt deposits, signs
of incipient seizure and mechanical abrasion at the throttling gaps.
If the thrust bearing was damaged, the motor should be dismantled. The damaged
components should be replaced by new ones or touched up.
(2.5) Should components be replaced or touched up, it is, for reasons regarding insurance,
absolutely necessary to have the damage documented by an insurance expert.
The cost of damage occurred, as well as insurance premium, inspection of the pump and
new parts or repair, if any, will be charged to the order.
(3) Flushing of the motor compartment with clean, cold water, at the rate of 0.3 m3/h approx.,
via the motor filling line. (The flushing procedure should commence before the pump is
switched on, and should proceed without interruption until one hour approx. after the
boiler cleaning procedure has been completed.)
Refer to Item 5.5 Motor Flushing.
The flushing water pressure for the motor is more than (pump discharge
pressure) + (2～3 kg/cm2g).
Insufficient pressure will cause a reverse flow from the pump to the motor and
silldamage the stator coil.
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Date: 18/8/2017
9. Dismantling and Reassembly of Pumping Set

Any dismantling for the purpose of inspection of the pump internals and the fitting of spare parts
should be carried out either by one of our own skilled erectors or by skilled personnel.
In the case of major overhauls, or of damage to the motor winding, please contact our Head Office or
nearest agency in order to arrange for our service.
If the pump casing (1010) is welded in, it can remain in the piping.
If the inspection after dismantling reveals that it will be necessary to send the pumping set back to
our Works for repair, it should be reassembled and set with the covers prior to despatch.
For dismantling and assembling of the unit, please use lifting tools suitable to weight of
corresponding components. Dismantling weight is indicated on pump name plates.
Lifting lugs are designed as below;
(1) Lifting lug at pump casing (approx.7600kg) 1

(2) Lifting lug at motor casing flange (approx. 12000kg) 1
(3) Lifting eyelet at thrust bearing case (approx. 1200kg)
In any case, lifting lug at pump casing shall not be used for lifting the motor complete. For
dismantling motor complete, pull-out-space below the motor end (min. 1600 mm) is necessary
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Doc. No. 51006-41400-1055
Date: 18/8/2017
9.1 Dismantling
Dismantling should only be commenced after the pumping set has been made pressureless and is cold.
Sectional Drawing should be referred to when dismantling the pump.
(See 41400-1041-Lifting Plan Drawing) 2
9.1.1 Dismantling the Complete Motor Assembly from the Pump Casing
(1) Cut off the power supply cable to the motor, disconnect it at the terminal box, and safeguard
it against accidental switching on.
(2) Register the exact position of the individual components by a suitable marking on the
outside.
(3) Open drain valves in pump casing and drain off the water content of the pump casing.
In addition Item 5.4 must be observed.
(4) Drain off the water content of the motor and cooler via the motor drain connection.
In addition Item 5.4 must be observed.
(5) Dismantle low pressure cooling water piping to the motor cooler and to the heat barrier.
(6) Dismantle motor cooler together with HP connecting piping.
(7) Remove temperature monitoring devices on the motor flange.
(8) Slacken cap nuts (7342), while complete motor weight must be lifted by hoist. To do this,
heat all the stud bolts (9020.1) by means of the bolt heaters for as long as necessary to
enable the nuts to be slackened by hand with the aid of a conventional spanner (a single
heating period will be sufficient). For further details of this procedure and duration and
temperature of the heating up, See Items 9.4.1 to 9.4.6.
(9) Unscrew the nuts and disconnect the complete motor (8110) together with thrust bearing
case (3540), heat barrier (1520), shaft (2100) and impeller (2300), from pump casing (1010).
During lowering down the complete motor, please be careful so as not to damage the terminal box.
In case the heat barrier is tightly wedged inside the pump casing, heat the pump casing flange
uniformly at its outer periphery with the aid of three welding torches. During this heating
process, low pressure cooling water should be allowed to flow through the cooling channels of
the heat barrier.
It is vitally important to pull the heat barrier out of its seat in the pump casing first, and not
out of its seat in the motor casing, as the latter procedure might lead to bending of the shaft.
After the complete motor is dismantled, please be careful so as not to damage the sealing faces
of the pump casing and of the heat barrier. Anti-rust-grease should be applied on these faces.
When the complete motor assembly has been separated from the pump casing, dismantling of
the remaining components can proceed as follows:
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Date: 18/8/2017
9.1.2 Dismantling of Impeller (2300) and of Heat Barrier (1520)
(1) After removal of hex. bolt (9010.1)(first bend back lock washer (9311.1)) impeller (2300) will
be removed.
(2) Unscrew hex. nuts (9200.6) and remove heat barrier (1520) together with upper plain
bearing (3100.1).
9.1.3 Dismantling of Lower Bearing Assembly and Rotor
(1) Unscrew hex. nuts (9200.2) and remove thrust bearing case (3540) together with bottom
half of thrust bearing (3870.2, 3920, 1311.2).
(2) After removal of hex. bolt (9010.2)(first bend back lock washer (9311.2)), the thrust bearing
plate (3840) can be pulled off from the shaft (2100).
(3) After removal of socket head cap screw (9140.6), the top half of the thrust bearing (3870.1
and 3920) and the bearing bracket (3500) can be dismantled together with the complete
bottom plane bearing (3100.2).
(4) Then the rotor (8180) can be pulled out of the motor casing (8110).
During pulling out the rotor, please be careful so as not to damage the motor windings and
coil ends by using a soft (e.g. rubber) sheet.
9.1.4 Disassembly of the Filter
If the integrated separator element is to be dismantled in addition to the routine overhaul of the boiler,
this may be done without the necessity of removing the motor cooler.
The pump set must be drained, and it must be rendered pressureless.
Consequently, the system temperature must be less than 60℃． When draining the pump set,
it is absolutely necessary to observe the relevant instructions given in Item 5.4. of this
operating instructions.
(1) By removing the socket head cap screw (9140.10), the filter set can be withdrawn attached
to the Insert ring (5131).
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Date: 18/8/2017
9.2 Inspections
On the occasion of the regular boiler inspections, the following inspections should be carried
out on the pumps:
9.2.1 Annual Inspection During Boiler Inspection Period
(1) Inspection of thrust bearing (3840, 3870.1 and 3870.2)

(2) Inspection of bottom plane bearing and bearing sleeve (3100.2 and 5290.2)
Criteria for replacement by new components are an excessive bearing clearance or score marks
on the rubbing faces of the bearing. See clearance table, Item 9.2.3, for permissible bearing
clearances and surface finish.
(3) Cleaning of Filter (7911)
(4) Measurement of insulation resistance (See Item 5.3)
(5) Stator lower coil end Visual inspection
For disassembly, please refer to Item 9.1.3 (1)-(4) and Item 9.1.4.
For parts inspection, please refer to Item 9.3.
For re-assembly, please refer to Item 5.
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Date: 18/8/2017
9.2.2 Overhaul Inspection
For the first time approx. 1 year after the commissioning and thereafter once every 4 to 5 years,
the pumps are recommended to be completely stripped.
On this occasion, at least the following inspections should be carried out:
(1) Inspection of all parts subject to wear and of their fastenings, including fits, bolts and
screws, locking devices, pins and dowels. These components should be replaced by new ones,
depending on their condition. Criteria for replacement: See table of clearances, Item 9.2.3.
(2) Measurement of insulation resistance (See Item 5.3).
(3) Cleaning of pumping set (the motor winding ends should be lightly rinsed with water).
(4) Out-of-round (true running) check of rotor (max. permissible out-of-round: 0.08 mm).
If a new impeller is fitted, the rotor must be dynamically balanced (See Item 9.3.).
(5) Check of flow conditions through the cooling channels in the heat barrier (clean out same if
necessary). Pressure drop through heat barrier at the nominal rate of flow: 1 mAq approx.
(6) Cleaning out of LP side of the motor cooler.
Hydrostatic testing of the HP side (test pressure, See Item 1.1).
(7) Cleaning out of the Filter.
(8) Visual examination of the motor winding.
For disassembly, please refer to Item 9.1.

For part inspection, please refer to Item 9.3.
For reassembly, please refer to Item 9.4 and 9.3.1
For disassembly and inspection of Filter only, please refer to Item 4.6.
In the case of major overhauls, or of damage to the motor winding, please

contact our office and despatch the pumping set to manufacturer works
for complete inspection and repairs.
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9.3 Parts Inspection and Re-Assembly
(1) All the parts should be cleaned up. Stator coil and coil heads should be cleaned up by cold
clean water (chemical or mechanical clean up is not allowed).
(2) All the potential wear surfaces and sealing surfaces should be inspected.
(3) All the pressure retaining gaskets and O-rings should be replaced by new ones at each re-
assembly.
(4) For checking out-of-roundness of the rotor shaft, rotor shaft without shaft sleeve, impeller
and thrust bearing plate is supported at radial bearing area by roller. If out-of-roundness
measured by dial gauge at impeller area and at thrust bearing plate area is 0.08 mm,
please contact pump maker for corrective action.
(5) When impeller is replaced, rotor assembly (with impeller, shaft sleeve and thrust bearing
plate) should be dynamically balanced. For balance criteria value, please contact us.
(6) Insulation resistance of motor windings is checked acc. to item 5.3. Stator winding and
terminal penetration parts need not to be disassembled.
(7) Low pressure side of motor cooler should be cleaned up and inspected. High pressure side
of motor cooler should be subjected to hydrostatic pressure test.
(8) Potential wear parts should be touched up within clearance tolerance values acc. to Item
9.2.3.
Hex. bolts, washers, stud bolts, etc. should be replaced by new ones so far as necessary.
(9) In case of measured clearances beyond the tolerance value acc. to item 9.2.3, related parts
should be replaced by new ones.
(10) Pump casing seal faces should be protected by application of anti-rust-agents, after
inspection.
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Doc. No. 51006-41400-1055
Date: 18/8/2017
9.3.1 Reassembly
After overhaul inspection, reassembly is made in reversed sequence to disassembly.

After reassembly of the unit, the unit is installed acc. to item 4. Immediately after installation
together with the motor cooler and pipes, cold clean water should be filled (Item 5.1) and
motor drain connections and HP cooling water vent valves should be fully closed.
In case of “dismantling and inspection of lower bearing” acc. to Item 9.1.3, please make sure
that nut (9200.2) at thrust bearing casing (3540) should be tightened up to 12 scale divisions
(tightening torque approx. 992 kgf・m).
In case the above tightening is insufficient, O-ring malfunction will be caused.
φ730
PCD φ620
11
9
67
77
30
40
Ｍ64Ｘ2
M56 ×2 M
5041
895
5
Fig. 9.1 Nut (9200.2)
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Date: 18/8/2017
9.4 Assembly
With each assembly, a new spiral wound gasket (4113) must be fitted. In this respect, make sure that
the spiral wound gasket fits properly in the groove before commencing reassembly of the pump,
and also make sure that the mating face on the pump casing is in perfect condition.
The overhauled pump is assembled in reverse order of dismantling.
Prior to assembling the complete motor into the pump casing, it is advisable to check smooth running
of the shaft by turning the impeller by hand (has been assured for the pumps assembled at
Maker's Works).
Coat threads of stud bolts (9020.1) and washers (5500.1) with molybdenum sulphide.
The details are given in Lifting Plan Drawing (41400-1041).
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Date: 18/8/2017
10. Operational Conditions

10.1 "On" Criteria
When a pump is started up, the following, conditions must be fulfilled, in addition to the
general preparations (i.e. priming, venting, checking direction of rotation):
(1) Discharge valve open.
(or to be opened after attaining operating speed).
(2) Adequate water level in suction vessel.
(3) LP cooling water supply for motor cooler (not less than 8.1 m3/h). (01/02PGA02CF201) 2
(4) LP cooling water supply for heat barrier (not less than 1.9 m3/h). (01/02PGA02CF203) 2
(5) Temperature of HP cooling water below 63 ℃ at motor cavity. 2
10.2 "Off" Criteria
If the "On" criteria mentioned in Item 10.1 (1) to (3) inclusive are not fulfilled, and in the
event of the faults listed below, the pump must be shut down:
(1) Water level in suction vessel below minimum water level, resp. for differential pressure of
the pump.
(2) Temperature of HP cooling water above 66 ℃ at motor cavity.
(3) Excessive current (over current) or short circuit.
10.3 Alarm Annunciations
The following faults must be annunciated by an alarm signal:

(1) Failure of LP cooling water supply to motor cooler, or reduction of its rate of flow down to
70% (8.1 m3/h). (01/02PGA02CF201) 2
(2) Failure of LP cooling water supply to heat barrier, or reduction of its rate of flow down to
70% (1.9 m3/h). (01/02PGA02CF203) 2
(3) Increase in temperature of motor cavity to 63 ℃. (01/02HAG03CT031/032/033) 2
(4) Increase in diff. temperature of pump casing and suction tank more than 80 ℃. 2
(5) Reduction of BCP flow down to 90 m3/h. 2
10.4 Necessary Measures according to the Conditions of the Plant Demand
In addition, the conditions of the plant demand that the following measures should be taken
into account:
(1) Preliminary warming up of the pumps.

(Warming up of the pump is required until differential temperature between pump casing
and suction tank will be 80 degree C or less)
(2) Subcooling of the fluid entering the pump (if necessary).
(3) Preparation of purge water.
(4) Switching over to a pump standby mode.
(5) Emergency cooling water for the heat barrier ( 1.9 m3/h).
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11. Cause and Remedy of Operational Trouble

11.1 Instance of Abnormality
Numbers in the column correspond to those of clause 11.2
No. Instance Research and Remedy
(1) Pump does not start up 3 4 5 7 11 12
HP cooling water temp.

(2) 22 23 24 25 26 27
excessively high.
(3) Abnormal sound 1 2 10 12 13 14 15 16 17 18 19
(4) Abnormal vibration 1 2 10 12 13 14 15 16 17 18 19
(5) Over current relay actuated 4 6 7 12 13 14 15 16 20
(6) Low current 1 6 10 21
(7) Low insulation resistance 7 8 9 22 23 24 25 26 27
(8) Unstable current 3 4 5 6 13 14 15 16 17 18
Insufficient pump differential

(9) 1 2 10 17 18 20
press.
Note: Prior to beginning of revisional action, assure the relevant instruments and protection
protection devices are accurate.
And also investigate the abnormality by comparing with normal operating condition.
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Date: 18/8/2017
11.2 Research and Remedy
No. Cause Research Remedy
Reverse phase Examine the shut-off head

1 Reconnect the power cable.
sequence by short time operation.
Incorrect connection of Make certain the cable Reconnect the cables acc. to
2
motor terminals connection acc. to drawing. drawing.
Examine supply voltage Investigate power source and

3 Single-phase operation
between lines. make it correct.
Low terminal voltage of Examine the power source Investigate power source and
4
motor voltage. make it correct.
Malfunction of terminal Make certain the terminal Fasten terminals acc. to

5
connection in terminal box. connection acc. to drawing. drawing.
Investigate power source and

6 Unstable supply voltage Examine supply voltage.
make it correct.
Damage of stator coil or Examine insulation

7 Notify pump maker.
terminal insulation resistance.
Dry up by dryer.
Humidity of terminal box
8 Inspect the terminal box. Exchange gaskets if
inside
necessary.
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Leakage from cable Inspect inside of terminal

9 Notify pump maker.
penetration box.
Compare the current and

Reconnect acc. to phase
10 Reverse rotation of motor differential press. with the
marks.
shop test records.
Investigate which interlock Investigate cause of the

11 Interlock functioning
is concerned. interlock.
Mechanical lock or Overhaul unless other causes

12 Examine over current
resistance found.
Research abnormality of Overhaul and exchange parts

13 Bearing malfunction
sound and vibration. unless other causes found.
Overhaul and exchange parts

Research abnormality of
14 Scorch by foreign matter (if necessary) unless other
sound and vibration.
causes found.
Inspect the runout at

15 Shaft bending Notify pump maker.
overhaul.
Research abnormality of
Metallic contact of running Overhaul and exchange parts
16 sound (metal to metal
clearance. if necessary.
contact) and vibration.
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Date: 18/8/2017

Research the pump inlet
Reduce flow rate.
cavitation by observation of
17 Cavitation Increase subcooling flow
noise and ampere
rate.
fluctuation.
Inspect the sound if

18 Air intermixed in pump periodical, differential press. Avoid air introduction.
and current if fluctuating.
Completion of air vent

Inspect the sound from
19 Air remaining in Motor (Operate for short time 2 - 3
motor if abnormal.
times.)
Examine differential press.

20 Overflow operation Control flow rate adequate.
and current.
Operation under out of Examine pumping water Control water temp.

21
specified temp. temp. adequate.
Open valve fully.

Insufficient LP cooling Examine LP cooling water
22 Engage LP cooling water
water flow rate.
flow.
LP cooling water temp. Examine LP cooling water Engage LP cooling water

23
high temp. temp.
Refasten stud bolts.

24 Leakage from flange Visual inspection Exchange gasket if
necessary.
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Leakage from HP cooling Visual and liquid penetrant
25 Repair by welding.
piping examination.
Flushing and cleaning of

Malfunction of HP cooling Examine HP cooling water
26 HP cooling water piping
water circuit inlet / outlet temp.
and Filter
Examine motor cooler inlet /

Fouling of motor cooler outlet temp. Cleaning of motor cooler
27
tube Inspect shell inside via hand- tube.
hole.
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SECTION – C
DRAWINGS & DOCUMENTS
Page 64 of 245
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
H H
G G
F F
E E
D D
B B
A A
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Data sheets for Boiler Start-up re-circulation pump incl.motor
NTPC Doc./Drg. No.: 9578-001-102-PVM-Y-016 Rev No.: 3 Unit Designation: 1 & 2

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
0 Takeshi Ito 26/2/2016 Shinya Taniguchi 26/2/2016 Shinya Taniguchi 26/2/2016
1 Takeshi Ito 11/4/2016 Kazuya Yasui 11/4/2016 Shinya Taniguchi 11/4/2016
3 28/7/2016 28/7/2016 28/7/2016
Q4C0005280 - 1/7
POWER PROJECT
Data sheets for Boiler Start-up Doc. No.: 51006-41400-1040
Larsen & Toubro Ltd. re-circulation pump incl.motor Rev. No.: 3

Date: 28/7/2016
Rev
No.
1 REVISED 11/4/2016
2 REVISED 14/6/2016
3 REVISED 28/7/2016
Q4C0005280 - 2/7
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Date: 28/7/2016
Q4C0005280 - 3/7
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Date: 28/7/2016
CLAUSE
NO. DESCRIPTION VALUE
7.18.00 Startup Drain Re-circulation

Pump
Outdoor (In between water separator drain tank
i) Location of pumps and Eco inlet)
ii) Seperator 108.2 kg/cm2 abs {107.2 kg/cm2 (g)} 1
operating pressure
2
(Kg/cm abs)
1
iii) Feed water temperature at 305.9 deg. C
Eco inlet (deg. C)
iv) Mixed water temperature 303.6 deg. C
(deg.C) at Startup water
Recirculation pump inlet
v) Mixed water specific gravity 679 kg/m3 1 3
vi) Pump speed 1460 rpm
vii) Pump design capacity 588.47 t/h (830m3/h) 1
(Tonnes/hr.)
viii) Suction pressure at 111.4 kg/cm2 abs (110.4 kg/cm2g)
2
rated capacity (kg/cm abs)
ix) Discharge pressure at 116.51 kg/cm2 abs (115.51 kg/cm2g) 1
rated capacity (kg/cm2 abs)
x) Pump design pressure 315.6 kg/cm2g 1
(kg/cm2 g)
xi) Pump design temperature 345 deg. C 1
(deg. C)
xii) Total dynamic head 9.5 kg/cm2 abs (120m)
2
(kg/cm abs)
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Date: 28/7/2016
CLAUSE
xi) Maximum discharge 118.99 kg/cm2 abs (117.99 kg/cm2g) 1
2
pressure (kg/cm abs)
xii) NPSH available (MLC) 285 m
xiii) NPSH required (MLC) 5.5 m
xiv) Pump efficiency at design 70%
point (%)
xv) Pump break horse power 263.0 kW 1 3
xvi) Power consumption at 326.7 kW 3
design point
xvii) Power consumption at Approx. 150 kW
shut off condition
xviii) Pumps type Glandless Circulation Pump
xix) Type of casing Spherical
xx) Type of impellers Centrifugal, Closed
xxi) Type of shaft Vertical
xxii) Type of drive Wet stator three phase induction motor
xxiii) Type of seal Glandless
xxiv) Type of coupling N. A.
xxv) Type of mounting Pipe suspended
xxvi) Nozzle orientation －
a) Suction Axial
b) Discharge Radial
xxvii) Motor type Squirrel Cage Induction Motor (Wet motor)
xxviii) Liquid data －
a) Liquid temp. (degC) ≦ 45 deg. C (Motor priming water)
Q4C0005280 - 5/7
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Date: 28/7/2016
74.08
CLAUSE
b) Chemical composition Halogen (specially Cl) ≦ 50pm
Solid content ≦ 5pm
(Motor priming water)
c) Nature Pure water / Clean boiler feed water
(Motor priming water)
d) pH . > 6.5 @ 25deg. C (Motor priming water)
xxix) Materials of construction
a) Pump casing SF490A 2
b) Casing ring SUS420J2
c) Impeller SCS1-T2
d) Shaft SUS420J2
e) Journal bearing FRP
f) Motor housing cover SF490A
g) Thrust disc N/A
h) Thrust bearing pads FRP
i) Bearing sleeves SUS420J2
j) Motor housing SF490A
k) Stator Si - Steel
xxx) Rotor
a) Heat barrier SFVA F11B 2
b) Bolt SNB16 / SNB21-2
c) Nut SCM435H
xxxi) Whether following accessories
provided
a) Discharge Pressure
gauge Yes (LMB scope)
b) Suction pressure gauge Yes (LMB scope)
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Date: 28/7/2016
CLAUSE DESCRIPTION VALUE

NO.
c) Companion flanges Yes

d) Foundation bolts N/A
e) Base plate N/A
f) Strainer N/A
g) Bearing temp. gauges N/A
h) Portable trolley No
i) High pressure cooler
with interconnected
piping Yes
j) Cooler External
xxxii) Reference drawing No. 41400-1018 ( 0910015234 ) Sectional Drawing of Pump / Motor
Q4C0005280 - 7/7
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:
Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: BCP - Data sheet

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
3 4/8/2016 4/8/2016 4/8/2016
4 30/9/2016 30/9/2016 30/9/2016
5 24/10/2016 24/10/2016 24/10/2016
6 11/11/2016 11/11/2016 11/11/2016
Q4C0005282 - 1/6 6
POWER PROJECT
Doc. No.: 51006-41400-1005
BCP - Data sheet Rev. No.: 6
Larsen & Toubro Ltd. Date: 11/11/2016
Rev
No.
1 REVISED 13/5/2016
2 REVISED 14/6/2016
3 REVISED 4/8/2016
4 REVISED 30/9/2016
5 REVISED 24/10/2016
6 REVISED 11/11/2016
Q4C0005282 - 2/6
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Doc. No.: 51006-41400-1005
Q4C0005282 - 3/6
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Doc. No.: 51006-41400-1005
HLAV-PDS-E-A00
ＰＵＭＰ　ＤＡＴＡ　ＳＨＥＥＴ（1／3）
Glandless Circulation Pump
Marked ■ means the application for this Item.
1 Service BOILER RECIRCULATION PUMP DE SIG N
2 Product No. PU0137910/28/36 Pump Casing ■ Spherical □ Annular □ Volute
3 Type & Size HLAV250-630/1K Impeller Centrifugal, Closed
4 Quantity 1Pump /Unit x 2 (Total 2 pumps) + 1 Spare pump Number of Stage 1
5 Location Outdoor Radial Bearing Plain Bearing
6 Thrust Bearing Tilting Pads
7 PUMP Unit Specified Lubrication Forced Water Lubrication
8 Design Pressure kg/cm²g 315.6 1 Press. Retaining Pump : Spiral wound Gasket
9 Design Temperature ℃ 345 1 Seal Motor: O Ring
10 Hydrostatic Test Pressure kg/cm²g 473.4 1 CO NNE CTIO N
11 Medium handled - Boiler Water OD508 x Thickness 68(AWT)
12 Operating Temperature ℃ 303.6 Pump Inlet Butt weld
13 SF490A
14 Density kg/m³ 679 1 3 No. of Nozzle: ■Single ,□Double
15 Pump Outlet OD406.4 x Thickness 54(AWT)
16 NPSH(a) m 285 Butt weld
17 NPSH(r) m 5.5 SF490A
18 Suction Pressure kg/cm²g 110.4 TE R MINA L B O X
19 Discharge Pressure kg/cm²g 118.5 Protection IP55
20 Capacity m³/h 830 Location Side Bottom of Motor Casing
21 Minimum Flow m³/h 90 No. of Box 3 Boxes
22 Main Cable 4
3Rx1Cx150Sqmm AL/XLPE/AL/Unarmoured Cable
23 Total Head m 120 Cable Direction Downward

24 Pump Efficiency % 70 Cable Gland (Double compression) 5 Nickel plated Brass (BS-6121) (Gasket ID19&25mm)
6 4
25 Pump Shaft Power(SG=0.679) 1 3 kW 263.0 1 Body Earthing 100 mm2 Terminal
3
26 Pump Shaft Power(SG=1.000) kW 387.3 Terminal Box 4 ■ 80mm x 50mm Terminal, Flat Strip
27 PUMP- MO TO R - UNIT Earthing □ Common to Body Terminal
28 Overall Eff.(SG=0.679) (1) 1 3 % 56.4 1 3 MATE RIA L
29 Power Input (SG=0.679) 1 3 kW 326.7 (Calculated) 1 3 Part # Part Name Material
30 Overall Eff.(SG=1.000) (1) % 61.9 1010 Pump Casing compl. 2 SF490A
31 Power Input (SG=1.000) kW 438.2 (Calculated) 1520 Heat Barrier
2 SFVA F11B
32 Direction of Rotation - CW viewed from motor 8110 Motor Casing compl. SF490A
33 Speed of Revolution min-1 1460 3540 Thrust Bearing Case SF490A
34 8132 Stator Core Sheet Si-STEEL
35 2300 Impeller SCS1-T2
36 MO TO R 1710 Diffuser SCS1-T2
37 Type - Wet Stator Three 5020 Casing Wearing Ring SUS420J2
38 HLV55/4FQ45-335 Phase Induction Motor
2
39 Starting Method - Direct On-line 7231 Discharge Nozzle SF490A
40 Frequency Hz 50 2100 Shaft SUS420J2-HCrP
41 Rated Voltage V 3300 8182 Rotor Core Sheet Si-STEEL
42 Rated Output kW 450 5290 Bearing Sleeve SUS420J2-HCrP
43 Number of Poles P 4 3100 Plain Bearing compl. FC250/FRP
44 Nominal Current A 118.2 3870 Thrust Bearing Segment FRP
45 Efficiency at Full Load % 90 3840 Thrust Bearing Plate SUS420J2-HCrP
46 Power Factor at Full Load % 74 8140 Stator Coil Cu-VPE
47 Rated Slip % 2.7 8330 Terminal Box SS400
48 Torque, Start/Maximum % 60 / 205 9020.1 Stud Bolt SNB16
49 Starting Current A 709 9020.2 Stud Bolt SNB21-2
50 Starting Power Factor % Approx. 20
51 Starting Time sec 1.1
52 Allowable Lock Time sec 8
53 Insulation Class - Y
54 Design Pressure kg/cm²g 315.6 1
55 Design Temperature ℃ 345 1
56 Protection - IP68
57 【 NOTES】
58 (1) Overall Eff. = Pump Eff. × Motor Eff. (4) The terminal boxes shall not be removed, modified or relocated without our
59 (2) Allowable starting voltage drop : Less than 15%. acceptance. These actions may cause the damage of terminal lods and insulation
60 (3) Impluse - Withstand Voltage = 18.0kV-1.2x50μs bushings. Finally the motor may break.
61 【 REMARKS】 (5) Motor protection : Non explosion protection
62
Q4C0005282 - 4/6
POWER PROJECT
Doc. No.: 51006-41400-1005
Glandless Circulating Pump
1 HEA T B AR RIE R Unit RE CO MMEN DE D C O O LIN G W A TE R Q UA LITY
2 Fluid - Cooling Water ・ Cooling tower water, surface or well water.
3 Normal Cooling Flow Rate L/min 45 2 ・ Clear, colorless, without suspended matter.
4 Water Inlet Temp. ℃ 37.6*1 ・ Without corrosive and erosive contents.
1
5 Inlet Press. kg/cm²g TBA RE CO MMEN DED MO TO R FILLIN G W ATER Q U ALITY
6 Press. Loss m 5 or less ・ Boiler feed water ( ≦ 45℃ ) or drinking water.
7 Fluid - Cooling Water ・ Cl－ ≦ 50ppm， pH ≧ 6.5， Suspending solid ≦ 5ppm
8 Emergency (1) Flow Rate L/min 27 2 FILLIN G ,PUR G E AN D FLU SHIN G W ATE R R EQ U IR EME N TS * 2
9 Cooling Water Inlet Temp. ℃ 37.6*1 (1) Motor initial filling flow rate: max. 5 L/min
1
10 Inlet Press. kg/cm²g TBA (2) Purge water flow rate during cleaning: approx. 5 L/min
11 Press. Loss m 2 or less (Press. more than Pump discharge press. + 0.2 ～ 0.3 MPa)
12 MO TO R CO O LER Unit Shell Tube (3) Flow rate of motor pre-drain flushing: min.50 ～ 80 L/min
13 Type - Shell & Tube PR O TEC TIO N DE VIC E ( SE T PO INT)
14 Capacity kJ/h 189000 Motor Cavity Temp. high (ANN) more than 63 oC ON
15 Fluid - Cooling Water Boiler Water Motor Cavity Temp. high high (TRIP) more than 66 oC ON
16 Flow Rate L/min 191.6 (11.5m3/h) 130 (7.8m3/h) Motor Cooler LP CW Flow low (ANN) less than 70% ON
17 Inlet Temp. ℃ 37.6 50 Heat Barrier LP CW Flow low (ANN) less than 70% ON
1
18 Outlet Temp. ℃ 40.6 44 1
1
19 Press. Loss m 4 -
20 Design Press. kg/cm²g 10 1 3 315.6 Rods (incl. 2 spares)
1
21 Design Temp. ℃ 60 345 B O LT HEA TE R PO W ER SU PPLY ■ req'd □ not req'd
2 1
22 Test Press. kg/cm²g 15 473.4 Quantity of Bolt Heater 22 Rods (incl. 2 spares)
1 3 1
23 Switch Box Power Supply AC 240V 1 Phase 1Cable 4
24 Shell SA106 Gr.B Max. Power Consumption 37.8 kW
25 Material Tube SA213 TP 316L
Please be provided with above mentioned panel board within 10 meters distance from pump.
26 Tube sheet SA240 316L
27 Bonnet SA 350 LF2 APPR O X . MA SS ( DR Y ) kg
1
28 PU RG E W A TE R Pump Motor unit 19600 1 2 4
29 C O O LE R Unit Shell Tube Motor Cooler 295 4
30 Type - Shell & Tube Dismantled Motor mass*3 12000
1 2 4
31 Capacity kJ/h 311110
32 Fluid - Cooling Water Boiler Water
33 Flow Rate L/min 250 (15m3/h) 5 (0.3m3/h)
34 Inlet Temp. ℃ 37.6 305.9 1 TES T & IN SPE CTIO N
1
35 Outlet Temp. ℃ 43.6 45 ・ Test procedure (cold water) acc to JISB8301, JEC2137.
1
36 Press. Loss m 5 25 ・ Design, material and welding of pump and accessories
37 Design Press. kg/cm²g 10 354.3 acc to Maker's standard.
1 3 1
38 Design Temp. ℃ 60 306
2 1
39 Test Press. kg/cm²g 15 531.5 G UA RA N TEE S
1 3 1
40 ・ Guarantee period acc to commercial contract.
41 Shell SA240 304 ・ Proof of guarantee on Maker's test bed at cold water.
42 Material Tube SA213 TP 304
43 Cover SA182 F304
44
45
46 【 NOTES】
47 (1) In Blackout condition, Emergency cooling water shall be supplied to Heat Barrier, until the temperature of Pump casing gose down to 200 deg.C.
48 (2) ＊1： Outlet Temp： Normal - Approx 39.6℃ / Emergency - Approx 40.6℃
1
49 (3) ＊2： The details are given in O&M manual.
50 (4) ＊3： Please do not dismantle at wet condition.
51 (5) Operating cases
3
52 1.Cold clean-up (25%MCR) ： Flow rate-640 m /h , Total head-60 m
3
53 2.Start-up (5%MCR) ： Flow rate-830 m /h , Total head-120 m
54 (6) Purge water strainer： Mesh 150 or more, Design Pressure / Temperature - 354.3kg/cm2g / 306 ℃ 2
55
56
57 【 REMARKS】
58 The temperature of high pressure cooling water leaving the motor cavity to the cooler shall not exceed 60 deg C. The cooler has been adequately sized to reduce
59 this temperature to less than 50 deg C.
60
61
62
Q4C0005282 - 5/6
POWER PROJECT
Doc. No.: 51006-41400-1005
Glandless Circulating Pump
1 SC O PE O F SU PPLY Per One Pump Total Q'ty Remarks
2 PUMP & STAN DAR D ACC ESSO RIES
3 Pump Motor unit 1 2
4 Motor Cooler (HP Coil Tube, LP Shell) 1 2
5 High Press , Connection Pipings 1 2
6 RTD (Pump Casing Temp. monitoring) 3 6
7 Flow Switch (Motor Cooler LP CW Flow less 70% ANN) 1 2
8 Flow Switch (Heat Barrier CW Flow less 70% ANN) 1 2
9 Special Tool - 1
10 Erection Spare Parts (Pump Gasket, HP Flange Gaskets ) 1set 2sets
11
12
13
14
15
16
17
18
19 O PTIO NAL AC CES SO RIE S
20 Purge Water Cooler 1 2
21 Y-type Strainer 1 2
22 RTD (Motor Cavity Temp) 3 6
23 Thermometer (Pump Casing) 1 2
24 Thermometer (Motor Cavity) 1 2
25 Thermometer (Heat Barrier Cooling Water Outlet) 1 2
26 Thermometer (Motor Cooler Cooling Water Outlet) 1 2
27 Thermometer (Purge Cooler Cooling Water Outlet) 1 2
28 Flow Switch (Purge Cooler LP CW Flow less 70% ANN) 1 2
29 Pipe for LP CW Thermometer 3 6
30 Companion Flanges - 2sets Incl. Bolts, Nuts & Gaskets
31 Pump Casing Cover Out of scope Out of scope
1 1
32 Bushing Out of scope Out of scope For Punp Casing Cover
1 1
33
34
35
36 SPAR E PARTS
37 Complete Pump and Motor Assembly (Mandatory Spare) - 1 Incl. Pump Casing sets
38 Plain Bearing compl. (Mandatory Spare) - 1set Incl. upper & lower
39 Incl. upper & lower, Thrust
Thrust Bearing Segment (Mandatory Spare) - 2set
40 Bearing Plate
41 Casing Wearing Ring (Mandatory Spare) - 2sets
42 Set of gaskets - 3sets Incl. Motor Cooler gaskets
43 Set of O-rings - 3sets
44 Motor Cooler - 1set
45 RTD (Pump Casing : 3nos./unit, Motor Cavity : 3nos./unit ) - 6
46 Flow Switch (Motor Cooler : 1no./unit, Heat Barrier : 1no./unit, Purge Cooler:1no./unit) - 6
47 SHIPPING STY LE ■ Motor separated from Pump □ Pump and Motor assembled
48 ・ Pump casing installed with main stud bolts. ・ Pump motor unit fully assembled, branches
49 ・ Motor unit with heat barrier and impeller closed with steel closed with steel covers, filled with nitrogen gas
50 cover and filled with nitrogen gas.
51 ・ Cooler and instruments separately.
52
53
54
55
56 【 REMARKS】
57
58
59
60
61
62
Q4C0005282 - 6/6
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:
Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Pump Performance Curve
NTPC Doc./Drg. No.: Rev No.: 3 Unit Designation: 1 & 2

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
2 28/7/2016 28/7/2016 28/7/2016
3 8/12/2016 8/12/2016 8/12/2016
Q4C0005333 - 1/4
POWER PROJECT
Doc. No.: 51006-41400-1004
Pump Performance Curve Rev. No.: 3
Rev
No.
1 REVISED 19/5/2016
2 REVISED 28/7/2016
3 REVISED 8/12/2016
Q4C0005333 - 2/4
POWER PROJECT
Doc. No.: 51006-41400-1004
Q4C0005333 - 3/4
POWER PROJECT
Doc. No.: 51006-41400-1004
Product No. PU0137910/28 /36 Service BOILER RECIRCULATION PUMP

Type & Size HLAV250-630/1K Liquid Boiler Water
Total head ( m ) 120 Driver output ( kW ) 450

3
Capacity ( m /h) 830 Design Temperature ( ℃ ) 345 1
-1 3
Speed ( min ) 1460 Density ( kg/m ) 679 1 2
180
Min. Flow (90m3/hr)
160
140
120
Total Head m
100 Rated
(5%MCR)
80
60
40
Max. Wet operation
(30%MCR) 2 3 Cold clean-up
20 (25%MCR) 3
0
0 500 1000
100
90
80 Pump Eff.
70
Efficiency %
60
50
Total Eff. (ρ=679) 1 2 Total Eff. (ρ=1000)
40
30
20
10
0
0 500 1000
10
NPSH3 m
0
0 200 400 600 800 1000 1200
700
600
Motor Input (ρ=1000)
500 Pump Shaft Power (ρ=1000)
400
Shaft Power kW
300
200 Pump Shaft Power (ρ=679) 1 2
100 Motor Input (ρ=679) 1 2
0
0 500 1000
Capacity m3/h
Q4C0005333 - 4/4
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:
Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: BCP Motor Data Sheet (NTPC format)

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
2 24/6/2016 24/6/2016 24/6/2016
3 21/9/2016 21/9/2016 21/9/2016
4 28/10/2016 28/10/2016 28/10/2016
Q4C0005416 - 1/10 4
POWER PROJECT
Doc. No.: 51006-41400-1006
BCP Motor Data Sheet (NTPC format) Rev. No.: 4
Rev
No.
1 REVISED 27/5/2016
2 REVISED 24/6/2016
3 REVISED 21/9/2016
4 REVISED 28/10/2016
Q4C0005416 - 2/10
POWER PROJECT
Doc. No.: 51006-41400-1006
Q4C0005416 - 3/10
POWER PROJECT
Doc. No.: 51006-41400-1006
DE-1A HT MOTORS －
A. GENERAL －
1. Manufacturer & Country of origin. TORISHIMA PUMP MFG.

CO., LTD / JAPAN
2. Equipment driven by motor BCP
Squirrel Cage Induction Motor
3. Motor type (Wet motor)
4. Quantity 1 per unit
B. DESIGN AND PERFORMANCE DATA －
1. Frame size 55
2. Type of duty S1
3. Type of enclosure /Method of cooling/ Degree of protection IP68
4. Applicable standards to which motor generally conforms JEC, IEC 3 4
5. (a)Whether motor is flame proof No
(b)If yes, the gas group to which it conforms as per IS:2148 N. A.
6. Type of mounting Vertical
7. Direction of rotation as viewed from DE END CW viewed from motor
8. Standard continuous rating at 40 deg.C. ambient temp. as per 450kW

Indian Standard (KW)
9. Derated rating for specified normal condition i.e. 50 deg. C 450kW
ambient temperature (KW)
10. Maximum continuous load demand of driven equipment in KW 387.3kW
11. Rated Voltage (volts) / Frequency (Hz) 3300 V / 50 Hz
12. Permissible variation of : －
a. Voltage (Volts) ±6%
b. Frequency (Hz) +3%, -5%
c. Combined voltage and frequency 10%
13. Rated speed at rated voltage and frequency 1460
14. At rated Voltage and frequency: －
a. Full load current 118.2 A
b. No load current Approx. 60A
Q4C0005416 - 4/10
POWER PROJECT
Doc. No.: 51006-41400-1006
15. Power Factor at －
1. 100% / 75% / 50% load 0.74 / 0.69 / 0.57
2. NO load Approx. 30%
3. Starting. Approx. 20%
16. Efficiency at rated voltage and frequency, (Inclusive of tolerance) －
1. 100% load 90%
2. 75% load 86%
3. 50% load 77%
17. Starting current (amps) at －
a. 100 % voltage 709A (Inclusive of tolerance)
b. 85% voltage 603A
c. 80% voltage 567A
18. Minimum permissible starting Voltage (Volts) 2805V
19. Starting time with minimum permissible voltage －
a. Without driven equipment coupled 2.1sec
b. With driven equipment coupled 2.4sec
20. Safe stall time with 100% and 110% of rated voltage －
a. From hot condition 5.6sec (110% of rated voltage)

6.0sec (100% of rated voltage)
b. From cold condition 7.4sec (110% of rated voltage)
8.0sec (100% of rated voltage)
21. Torques : －
a. Starting torque at min. permissible voltage(kg-mtr.) 129.9 kg・m

2
b. Pull up torque at rated voltage. 180 kg・m
c. Pull out torque 615 kg・m
d. Min accelerating torque (kg.m) available 39.9 kg・m
2
e. Rated torque (kg.m) 300 kg・m
22. Stator winding resistance per phase (ohms at 20 Deg.C.) 0.18 Ω 3 2
9 Kgm2
23. GD2 value of motors
24. No of permissible successive starts when motor is in hot condition 2
Q4C0005416 - 5/10
POWER PROJECT
Doc. No.: 51006-41400-1006
25. Locked Rotor KVA Input 4054kVA
26. Locked Rotor KVA/KW 9.0 (Inclusive of tolerance)
27. Vibration limit －
a. Velocity (mm/s) N. A.
b. Displacement (microns) N. A.
28. Noise level limit (dBA) 85dB(A) at 1.0m (site)
C. CONSTRUCTIONAL FEATURES －
1. Stator winding insulation －
a. Class & Type Class Y
b. Winding Insulation Process shall be VPI No

Cross linked polyethylene
(Cu/VPE)
c. Tropicalised (Yes/No) N. A.
d. Temperature rise over specified max. －
i. Cold water temperature of 37.6 DEG. C. 1

42.4°C Maximum
1
ii. Ambient Air 50 DEG. C. N. A.
e. Method of temperature measurement N. A.
f. Stator winding connection Y
g. Number of terminals brought out 3
2. Type of terminal box for following: －
a. Stator leads Phase Segregated
b. Space heater N. A.
c. Temperature detectors(RTDs,BTDs) N. A.
d. Instrument switch etc. N. A.
Q4C0005416 - 6/10
POWER PROJECT
Doc. No.: 51006-41400-1006
3. Bearing －
a. Type DE/NDE Sleeve
b. Manufacturer Torishima
c. Self Lubricated or forced Lubricated Self-water lubricated
d. Recommended lubricant Self-water
e. Oil quantity N. A.
f. Max cold oil temp. to bearing N. A.
g. Guaranteed life in Hrs N. A.
h. Lubrication type N. A.
4. Oil pressure gauge/ switch －
a. Range N. A.
b. Contact Nos. & ratings N. A.
c. Accuracy N. A.
5. Type of cooler (CACA/CACW)/ Number CWCW / 1
6. Cooling water requirements －
a. Quantity required 11.5 m3/h (192 L/min)

: Low Pressure Cooling Water
b. Maximum permissible inlet water temp. in deg.C 37.6 deg. C 1
c. Pressure of water at inlet to coolers 6 ～7 kg/cm2(g) 3
d. Outlet temperature of water at full load 40.6 deg. C 1

e. Cold air temp. at outlet N. A.
7. Paint shade RAL5012
8. Max. permissible temperature of rotor (deg.C) 90 deg. C

st
9. Temp. Rise of rotor during 1 start (deg.C) 40 deg. C
nd
10. Temp. rise of rotor during 2 start (deg.C) 40 deg. C
Q4C0005416 - 7/10
POWER PROJECT
Doc. No.: 51006-41400-1006
11. Surge withstand voltage (stator winding) －
a. 0.2/3 micro sec surge(KVp) 12kV
b. 1.2/50 micro sec surge(KVp) 18kV
12. Weight of －
a. Motor stator (KG) Approx. 4200kg
b. Motor Rotor (KG) Approx. 710kg
c. Total weight (KG) Approx. 4910kg
D. List of accessories. －
i) RTDs for winding(Type/Nos/Leads/Location/make/Res.at 0 Deg.C) N. A.

ii) RTDs for bearing(Type/Nos/Leads location/make/Res.at 0 Deg.C) N. A.
iii) RTDs for Hot Air (Type/No/Leads) N. A.
iv) RTDs for Cold Air (Type/No./Leads) N. A.

v) Space Heaters －
i) Nos. N. A.
ii) Total Power (Watts) N. A.
iii) Supply Voltage N. A.
vi) Stator Terminal Box －
i) Type Phase Segregated
ii) Fault Level (MVA)/Fault Level duration (secs) 250 MVA for 0.12 sec
iii) Location(viewed from NDE side) Side Bottom of Motor Casing
iv) Entry of cables (bottom/side) Bottom
v) Recommended cable size(To be matched with cable size 3Run x 1C x 150Sqmm AL

envisaged by owner) XLPE, Unarmoured Cable 3
vii) Cable glands & lugs details (shall be suitable for power cable) Double compression nickel
plated Brass cable Glands
(BS-6121) & tinned copper
lugs (JIS C 2805) 3 4
viii) Neutral Terminal box Type N. A.
Q4C0005416 - 8/10
POWER PROJECT
Doc. No.: 51006-41400-1006
9. Current Transformer －
i) Nos. N. A.
ii) Ratio N. A.
iii) Accuracy Class N. A.
iv) Knee Point Voltage-Vk (Volts) N. A.
v)Exciting Current N. A.
vi) Max Secondary Resistance N. A.
10. Dial Type Thermometer －

(Type/make/Accuracy/Connection type & size)
i) For Bearings (Nos.) N. A.
ii) For Air Temp (Nos.) N. A.

a. Hot Air N. A.
b. Cold Air N. A.
iii) Contact Rating N. A.
iv) Range N. A.
v) Supply Voltage N. A.
11. Rotor Terminal Box N. A.
12. TBs for RTDs. BTDs & Space Heater (Yes/No) N. A.
13. Sole Plate (Yes/No) N. A.
14. Foundation & Anchoring bolts (Yes/No) N. A.
15. Base Frame (Yes/No) N. A.
16. Speed switch (Yes/No) －
i) No of contacts and contact ratings of speed switch N. A.
17. Insulation of bearing (Yes/No) N. A.
18. Forced oil lubrication (Yes/No) N. A.
19. Oil level indicator (Yes/No) N. A.
20. Noise reducer(Yes/No) N. A.
21. Flow switch for CACW motor (Quantity) －
i) No of contacts and contact ratings N. A.
Q4C0005416 - 9/10
POWER PROJECT
Doc. No.: 51006-41400-1006
22. Water leakage detector －
i) No of contacts and contact ratings N. A.
23. Grounding pads －
i) No and size on motor body 2 (□30x65)
ii) Nos on terminal Box 1 per each terminal box)

(□80x50)
24. Vibration pads －
i) Nos and size N. A.
ii) Location N. A.
25. Any other fitments N. A.
E. List of curves. －
1. Torque speed characteristic of the motor Yes
2. Calibration characteristic of platinum type resistance temperature N. A.

detector
3. Calibration characteristic of platinum BTD N. A.
4. Thermal withstand characteristic Yes
5. Starting. current Vs. Time Yes
6. Starting. current Vs speed Yes
7. Neg. sequence current vs Time.. Yes
8. P.F. and Effi. Vs Load Yes
Q4C0005416 - 10/10
c "THIS DRAWING IS THE PROPERTY OF AND CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF L&T-MHPS BOILERS PRIVATE LIMITED AND SHALL UNLESS OTHERWISE STATED ALL DIMENSIONS ARE
NOT BE REPRODUCED, USED, DISCLOSED OR TRANSMITTED IN WHOLE OR IN PART UNLESS AUTHORISED IN WRITING BY L&T-MHPS BOILERS PRIVATE LIMITED" IN MILLIMETRES. DO NOT SCALE. IF IN DOUBT, ASK.
A
B
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C
D
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5
4
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L&T
3
3
NTPC LIMITED
2
2
L & T - SARGENT & LUNDY LTD.

L & T - MHPS BOILERS PVT. LTD.
1
1
2 X 660MW KHARGONE SUPER THERMAL POWER PROJECT

C
F
A
B
E
D
H
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A
B
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L&T
3
3
NTPC LIMITED
2
2

1
1

C
F
A
B
E
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H
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16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
H H
G G
F F
E E
D D
B B
A A
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: BCP Motor Curve
Doc./Drg. No.: 51006-41400-1034/35/36/37/38/46 Rev No.: 1 Total No. of Pages : 8

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
1 24/6/2016 24/6/2016 24/6/2016
Q4C0005380 - 1/8 1
POWER PROJECT
Doc. No.: 51006-41400-1034/35/36/37/38/46
BCP Motor Curve Rev. No.: 1
Date: 24/6/2016
Rev
No.
1 REVISED 24/6/2016
Q4C0005380 - 2/8
POWER PROJECT
Doc. No.: 51006-41400-1034/35/36/37/38/46
BCP Motor Curve Rev. No.: 1
Date: 24/6/2016
Q4C0005380 - 3/8
POWER PROJECT
Doc. No.: 51006-41400-1034/35/36/37/38/46
Rev. No.: 1
Date: 24/6/2016
Q4C0005380 - 4/8
POWER PROJECT
Doc. No.: 51006-41400-1034/35/36/37/38/46
Thermal Limit & Time vs Current Curve Rev. No.: 1
Date: 24/6/2016
Q4C0005380 - 5/8
POWER PROJECT
Load vs Efficiency, Power Factor, (FORMERLY KNOWN AS L&T-MHI BOILERS PRIVATE LIMITED)
Doc. No.: 51006-41400-1034/35/36/37/38/46
Current and Input Power Rev. No.: 1
Date: 24/6/2016
Q4C0005380 - 6/8
POWER PROJECT
Doc. No.: 51006-41400-1034/35/36/37/38/46
Negative Sequence Curve for Motor Rev. No.: 1
Date: 24/6/2016
Q4C0005380 - 7/8
POWER PROJECT
Doc. No.: 51006-41400-1034/35/36/37/38/46
Heating and Cooling Time Constant Curve Rev. No.: 1
Date: 24/6/2016
Q4C0005380 - 8/8
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Utility List

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
Q3C0006029 - 1/11 1
POWER PROJECT
Doc. No.: 51006-41400-1010
Utility List Rev. No.: 1
Date: 3/6/2016
Rev
No.
1 REVISED 3/6/2016
Q3C0006029 - 2/11
POWER PROJECT
Doc. No.: 51006-41400-1010
Date: 3/6/2016
Q3C0006029 - 3/11
CLOSED CIRCUIT COOLING WATER CONSUMPTION LIST
No's of
No's of
CCCW Flow Rate per Total Flow
No. Equipment name No's of Equip. Operating Inlet Temp. Outlet Temp. Heat Duty Remarks
supplied one Equip. Rate

Equip.
Equip.
(m3/h) (m3/h) (degC) (degC) (x10３kcal/h)
1 1 1 1 1 Inlet Press. T.B.A.

1 Heat Barrier 1 1 1 2.7 2.7 37.6 39.6 5.4
Press. Loss 5 m or less
1 1 1 Inlet Press. T.B.A.

2 Motor Cooler 1 1 1 11.5 11.5 37.6 40.6 34.5
Press. Loss : 4 m or less
1 1 1 Inlet Press. T.B.A.

3 Purge Cooler 1 1 1 15.0 15.0 37.6 43.6 90.0
Press. Loss : 5 m or less
4
5
Utility List
POWER PROJECT
6
7
8
1 1
TOTAL 29.2 129.9
Pressure Loss (From / To Terminal Point between Boiler and Closed Cooling water supplier) :
kg/cm2g
Q3C0006029 - 4/11
Doc. No.: 51006-41400-1010

Date: 3/6/2016
Rev. No.: 1
DEMINERALIZED WATER CONSUMPTION for Lot 1
1. Demineralized Water Consumption
3
Consumption (m /h per one Boiler)
No. Item before Start-up Start-up Load Operation Remarks
1 Motor Priming (Initial) 0.3 Max. - - BRP require the water at Motor installation stage.
3.0 BRP require the water at Motor de-installation

2 Motor Pre-Drain Flushing - -
～ 4.8 (removal) stage.
4
Utility List
5
POWER PROJECT
6
2. Required Total Quantity of Demineralized Water for Boiler Water Filling and Hydrostatic Test
Consumed
No. Items
Quantity *c
The quantity listed on the table is the total volume of water which is filled
1 Normal Wet Lay up (Before Start-up) 0.8 (m3 /unit) in BRP, Motor Cooler and Purge Cooler
2 Complete Wet Lay up 0.8 (m3 /unit)
3 Hydrostatic Test 0.8 (m3 /unit) *c : Boiler scope only.
3. Required Head
Required head for Boiler water filling 10 [m] (from Ground level)
Bottom of each equipment
Note :
Q3C0006029 - 5/11
Doc. No.: 51006-41400-1010

Date: 3/6/2016
Rev. No.: 1
POWER PROJECT
Doc. No.: 51006-41400-1010
Date: 3/6/2016
UTILITY REQUIREMENT FOR

GLANDLESS SUBMERGED MOTOR PUMP
In order to secure safe and trouble free operation of Torishima glandless

submerged motor pump, it is essential to keep the water inside the motor part
cool and clean.
Therefore, in addition to the supply of normal low pressure cooling water, it is
required to purge pressured water continuously from motor bottom in some
special operation mode like boiler cleaning operation.
Please refer to the following instruction and make sure to prepare the suitable water
source required for each case.
Q3C0006029 - 6/11
POWER PROJECT
Doc. No.: 51006-41400-1010
Date: 3/6/2016
Utility For Motor Priming

At the stage of motor priming
Purpose
(After initial installation / maintenance)
Clean Water (Filtered water through 150 mesh screen)
Water Quality
For example: Boiler Feed Water, Potable Water, Deaerated Demineralized Water etc.
Temperature ≦ 45 ℃
Pressure ≧ 0.5～1 kg/cm2g
Quantity ≦ 0.3 m3/h
Flow Diagram
Water shall be supplied as slow as possible to prevent air from remaining inside the motor
casing.
Note
The air remaining will be compressed as system pressure rises and allow hot water of the same
volume enter the motor casing.
Q3C0006029 - 7/11
POWER PROJECT
Doc. No.: 51006-41400-1010
Date: 3/6/2016
Utility For Low Pressure Cooling Water for Motor Cooler

Purpose To remove heat from motor part
Clean Water (Not Erosive / Corrosive)
Water Quality
For example: Closed Circuit Cooling Water etc.
Temperature As per instruction ( ≦ 37.6 ℃ ) 1
Pressure As per instruction ( Preferably ≧ 1.5 kg/cm2g )

Quantity As indicated in P&I Diagram / Data Sheet
Flow Diagram
Cooling water supply shall be started prior to pump operation.

Note
Continuous cooling water supply is required during hot stand-by.
Q3C0006029 - 8/11
POWER PROJECT
Doc. No.: 51006-41400-1010
Date: 3/6/2016
Utility For Low Pressure Cooling Water for Heat Barrier

To prevent heat transfer from pump part to motor part
Purpose
( Especially during hot stand-by )
Water Quality Same as Low Pressure Cooling Water for Motor Cooler
Temperature As per instruction ( ≦ 37.6℃ ) 1
Pressure As per instruction ( Preferably ≧ 1 kg/cm2g )

Flow Diagram
Since cooling water jacket of heat barrier has complex construction for efficient heat
removal and high internal surface temperature, it is very important to supply clean water
which has less tendency of scaling.
Note Cooling water supply shall be started prior to pump operation.
Continuous cooling water supply is required during hot stand-by.
BRP is required inlet pressure of 1 kg/cm2g or more for heat barrier.
Q3C0006029 - 9/11
POWER PROJECT
Doc. No.: 51006-41400-1010
Date: 3/6/2016
Utility For Emergency Cooling Water for Heat Barrier

In case of sudden stop of low pressure cooling water, motor will be exposed to high
temperature due to heat remaining in pump / motor part even with pump isolating valves
Purpose closed.
To protect motor from overheating, cooling water from backup source shall be supplied at
least to heat barrier for a certain period.
Water Quality Same as Low Pressure Cooling Water for Motor Cooler / Heat Barrier
Temperature As per instruction ( ≦ 37 .6℃ ) 1
Pressure As per instruction ( Preferably ≧ 1 kg/cm2g )

Flow Diagram
Emergency cooling water (EMG. C.W.) should be provided from reliably continuous flow
line with emergency power or head tank. And EMG. C.W. line should be separated from
Normal cooling water (NOR. C.W.) line.
If plant is blackout, Suction and Discharge valve for BCP should be closed in order to
Note restrict thermal source and EMG. C.W. should be provided immediately.
And then, EMG. C.W. should be provided continuously until pump casing temperature turns
into below 200 degree C.
If EMG. C.W. capacity is insufficient, NOR. C.W. should be restored or Pump should be
carried out forced cooling before EMG. C.W. is stopped.
Q3C0006029 - 10/11
POWER PROJECT
Doc. No.: 51006-41400-1010
Date: 3/6/2016
Utility For Flushing before Motor Drainage Low Pressure Cooling Water for Purge Cooler
To prevent scale, slug, etc. from entering the

Purpose
motor casing during motor drainage.
Same as Low Pressure Cooling Water for Motor
Water Quality Clean Water
Cooler
Temperature ≦ 45 ℃
Cooler
Pressure ≧ 1 kg/cm2g
Cooler
Quantity ≧3 m3/h As indicated in P&I Diagram / Data Sheet
Flow Diagram
Flushing water shall be supplied Cooling water quantity will be calculated based on
Note continuously until drainage is clean and the condition of purge water source ( temperature
clear. and flow rate )
Q3C0006029 - 11/11
A
B
E
C
D
H
12
12
11
11
10
10
9
9
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
A
B
E
C
D
H
G
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Valve List

Checked
This document is also applicable for L&T-S&L Date Name

51006B Unit #2 also.
Checked
REVISION STATUS
1 12/7/2016 12/7/2016 12/7/2016
2 20/7/2016 20/7/2016 20/7/2016
Q3C0006584 - 1/4 2
POWER PROJECT
Doc. No.: 51006-41400-1012
Valve List Rev. No.: 2
Date: 20/7/2016
Rev
No.
1 REVISED 12/7/2016
2 REVISED 20/7/2016
Q3C0006584 - 2/4
POWER PROJECT
Doc. No.: 51006-41400-1012
Valve List Rev. No.: 2
Date: 20/7/2016
Q3C0006584 - 3/4
DESIGN DESIGN PRESSURE CON. PIPE

SERIAL Q' VALVE BODY CONNECTION END
1 TAG No. *1 SERVICE NAME PRESS. TEMP. FLUID RATING NOMINAL P&ID No. REMARKS
No. TY TYPE MATERIAL SIZE DETAILS
kg/cm2G ℃ DESIGNATION DIAMETER
BOILER
1 01HAG03AA916 BRP PUMP CASING DRAIN 1 GLOBE A105 315.60 345 1" BW CLASS 2500 1" 41400-1011
WATER
BOILER
2 01HAG03AA917 BRP PUMP CASING DRAIN 1 GLOBE A105 315.60 345 1" BW CLASS 2500 1" 41400-1011
WATER
3 01HAG03AA918 BRP MOTOR COOLER - AIR VENT 1 GLOBE A105 2 10.0 60 CW 1" RF CLASS 150 1" 41400-1011
4 01HAG03AA919 BRP MOTOR COOLER - DRAIN 1 GLOBE A105 2 10.0 60 CW 1" RF CLASS 150 1" 41400-1011
5 01HAG03AA932 BRP PURGE COOLER - AIR VENT 1 GLOBE A105 2 10.0 1 120 CW 1" RF CLASS 150 1" 41400-1011
6 01HAG03AA910 BRP PURGE COOLER - DRAIN 1 GLOBE A105 2 10.0 120 CW 1" RF CLASS 150 1" 41400-1011
BRP PURGE COOLER - PRESSURE RELIEF

7 01HAG03AA101 1 RELIEF A351 CF8 2 10.0 120 CW 2" RF CLASS 150 2" 41400-1011
VALVE
Valve List
POWER PROJECT
8 01HAG03AT992 BRP PURGE WATER STRAINER 1 - A182 F316 354.3 306 CW 1" SW CLASS 2500 1" 41400-1011 mesh 150 or more
BRP MOTOR COOLER - PRESSURE RELIEF

9 01HAG03AA102 1 RELIEF A351 CF8 2 10.0 60 CW 2" RF CLASS 150 2" 41400-1011
VALVE
10
11
12
CW　： COOLING WATER
1 *1:Tag No. indicated on the list are for Unit 1.

SW　： SOCKET WELDING
The first 2 digits number of Tag No. (01) is to be replaced w ith 02 for Unit 2.
For example : 02HAG03AA916 etc.
BW　： BUTT WELDING
Note : Counter flanges w ith Gaskets, Nuts and Bolts at all flanged terminal points are in
RF　： RAISED FACE (ASME B16.5-2009)
Torishima scope of supply.
Q3C0006584 - 4/4
Doc. No.: 51006-41400-1012

Date: 20/7/2016
Rev. No.: 2
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:
Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Instrument List

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
1 7/7/2016 7/7/2016 7/7/2016
2 15/7/2016 15/7/2016 15/7/2016
3 28/7/2016 28/7/2016 28/7/2016
4 2/8/2016 2/8/2016 2/8/2016
5 28/10/2016 28/10/2016 28/10/2016
Q3C0006083 - 1/6
POWER PROJECT
Doc. No.: 51006-41400-1013
Instrument List Rev. No.: 5
Rev
No.
1 REVISED 7/7/2016
2 REVISED 15/7/2016
3 REVISED 28/7/2016
4 REVISED 2/8/2016
5 REVISED 28/10/2016
Q3C0006083 - 2/6
POWER PROJECT
Doc. No.: 51006-41400-1013
Instrument List Rev. No.: 5
Q3C0006083 - 3/6
RESISTANCE TEMPERATURE DETECTOR (TE)
INSTRUMENT LIST
2 1 THERMOWELL
SERIAL Q' TY Q' TY OPERATING CABLE RTD PROCESS THERMOWELL REFERENCE
TAG No. *1 SERVICE NAME TYPE OF TE ELEMENT PROCESS MAKER MODEL No. REMARKS
No. / PUMP UNIT / TOTAL TEMP. CONNECTION CONNECTION MATERIAL DWG. No.
1 CONNECTION
SF490A 41400-1002 Duplex
1 01HAG03CT034 BRP PUMP CASING TEMPERATURE 1 2 Pt 100 SHEATH 303.6 ℃ Plug in NPT1/2" G 1" / Welding YAMARI LS
/ SUS316 41400-1011 4-Wire
SF490A 41400-1002 Duplex
/ SUS316 41400-1011 4-Wire
SF490A 41400-1002 Duplex
/ SUS316 41400-1011 4-Wire
41400-1002 Duplex
4 01HAG03CT031 BRP MOTOR CAVITY TEMPERATURE 1 2 Pt 100 SHEATH 50 ℃ Plug in NPT1/2" G 1" / Welding SF490A YAMARI LS
41400-1011 4-Wire
41400-1002 Duplex
41400-1011 4-Wire
41400-1002 Duplex
41400-1011 4-Wire
9
POWER PROJECT
Instrument List
10
1 ＊1：　Tag No. indicated on the list are for Unit 1.
The first two digits of the tag No. (01) is to be replaced with 02 for Unit 2.
For example : 02HAG03CT034
Q3C0006083 - 4/6
Doc. No.: 51006-41400-1013
Date: 28/10/2016
Rev. No.: 5
THERMOMETER (TI)
INSTRUMENT LIST
THERMOWELL
SERIAL Q' TY Q' TY OPERATING SCALE THERMOWELL TI PROCESS REFERENCE
TAG No. *1 SERVICE NAME PROCESS MAKER MODEL No. REMARKS
No. / PUMP UNIT / TOTAL TEMP. RANGE MATERIAL CONNECTION DWG. No.
1 CONNECTION
SF490A 41400-1002
1 01HAG03CT532 BRP PUMP CASING TEMPERATURE 1 2 303.6 ℃ 0～500 ℃ NPT3/4" G 1" / Welding WIKA F73.160 Dial type
/ SUS316 41400-1011
41400-1002
2 01HAG03CT531 BRP MOTOR CAVITY TEMPERATURE 1 2 50 ℃ 0～100 ℃ SF490A NPT3/4" G 1" / Welding WIKA F73.160 Dial type
41400-1011
4 3 BRP MOTOR COOLER
3 01PGA02CT542 1 2 43 ℃ 0～100 ℃ SUS316 NPT3/4" Rc 1" WIKA F73.160 41400-1011 Dial type
C.W. OUTLET TEMPERATURE
3 BRP HEAT BARRIER
4 3 BRP PURGE COOLER
8
POWER PROJECT
Instrument List
10
1 ＊1：　Tag No. indicated on the list are for Unit 1.

For example : 02HAG03CT532
Q3C0006083 - 5/6
Doc. No.: 51006-41400-1013
Date: 28/10/2016
Rev. No.: 5
FLOW SWITCH (FS)
INSTRUMENT LIST
5 PRESSURE
SERIAL Q' TY Q' TY BODY SET No. OF SWITCH OPERATING DESIGN CABLE CONNECTION END REFERENCE
TAG No. *1 SERVICE NAME RATING MAKER MODEL No. REMARKS
No. / PUMP UNIT / TOTAL MATERIAL POINT CONTACT RATING PRESS. PRESS. CONNECTION SIZE DETAILS DWG. No.
1 DESIGNATION 1
FLAPPER TYPE
5A, 250VAC/
1 01PGA02CF201 BRP MOTOR COOLER C.W. FLOW RATE LOW 1 2 SUS316 8.1 m3/h 2XSPDT - 10 kg/cm2 g Plug in 2" RF CLASS 150 KAWAKI SF-MAA 41400-1011 Range:0~15㎥/h
0.28A, 220VDC Nor.:11.5㎥/h
FLAPPER TYPE
2 5A, 250VAC/
2 01PGA02CF203 BRP HEAT BARRIER C.W. FLOW RATE LOW 1 2 SUS316 2XSPDT - 10 kg/cm2 g Plug in 1" RF CLASS 150 KAWAKI SF-MAA 41400-1011 Range:0~4㎥/h
1.9 m3/h 0.28A, 220VDC Nor.:2.7㎥/h
FLAPPER TYPE
5A, 250VAC/
3 01PGA02CF202 BRP PURGE COOLER C.W. FLOW RATE LOW 1 2 SUS316 10.5 m3/h 2XSPDT - 10 kg/cm2 g Plug in 2" RF CLASS 150 KAWAKI SF-MAA 41400-1011 Range:0~20㎥/h
0.28A, 220VDC Nor.:15㎥/h
10
POWER PROJECT
Instrument List
1 ＊1：　Tag No. indicated on the list are for Unit 1. RF：RAISED FACE (ASME B16.5-2009)
For example : 02PGA02CF201

Q3C0006083 - 6/6
Doc. No.: 51006-41400-1013
Date: 28/10/2016
Rev. No.: 5
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Logic Diagram / Control Philosophy

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
0940015343 - 1/4 1
POWER PROJECT
Logic Diagram Doc. No.: 51006-41400-1014
Larsen & Toubro Ltd. / Control Philosophy Rev. No.: 1

Date: 17/6/2016
Rev
No.
1 REVISED 17/6/2016
0940015343 - 2/4
POWER PROJECT

Date: 17/6/2016
0940015343 - 3/4
POWER PROJECT

Date: 17/6/2016
0940015343 - 4/4
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: I/O List (BRP)
NTPC Doc./Drg. No.: Unit Designation: 1

Checked

Checked
REVISION STATUS
2 29/6/2016 29/6/2016 29/6/2016
3 26/7/2016 26/7/2016 26/7/2016
Q3C0006030 - 1/5 3
POWER PROJECT
Doc. No.: 51006-41400-1016
I/O List (BRP) Rev. No.: 3
Date: 26/7/2016
Rev
No.
1 REVISED 17/6/2016
2 REVISED 29/6/2016
3 REVISED 26/7/2016
Q3C0006030- 2/5
POWER PROJECT
Doc. No.: 51006-41400-1016
Date: 26/7/2016
Q3C0006030- 3/5
POWER PROJECT
Doc. No.: 51006-41400-1016
Date: 26/7/2016
COLUMN
DESCRIPTION
NUMBER
1 SERIAL NO. :This column shows a serial sequence of the field instruments.
2 TAG NO : Instrument identification number as per KKS numbering system
3 INST. TYPE : Detail description of field instrument type.
4 SERVICE NAME : Service description of each instrument.
5 FROM/TO : "FROM" means the signal source of the equipment or device and
"TO" means the signal destination of the equipment or device.
FLD : FIELD (or Local)
DCS : Distributed Control System (Out of Torishima scope)
6 UNIT : The measuring units in the list are shown as follows:
UNIT(Symbol) MEASUREMENTS REMARKS
degC Temperature Deg. Celsius

m3 / h Flow m3 / h
7 SIGNAL : The type of output signal of each instrument are shown.
DI : Digital Input
8 SET POINT :
HH : High High LL : Low Low

H : High L : Low
9 DISPLAY RANGE : Display range of instrument.
10 CALIBRATION RANGE : Calibration range of instrument.
11 P&ID : P&ID drawing Number.
12 REMARK
13 REVISION
Q3C0006030- 4/5
POWER PROJECT
Doc. No.: 51006-41400-1016
Date: 26/7/2016
Q3C0006030- 5/5
A
B
E
C
D
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
A
B
E
C
D
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Detailed Drawing of Motor Cooler

Checked

Checked
REVISION STATUS
2 19/8/2016 19/8/2016 19/8/2016
3 23/9/2016 23/9/2016 23/9/2016
0920016017 - 1/4 3
POWER PROJECT
Doc. No.: 51006-41400-1020
Detailed Drawing of Motor Cooler Rev. No.: 3
Date: 23/9/2016
Rev
No.
1 REVISED (COOLER MAKER REV.0) 11/5/2016
0920016017 - 2/4
POWER PROJECT
Doc. No.: 51006-41400-1020
Detailed Drawing of Motor Cooler Rev. No.: 3
Date: 23/9/2016
0920016017 - 3/4
0920016017 - 4/4
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Sub Vendor Job No.: PU0137910/28
Title: Detailed Drawing of Purge Cooler

Checked

Checked
REVISION STATUS
1 19/8/2016 19/8/2016 19/8/2016
0930016256 - 1/5 1
POWER PROJECT
Doc. No.: 51006-41400-1021
Detailed Drawing of Purge Cooler Rev. No.: 1
Date: 19/8/2016
Rev
No.
0 FIRST ISSUE (COOLER MAKER REV.2) 20/5/2016
0930016256 - 2/5
POWER PROJECT
Doc. No.: 51006-41400-1021
Detailed Drawing of Purge Cooler Rev. No.: 1
Date: 19/8/2016
0930016256 - 3/5
0930016256-4/5
0930016256-5/5
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Detailed Drawing of Strainer

Checked

Checked
REVISION STATUS
1 15/7/2016 15/7/2016 15/7/2016
0940016705 - 1/4 1
POWER PROJECT
Doc. No.: 51006-41400-1022
Detailed Drawing of Strainer Rev. No.: 1
Date: 15/7/2016
Rev
No.
1 REVISED 15/7/2016
0940016705-2/4
POWER PROJECT
Doc. No.: 51006-41400-1022
Detailed Drawing of Strainer Rev. No.: 1
Date: 15/7/2016
0940016705-3/4
0940016705 - 4/4
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Detailed Drawing of Valves

Checked

Checked
REVISION STATUS
0 Takeshi Ito 17/6/2016 Kazuya Yasui 17/6/2016 Kazuya Yasui 17/6/2016
1 15/7/2016 15/7/2016 15/7/2016
2 13/10/2016 13/10/2016 13/10/2016
0940016794 - 1/10 2
POWER PROJECT
Doc. No.: 51006-41400-1023
Detailed Drawing of Valves Rev. No.: 2
Date: 13/10/2016
Rev
No.
1 REVISED 15/7/2016
2 REVISED 13/10/2016
0940016794 - 2/10
POWER PROJECT
Doc. No.: 51006-41400-1023
Date: 13/10/2016
0940016794 - 3/10
POWER PROJECT
Doc. No.: 51006-41400-1023
Date: 13/10/2016
CONTENTS
１． GLOBE VAVE ······················································································································· 5/10

( MOTOR COOLER AIR VENT / DRAIN, PURGE COOLER AIR VENT / DRAIN )
２． GLOBE VAVE························································································································ 6/10

( BCP PUMP CASING DRAIN )
３． SAFETY RELIEF VALVE·········································································································· 7/10

(MOTOR COOLER, PURGE COOLER )
0940016794 - 4/10
Tag No.
01HAG03AA918, 02HAG03AA918
01HAG03AA919, 02HAG03AA919
01HAG03AA932, 02HAG03AA932
01HAG03AA910, 02HAG03AA910
Tag No.
01HAG03AA916, 01HAG03AA917
02HAG03AA916, 02HAG03AA917
0940016794 - 6/10
2
Sheet No. 2 of 3 Rev.No. 4
Pressure Safety & Relief Valve Project Name

Specifications Project No.
Date 2016. 07. 25. By K.M SEO
Checked S.C.KIM Approved S.C.KIM
P&ID No. 1
Tag No. 2 01HAG03AA102/02HAG03AA102
CALCULATION
Service Line 3 SHELL
Ｌ * Calculation of Area
Ａ Number Required 4 2
Ｒ
Ｅ Nozzle Type, Full or Semi 5 Full Nozzle A1 = 11.78*W1*(√
Ｎ G/(1.25P-Pb))/(Kd*Kb*Kc*Kv*Kp)
Ｅ Design Type 6
Ｇ
A.Conventional or Bellows Conventional = 11.78 *191.667 * (√1 / ( 1.25 *980 -0)) /
B.Full Bore, Low or High Lift Full Bore Type (0.62 *1 *1 *1 *0.6)
Bonnet Type. Open or Close 7 Close
Ｎ
Ｏ
Ｉ Size. Inlet / Outlet 8 1"X2"
Ｔ
Ｃ = 173.41 ㎟
Ｅ
Ｎ Inlet. Rating / Facing 9 ANSI 150LB RF
Ｎ
Ｏ
Ｃ Outlet. Rating / Facing 10 ANSI 150LB RF
Body 11 A351 CF8 * Calculation of Capacity
Ｓ Bonnet 12 A351 CF8 W = A*Kd*Kb*Kc*Kv*Kp/(11.78*√
Ｌ
Ａ Seat 13 A351 CF8-st. (G/(1.25P-Pb)))
Ｉ
Ｒ Disc 14 A276 304-st.
Ｅ = 283.529 *0.62 *1 *1 *1 *0.6 / ( 11.78 * √(1
Ｔ Guide 15 A351 CF8 / ( 1.25 *980 -0)))
Ａ Gasket 16 PTFE
Ｍ
Spring 17 SWOSC
Bellows 18 = 313.4 ℓ/min
Ｙ 19 Screwed
Ｒ Cap. Type 18.8 m3/h
Ｏ
Ｓ Lever. Plain or Packed 20 None Lever
Ｓ
Ｅ 21
Ｃ Test Gag No
Ｃ
Ａ Paint Color 22 None
Ｃ
Ｉ Code 23 API RP 520 W = Valve Capacity ........................ 313.40 ℓ/min
Ｓ Fire 24 No
Ａ W1 = Required Capacity .................. 191.67 ℓ/min
Ｂ Sizing Basis 25 NA P = Set Pressure ............................. 980 KPag
Fluid and State 26 COOLING WATER(L)
A1 = Calculated Area ....................... 173.41 ㎟
Required Capacity 27 11.5 m3/h
Mol. Weight or Specific Gravity 28 1 A = Selected Area .......................... 283.529 ㎟
Viscosity 29 Kd = Coefficient of Discharge ........ 0.62
Operating / Set Pressure 30 10 Kgf/㎠g G = Specific Gravity
Ｅ Operating / Blowout Temp 31 37.6 / 40.6 ℃ ................................................. 1.000
Ｃ
Ｉ Constant Back Pressure 32 Kgf/㎠g
Ｖ Pb = Back Pressure............................... 0 KPag
Ｒ
Variable Back Pressure 33 Kgf/㎠g
Ｅ Built-up Back Pressure 34 Kgf/㎠g Kb = Correction Factor Due to Back Pressure 1
Ｓ
Total Back Pressure 35 0 Kgf/㎠g Kc = Correction Factor for a rupture disk 1
Closing Pressure 36 Min. 0 Kgf/㎠g Kv = Correction Factor due to Viscosity.......... 1
Hydrostatic Test 37 15 Kgf/㎠g
Kp = Correction Factor due to Overpressure... 0.6
Allowable Overpressure 38 10 %
Compressibility Factor 39 Remark
Ratio of Specific Heat 40 *Required capacity : 191.67 L/min
*CDTP : 10 Kgf/㎠g
Ｅ Calculated Area 41 173.41 ㎟
Ｃ
Ｉ Selected Area 42 283.529 ㎟
Ｆ Orifice Dia.(mm) 43 F(19)
Ｉ
Ｒ Valve Capacity 44 18.8 m3/h
Ｏ
Model No. 45 JSV-FF21
Cert. Approved by 46 /
Ref. No : 160608-091-20-413926-0 JOKWANG I.L.I CO.,LTD. No.TTIPCF500-2

0940016794 - 7/10
2
2016-07-26
TAG NO. 01HAG03AA102/02HAG03AA102
0
0
0
0
0 4
dwg02 36 PLUG A276 304 1

30 SET SCREW GASKET PTFE 2
CF8 29 SEAT GASKET PTFE 1
28 CAP GASKET PTFE 1
27 BONNET GASKET PTFE 1
025050 20 DISC RING A276 304 1
18 SET SCREW(UPP.) A276 316 1
F 17 SET SCREW(LOW.) A276 316 1
16 LOCK NUT A276 304 1
10
15 STUD BOLT A193 B8M 4
C 14 STUD NUT A194 8M 4
13 ADJUST SCREW A276 304 1
N 12 SPRING SEAT(UPP.) A276 304 1
11 SPRING SEAT(LOW.) A276 304 1
150
10 SPRING SWOSC 1
R 9 VALVE STEM A582 303 1
8 ADJUST RING(UPP.) A351 CF8 1
150 7 ADJUST RING(LOW.) A351 CF8 1
6A DISC A276 304-st. 1
R 6 DISC HOLDER A351 CF8 1
N 5 DISC GUIDE A351 CF8 1
0940016794 - 8/10
4 SEAT A351 CF8-st. 1

3 CAP A351 CF8 1
ANSI
2 BONNET A351 CF8 1
1 BODY A351 CF8 1
NO PART NAME MATERIAL Q'TY REMARK
DWG NO. JKS-SLQ024798 -20 Designed Checked Approved
MODEL JSV-FF21
DIMENSION UNIT : mm
INLET FLANGE ASME B 16.5 CL150 RF OUTLET FLANGE ASME B 16.5 CL150 RF Wt(kg) DATE 2016-07-11 J.Y.LIM Y.S.KIM J.K.KIM
SIZE d d1 dt L H1 H FULL BORE TYPE SAFETY RELIEF VALVE REV
D g k c T f N-H D1 g1 c1 T1 f1 n-h
12.45
1xFx2 25 50 19 103 104 338 108 51 - 79.5 22 7 4-16 152 92 120.5 19.1 1.6 4-19 JOKWANG I.L.I CO.,LTD. 4
2
Sheet No. 1 of 3 Rev.No. 4
Pressure Safety & Relief Valve Project Name

Specifications Project No.
Date 2016. 07. 25. By K.M SEO
Checked S.C.KIM Approved S.C.KIM
P&ID No. 1
Tag No. 2 01HAG03AA101/02HAG03AA101
CALCULATION
Service Line 3 SHELL
Ｌ * Calculation of Area
Ａ Number Required 4 2
Ｒ
Ｅ Nozzle Type, Full or Semi 5 Full Nozzle A1 = 11.78*W1*(√
Ｎ G/(1.25P-Pb))/(Kd*Kb*Kc*Kv*Kp)
Ｅ Design Type 6
Ｇ
A.Conventional or Bellows Conventional = 11.78 *250 * (√1 / ( 1.25 *980 -0)) / (0.62
B.Full Bore, Low or High Lift Full Bore Type *1 *1 *1 *0.6)
Bonnet Type. Open or Close 7 Close
Ｎ
Ｏ
Ｉ Size. Inlet / Outlet 8 1"X2"
Ｔ
Ｃ = 226.19 ㎟
Ｅ
Ｎ Inlet. Rating / Facing 9 ANSI 150LB RF
Ｎ
Ｏ
Ｃ Outlet. Rating / Facing 10 ANSI 150LB RF
Body 11 A351 CF8 * Calculation of Capacity
Ｓ Bonnet 12 A351 CF8 W = A*Kd*Kb*Kc*Kv*Kp/(11.78*√
Ｌ
Ａ Seat 13 A351 CF8-st. (G/(1.25P-Pb)))
Ｉ
Ｒ Disc 14 A276 304-st.
Ｅ = 283.529 *0.62 *1 *1 *1 *0.6 / ( 11.78 * √(1
Ｔ Guide 15 A351 CF8 / ( 1.25 *980 -0)))
Ａ Gasket 16 PTFE
Ｍ
Spring 17 SWOSC
Bellows 18 = 313.4 ℓ/min
Ｙ 19 Screwed
Ｒ Cap. Type 18.8 m3/h
Ｏ
Ｓ Lever. Plain or Packed 20 None Lever
Ｓ
Ｅ 21
Ｃ Test Gag No
Ｃ
Ａ Paint Color 22 None
Ｃ
Ｉ Code 23 API RP 520 W = Valve Capacity ........................ 313.40 ℓ/min
Ｓ Fire 24 No
Ａ W1 = Required Capacity .................. 250.00 ℓ/min
Ｂ Sizing Basis 25 NA P = Set Pressure ............................. 980 KPag
Fluid and State 26 COOLING WATER(L)
A1 = Calculated Area ....................... 226.19 ㎟
Required Capacity 27 15 m3/h
Mol. Weight or Specific Gravity 28 1 A = Selected Area .......................... 283.529 ㎟
Viscosity 29 Kd = Coefficient of Discharge ........ 0.62
Operating / Set Pressure 30 10 Kgf/㎠g G = Specific Gravity
Ｅ Operating / Blowout Temp 31 37.6 / 43.6 ℃ ................................................. 1.000
Ｃ
Ｉ Constant Back Pressure 32 Kgf/㎠g
Ｖ Pb = Back Pressure............................... 0 KPag
Ｒ
Variable Back Pressure 33 Kgf/㎠g
Ｅ Built-up Back Pressure 34 Kgf/㎠g Kb = Correction Factor Due to Back Pressure 1
Ｓ
Total Back Pressure 35 0 Kgf/㎠g Kc = Correction Factor for a rupture disk 1
Closing Pressure 36 Min. 0 Kgf/㎠g Kv = Correction Factor due to Viscosity.......... 1
Hydrostatic Test 37 15 Kgf/㎠g
Kp = Correction Factor due to Overpressure... 0.6
Allowable Overpressure 38 10 %
Compressibility Factor 39 Remark
Ratio of Specific Heat 40 *Required capacity : 250 L/min
*CDTP : 10 Kgf/㎠g
Ｅ Calculated Area 41 226.19 ㎟
Ｃ
Ｉ Selected Area 42 283.529 ㎟
Ｆ Orifice Dia.(mm) 43 F(19)
Ｉ
Ｒ Valve Capacity 44 18.8 m3/h
Ｏ
Model No. 45 JSV-FF21
Cert. Approved by 46 /
Ref. No : 160608-091-10-413925-0 JOKWANG I.L.I CO.,LTD. No.TTIPCF500-2

0940016794 - 9/10
2
2016-07-26
TAG NO. 01HAG03AA101/02HAG03AA101
0
0
0
0
0 4
dwg02 36 PLUG A276 304 1

30 SET SCREW GASKET PTFE 2
CF8 29 SEAT GASKET PTFE 1
28 CAP GASKET PTFE 1
27 BONNET GASKET PTFE 1
025050 20 DISC RING A276 304 1
18 SET SCREW(UPP.) A276 316 1
F 17 SET SCREW(LOW.) A276 316 1
16 LOCK NUT A276 304 1
10
15 STUD BOLT A193 B8M 4
C 14 STUD NUT A194 8M 4
13 ADJUST SCREW A276 304 1
N 12 SPRING SEAT(UPP.) A276 304 1
11 SPRING SEAT(LOW.) A276 304 1
150
10 SPRING SWOSC 1
R 9 VALVE STEM A582 303 1
8 ADJUST RING(UPP.) A351 CF8 1
150 7 ADJUST RING(LOW.) A351 CF8 1
6A DISC A276 304-st. 1
R 6 DISC HOLDER A351 CF8 1
N 5 DISC GUIDE A351 CF8 1
0940016794 - 10/10
4 SEAT A351 CF8-st. 1

3 CAP A351 CF8 1
ANSI
2 BONNET A351 CF8 1
1 BODY A351 CF8 1
NO PART NAME MATERIAL Q'TY REMARK
DWG NO. JKS-SLQ024798 -10 Designed Checked Approved
MODEL JSV-FF21
DIMENSION UNIT : mm
INLET FLANGE ASME B 16.5 CL150 RF OUTLET FLANGE ASME B 16.5 CL150 RF DATE 2016-07-11 J.Y.LIM Y.S.KIM J.K.KIM
Wt(kg)
SIZE d d1 dt L H1 H FULL BORE TYPE SAFETY RELIEF VALVE REV
D g k c T f N-H D1 g1 c1 T1 f1 n-h
12.45
1xFx2 25 50 19 103 104 338 108 51 - 79.5 22 7 4-16 152 92 120.5 19.1 1.6 4-19 JOKWANG I.L.I CO.,LTD. 4
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Detailed Drawing of Major Pump Components

Checked

L&T-S&L Date Name
Checked
REVISION STATUS
1 9/9/2016 9/9/2016 9/9/2016
Q3C0006598 - 1/5 1
POWER PROJECT
Detailed Drawing of Doc. No.: 51006-41400-1024
Larsen & Toubro Ltd. Major Pump Components Rev. No.: 1

Date: 9/9/2016
Rev
No.
1 REVISED 9/9/2016
Q3C0006598 - 2/5
POWER PROJECT
Detailed Drawing of Doc. No.: 51006-41400-1024
Larsen & Toubro Ltd. Major Pump Components Rev. No.: 1

Date: 9/9/2016
Q3C0006598 - 3/5
Item No. Name of Parts Sketch Size Material ( Eq. ASTM Mat. ) Weight [kg] Remarks
L W H Approx.
ROTOR SET
1 2620 φ246 - *1 950

・SHAFT (2100)
・ROTOR COMPLETE (8180)
HEAT BARRIER SET
・HEAT BARRIER (1520) 1

2 705 φ980 - *1 1700
・SUPPORT RING (5011)
・HEAT INSULATION (6890)
・CASING WEARING (5020.2)
SCS1-T2
3 IMPELLER (2300) 334 φ630 - 100
( A743 Gr. CA15 )
POWER PROJECT
Detailed Drawing of
Major Pump Components
MOTOR CASING SET
・MOTOR CASING COMPLETE

(8110)
・STATOR COMPLETE (8130)
4 2265 φ1340 1405 *1 10000 8000 1
・TERMINAL BOX DRAWING
　(41400-1019)
*1：The detail are given in Sectional Drawing of Pump / Motor ( 41400-1018) and Main Terminal Box ( 41400-1019).
Q3C0006598 - 4/5
Doc. No.: 51006-41400-1024

Date: 9/9/2016
Rev. No.: 1
Item No. Name of Parts Sketch Size Material ( Eq. ASTM Mat. ) Weight [kg] Remarks
L W H Approx. Larsen & Toubro Ltd.
SF490A
5 THRUST BEARING CASE (3540) 411 φ800 - 1155
(A266 Gr.2)
PLAIN BEARING COMPLETE FC250/FRP

6 (3100.1 / 2) 225 φ310 - 35 Upper and Lower
( A48 Cl. 250 / FRP )
POWER PROJECT
SUS420J2 HCr Plating

7 THRUST BEARING PLATE (3840) 230 φ310 - 50
( A473 S42000 )
Detailed Drawing of
Major Pump Components
*1：The detail are given in Sectional Drawing of Pump / Motor ( 41400-1018) and Main Terminal Box ( 41400-1019).
Q3C0006598 - 5/5
Doc. No.: 51006-41400-1024

Date: 9/9/2016
Rev. No.: 1
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Drawing & Data sheets of Instruments

Checked

Checked
REVISION STATUS
1 6/7/2016 6/7/2016 6/7/2016
2 5/8/2016 5/8/2016 5/8/2016
0940016810 - 1/25 2
POWER PROJECT
Drawing & Data sheets Doc. No.: 51006-41400-1025
Larsen & Toubro Ltd. of Instruments Rev. No.: 2

Date: 5/8/2016
Rev
No.
1 REVISED 6/7/2016
2 REVISED 5/8/2016
0940016810 - 2/25
POWER PROJECT

Date: 5/8/2016
0940016810 - 3/25
POWER PROJECT

Date: 5/8/2016
CONTENTS
１． RESISTANCE TEMPERATURE DETECTOR ･･･････････････････････････････ 5/25
２． THERMOMETER ･･･････････････････････････････ 7/25
３． FLOW SWITCH ･･･････････････････････････････ 12/25
ANNEX 1. CATALOGUE OF RESISTANCE TEMPERATURE DETECTOR･･････････ 16/25
ANNEX 2. CATALOGUE OF THERMOMETER ･･･････････････････････････････ 18/25
ANNEX 3. CATALOGUE OF FLOW SWITCH ････････････････････････････････ 25/25
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0940016810 - 24 / 25
0940016810 - 25 / 25
"THIS DRAWING IS THE PROPERTY OF AND CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF L&T-MHPS BOILERS PRIVATE LIMITED AND SHALL UNLESS OTHERWISE STATED ALL DIMENSIONS ARE
"THIS DRAWING IS THE PROPERTY OF AND CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF L&T-MHPS BOILERS PRIVATE LIMITED AND SHALL UNLESS OTHERWISE STATED ALL DIMENSIONS ARE
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Detail drawing of Bolt heater & Switch box
Unit Designation: 1 & 2

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
1 29/9/2016 29/9/2016 29/9/2016
0930016642 - 1/7 1
POWER PROJECT
Detail drawing of Doc. No.: 51006-41400-1033
Larsen & Toubro Ltd. Bolt heater & Switch box Rev. No.: 1
Date: 29/9/2016
Rev
No.
1 REVISED 29/9/2016
0930016642 - 2/7
POWER PROJECT
Detail drawing of Doc. No.: 51006-41400-1033
Larsen & Toubro Ltd. Bolt heater & Switch box Rev. No.: 1
Date: 29/9/2016
0930016642 - 3/7
0930016642-4/7
0930016642-5/7
0930016642-6/7
0930016642-7/7
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Lifting Plan Drawing

Checked

L&T-S&L Date Name
Checked
REVISION STATUS
1 9/9/2016 9/9/2016 9/9/2016
G5C0003366 - 1/28 1
POWER PROJECT
Doc. No.: 51006-41400-1041
Lifting Plan Drawing Rev. No.: 1
Date: 9/9/2016
Rev
No.
1 REVISED 9/9/2016
G5C0003366 - 2/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
G5C0003366 - 3/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
Contents
0. General ・・・・5/28
0. Safety precautions ・・・・6/28
1. Handling Instruction ・・・・7/28
1.1 Description of Major Component ・・・・7/28
1.2 Guidelines for temporary storage on site ・・・・7/28
1.3 Guidelines for conservation on site ・・・・7/28
1.4 Special precaution for transportation ・・・・8/28

and installation on site
2. Delivery Condition ・・・・9/28
3. Pump Casing Installation ・・・・10/28
3.1 Lifting Pump Casing ・・・・10/28
3.2 Misalignment ・・・・10/28
4. Lifting the Motor ・・・・11/28
5. Tightening of Stud Bolts ・・・・14/28
5.1 Determination of Initial Tightening Starting Position ・・14/28
5.2 Tightening by Bolt Heaters ・・・・17/28
6. Installation of Motor Cooler ・・・・22/28
7. Installation of the Cooling Water Piping

and the Instruments ・・・・23/28
8. Installation of Purge Cooler ・・・・24/28
9. Dismantling & Hanging down of the Motor ・・・・25/28
9.1 Preparation of Dismantling ・・・・25/28
9.2 Dismantling of the Motor ・・・・25/28
Tightening Record Sheet ・・・・28/28
G5C0003366 - 4/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
General
● In order to ensure trouble-free operation of the pumpset, it shall be carefully installed
according to the instructions contained herein.
Before installation of the pumpset, read this manual and all and related documents to fully
understand the contents.
● Modifications or alterations of the equipment supplied shall not be made without prior
permission from the manufacturer. Original spare parts and accessories authorized by
the manufacturer ensure safety. The use of third party parts invalidates any liability of
the manufacturer for the damage caused.
● During the validity period of guarantee by Torishima, NO dismantling of the pump or its
individual components shall be carried out without obtaining Torishima’s consent in this
respect.
● The pump name plate indicates pump type, main operating data, production No. and unit No.
Please quote this information in all queries.
G5C0003366 - 5/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
Safety precautions
This manual contains fundamental information and instructions that must be complied with during.
the erection of the pumpset.
Non-compliance with the instructions contained herein can cause injury of operator, failure of unit
functioning and damage to the pumpset. Therefore, this manual must be read and understood
prior to the installation.
Qualification of Staff
Only appropriately qualified staff must be employed in the erection activities.
Safety Alerts and Warning Notes
The safety instructions and warning notes contained in this manual are marked by symbols as follows.
SYMBOL DESCRIPTION
Potential hazard that could result in death or serious injury
Potential hazard that could result in minor or moderate injury

Alert against unsafe practices
Potential hazard that could result in damage to the equipment

and/or equipment malfunction
Informational notes
General safety instructions for erection

● Never open the terminal cover of any electrical device when it is energized. There is a risk of
electric shock.
● Wear helmet, safety shoes, etc before approaching the erection.
● When lifting equipment or component using lifting device, check the center of gravity first and
apply appropriate arrangement of lifting tackle to prevent accidental drop of the goods.
● Never enter underside of the lifted heavy equipments or components.
● Make sure the motor is isolated from power source.
● When moving heavy equipments or components, hang wire ropes to the positions as shown
in the instruction manual and use a chain block, etc.
● Never touch the Bolt heaters, Stud Bolts or other components of pump while is hot.
G5C0003366 - 6/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
1.Handling Instruction
1.1 Description of Major Component
Refer to the following documents for the detailed description of the pumpset.
TITLE DRAWING NO.
GA Drawing 41400-1002
P&I Diagram 41400-1011
Sectional Drawing of Pump Motor 41400-1018
Sectional Drawing of Main Terminal Box 41400-1019
Detailed Drawing of Motor Cooler 41400-1020
Special Tool List 41400-1051
O&M Manual 41400-1050
1.2 Guidelines for temporary storage on site
When it becomes necessary to store the equipment for a short time before erection, place the
pumpset in a dry location, protected from the elements if possible, where it cannot be affected
by ingress of moisture.
It is important that bearings, pipings, etc. are suitably protected against ingress of insects, grit
dust or other foreign matter.
1.3 Guidelines for conservation on site
In addition to the measure described for temporary storage, the following should be applied.
Check the condition of the painted surfaces every three months. If corrosion is observed, remove
it and apply a coat of paint again.
Check the condition of anti-corrosive coating on blank metal surfaces (e.g. screw of bolts) every
three months. If any corrosion is observed, remove it with a fine emery cloth and perform
the anti-corrosive treatment again.
In order to prevent the inside of motor from rusting, N2 gas should be filled in Motor every 2-3
month.
Refer to Operation and Maintenance manual - item 3.2.2 : Dry Preservation about detail procedure
for N2 gas filling.
G5C0003366 - 7/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
1.4 Special precaution for transportation and installation on site
● When receive unit, inspect it that there are neither discrepancy from your requested
specifications nor damages during transportation. This unit is shipped after our inspection
is done under QA systems.
● Be careful not to damage the goods when unpacking.
● Care must be taken in handing and installing equipment, particularly in protecting Rotor
extensions, machined faces, electric cables, instrumentation, small bore pipework and
ancillary parts. Use soft padding material as necessary to protect the equipments from
damage by lifting tackles.
Move equipments slowly when placing on the floor.
● Do not place equipments directly on the ground. Use protecting material like wooden block.
● Pay due attention to prevent the rusting of the goods before pump operation.
● Do not remove the desiccant (Silica-gel) in the terminal box in order to protect the terminal
box from the moisture.
G5C0003366 - 8/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
2.Delivery Condition
( Main components)
MOTOR SET
approx. 12000 kg 1
※N2 gas is filled in the Motor.
PUMP CASING
approx. 7600 kg 1
MOTOR COOLER
approx. 295 kg 1
G5C0003366 - 9/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
3. Pump Casing Installation
3.1 Lifting the Pump Casing
The pump casing mass is approx. 7600 kg. 1
The cover fixed on suction nozzle, discharge

nozzle and bottom of casing should be removed
just before welding.
The protection for bolt screw should also be

removed just before installation of
the motor.
3.2 Misalignment
Misalignment between pump center line and

perpendicular shall be within 1 degree.
Pump casing position for welding
G5C0003366 - 10/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
4. Lifting the motor
The motor assembly mass is approx. 12000 kg. 1
Don't remove the temporary cover during

lifting work.
Lifting Device (1)

- To be prepared by customer.
Lifting lugs are attached to the motor flange.
Lifting Device (2)

The Motor is bound by the lifting device (2). Lifting Device (1)
g
Lifting Device (2)
g
In case removal of temporary cover
during motor lifting (shown in the next page)
is impossible, following conditions must be
secured.
・Don't damage sealing surface.
・Don't damage motor set.
・Prevent any dust from sealing surface.
・Prevent any dust entering motor inside.
・Prevent any shock from impeller.
If the above mentioned instructions are
not secured, performance and operation Mass approx. 12000 kg 1
of the pump/motor unit should not be
guaranteed.
Take great care in case the other
procedure than that written in this
manual would be carried out.
Set the terminal box orientation as per

GA Drawing.
(DRAWING NO. 41400-1002)
G5C0003366 - 11/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
Paint the bolt numbers on both pump casing

and motor flange. ( 1 to 20 )
Bolts number
1 to 20
* Removing plan for temporary cover (For example)
Remove the temporary cover & ring .

Then inspect pump and motor sealing faces .
Temporary cover is approx. 200 kg.
Temporary ring is approx. 20 kg.
When removing a cover, be careful

enough about a damage to motor set
and sealing surfaces.
G5C0003366 - 12/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
Strip paint around measuring points.

- Bottom of pump casing. ( 4 points.)
- Top of Motor flange. ( 4 points.)
Measuring point
① Bolt 3- 4
② Bolt 8- 9
③ Bolt 13-14
④ Bolt 18-19
G5C0003366 - 13/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
5. Tightening of Stud Bolts
5.1 Determination of Initial Tightening

Starting Position
Measure dimensions B & C at 4 points each

by Digital depth gauge or Inside micro meter.
※ The variation of each value should be

within 0.05mm
Max. value – Min. value ≦ 0.05
Initial Tightening Starting Position "A" should

be calculated by the formula below.
Initial Tightening Starting Position "A"
Calculated “A” = C － B + 1.6

Record Dimensions (A, B, C)
( Recording format ： Page 25 )
※ B：Average value of measured 4 points.

C：Average value of measured 4 points.
G5C0003366 - 14/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
Set the Gasket (4113) on the groove of

Heat barrier.
Refer to Sectional Drawing of Pump Motor

about parts number 4113.
(DRAWING NO. 41400-1018)
Stop lifting motor set at the position

Impeller approaches Casing Wearing Ring.
Lift motor set slowly by Calculated “A” for the 4

points and carefully operating 2 nos. of chain blocks
at the same time till Impeller is positioned into
Casing Wearing Ring smoothly.
Stop lifting motor set in case the Impeller touches

Casing Wearing Ring during lifting, then lift down
motor set and inspect Impeller and Casing Wearing
Ring for damage.
Repeat lifting and setting properly.

approx.230mm
When the motor set is lifted forcibly,

Impeller or Casing Wearing Ring
breaks.
Locate washers and nuts on Stud bolts,

as the heads of stud bolts protrude
approx.230mm from motor flange.
Coat threads of Stud bolts and nuts end with

molybdenum sulfide.
Starting distance "A" should be measured by

inside micrometer and confirm the measured
is"A" within the above calculated
"A" ±0.1mm.
Measured “A” － Calculated “A” ≦ ±0.1mm
The variation of each value Measured "A"

should be within 0.05mm
G5C0003366 - 15/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
Indicate mating mark between each nut and

motor flange.
The marks are attached to the hex. Nut

and equally divided into 24.
360
24
15
G5C0003366 - 16/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
5.2 Tightening by Bolt Heaters
(1) Turn off all the switch of the switch box.
(2) Connect the Power supply cable

for Switch box.
G5C0003366 - 17/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
(3) Connect all the Bolt heaters

to the Switch box.
(4) Set the 20 bolt heaters to each stud bolt.
G5C0003366 - 18/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
(5) Switch on Group No.1 bolt heaters.

(10 heaters.)
Group No.1：●
（positionN0.：1, 3, 5, 7, 9, 11, 13, 15, 17, 19）
Group No.2：○
（positionN0.：2, 4, 6, 8, 10, 12, 14, 16, 18, 20)
(6) Confirm all the stud bolts of Group No.1 are

being heated up.
(7) During the heating up process, surface

temperature of the stud bolts should not
be allowed to exceed 300 ℃.
The temperature can be monitored e.g.
with aid of temperature crayon or
surface thermometer.
Don't touch bolt surface while they are hot.
To protect the bolt heater, do not

heat the stud bolts continuously
for 1 hour or more.
G5C0003366 - 19/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
Group No.1 Stud bolts
(8) Tighten each nut for Group No.1 Stud bolts

by 13 scale divisions.
Use the spanner of special tool.
In order to turn by hand, it is not necessary
to measure torque.
Nut Scale
(9) Switch off all bolt heaters and let the stud
bolts cool down to approx.60℃.
( Group No.1 Stud bolts)
(10) Then switch on the Group No.2 bolt

heaters.
Group No.2 Stud bolts
(11) Tighten these 10 nuts for Group No.2

Stud bolts by 25 scale divisions.
to measure torque.
Nut Scale
G5C0003366 - 20/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
(12) Switch off the Group No.2 bolt heaters

and let the stud bolts cool down to
approx. 100℃.
(13) Switch on the Group No.1 bolt heaters. Group No.1 Stud bolts
(14) Tighten the nuts for Group No.1 additional

12 scale divisions.
( total 25 scale divisions)
to measure torque.
(15) After all the stud bolts are cooled down

to ambient temperature,
the flange to flange distance "A' "
should be measured 4 points by inside
micrometer and confirm the uniform
tightening.
Record the distances.
A
( Recording format ： Page 25)
G5C0003366 - 21/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
6. Installation of Motor Cooler
(1) Clean up the sealing surfaces of flanges

by the thinner.
(2) flanges ①,②,③ should be tightened

uniformly and diagonally.
Check the flange distance.
＊ The flange positions should be adjusted to

be able to tighten easily 4 bolts of flange.
(4 bolts should not touch the hole of
flange)
(3) Tightening torque (unit "kgf ･m")
① 2" : 46 to 57
② 1" : 31 to 38
③－ : 62 to 77
(4) Tighten the bolts (mark * )

of the cooler support.
① : ASME2500 RJ 2”
BOLT SIZE : 1-8UNCx180
NUT SIZE : 1-8UNC
GASKET :R26OCTAGONAL
② : ASME2500 RJ 1”
BOLT SIZE : 7/8-9UNC X 130
NUT SIZE : 7/8-9UNC
GASKET : R18 OCTAGONAL
③:－
BOLT SIZE : 1.1/8-8UNC X 140
NUT SIZE : 1.1/8-8UNC
GASKET : φ5－ID100
G5C0003366 - 22/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
7. Installation of the Cooling Water Piping

and the Instruments
Connect the cooling water piping and

install the instruments.
The cooling water piping should be flexible to

be free the pump set movement by the heat
expansion and contraction of main boiler
piping.
The pumping set should be primed with clean
and cold water immediately after completion
of erection, because of motor prevention.
Priming procedure refer to O&M manual item5.1
① : ASME150 RF 2”
BOLT SIZE : 5/8-11UNC
NUT SIZE : 5/8-11UNC
② : ASME150 RF 1”
G5C0003366 - 23/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
8. Installation of Purge Cooler
(1) Clean up the sealing surfaces of flanges

by the thinner.
(2) Fix the purge cooler by support.
(3) Connect the purge cooler B.F.W line,

the cooling water piping, air vent,
safety relief valve line and drain.
② BW 1”
①, ③ : ASME150 RF 2”
④, ⑤ : ASME150 RF 1”
G5C0003366 - 24/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
9. Dismantling and Hanging down of the

Motor
9.1 Preparation of Dismantling
(1) Drainage
( Procedure：refer to O&M manual item4.2 )
(2) Dismantling of the piping and the

Instrument.
(3) Dismantling of the Motor Cooler.
9.2 Dismantling of the Motor
(1) Set the chain block on the motor lifting lug.
Bolt Heater (x20)

(2) Prepare the bolt heaters, a switch box
and spanner.
G5C0003366 - 25/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
(3) Turn on 20 switches for bolt heaters.

(Exclude 1×spare bolt heaters.)
Don't turn on the switch while Bolt

heaters have not been set in the
stud bolts.
(4) Unscrew the nuts and remove washers.

Hang down the motor by chain block.
G5C0003366 - 26/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
(5) Set the cover.
Lifting Device (1)
Lifting Device (1) g

Lifting Device (2)
Lifting lugs are attached to the motor flange. g
Lifting Device (2)

The Motor is bound by the lifting device (2).
Mass approx. 11700 kg
G5C0003366 - 27/28
POWER PROJECT
Doc. No.: 51006-41400-1041
Date: 9/9/2016
製番　Product No. ：　　　　　　　　　　　　　　　　　　　

締付記録（現地）
Tightening Record (At Site)
形式　Pump Type ：　　　　　　　　　　　　　　　　　　　
寸法、位置、 B(ﾃﾞｼﾞﾀﾙﾃﾞﾌﾟｽ) C(内ﾏｲｸﾛﾒｰﾀ
精度
又はﾃﾞｼﾞﾀﾙﾃﾞﾌﾟｽ)
Bolt No.
by Inside Micrometer
Measure by Digital Depth Gauge
or Digital Depth Gauge View from Suction End
図面寸法　 (scale:1/100mm) (scale:1/100mm) 吸込裏側から見て
Nominal for reference
(140) (460)
No. 参考測定 For reference
ｶﾞｽｹｯﾄ厚　取付溝
Thickness of Gasket Depth of Groove
(4.5 +0.2
0 ) (3.05 +0.05
0 )
平均：Average 計測位置
締付起点の計算（平均値使用）
Initial Starting Distance
A = C - B + 1.6 = ±0.1(mm)
（測定値A　　-　　計算値A ≦ ±0.1 [mm] ）
　Measured A　　　　　　　　　Calculated A 計測位置 (Measure points)
A（締付前） A'（締付後)
寸法、位置、 A-A'
before tightening last tightening 締付前 (before tightening）
精度
内ﾏｲｸﾛﾒｰﾀ内ﾏｲｸﾛﾒｰﾀ
Measure by inside micrometer by inside micrometer
計算値
Calculate
Bolt No. (scale:1/100mm) (scale:1/100mm)
締付後
備考 (1) B,C,A & A'各点は4ヶ所それぞれ等分位置とする。 (Measurement after last tightening)
Remark: The component dimensions (B, C ,A & A') should
be measured at 4 circumferentially distributed
points.
(2) A,B,C各点の測定寸法の各々のバラツキは0.05mm
以内とする。
Each point of B, C & Measured A shall have a
dispersion value of within 0.05mm.
(3) ＋2
SKT : 25
　0
(4) ねじピッチ(Thread pitch) : 3
(5) A-A'の4点のバラツキは0.1mm以内とする。
A-A'shall have a dispersion value of within 0.1mm.
(6) 1度潰したｶﾞｽｹｯﾄを再使用すると完全なｼｰﾙ力が
発揮できません。
When the gasket crushed once was reused,
complete seal power will not be performed.
Signature
Name
Data
G5C0003366 - 28/28
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:
Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Special Tool List

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
0 1/7/2016 1/7/2016 1/7/2016
1 14/12/2016 14/12/2016 14/12/2016
Q3C0006688 - 1/6 1
POWER PROJECT
Doc. No.: 51006-41400-1058
Special Tool List Rev. No.: 1
Rev
No.
1 REVISED 14/12/2016
Q3C0006688- 2/6
POWER PROJECT
Doc. No.: 51006-41400-1058
Q3C0006688- 3/6
POWER PROJECT
Doc. No.: 51006-41400-1058
Item Size
Name of Parts Sketch Material Q'ty Remarks
No. L W H
BOLT
1 850 OD15 - SUS321 22 FOR MAIN STUD 9020.1
HEATER
SWITCH
2 600 250 600 SPCC 1 do.
BOX
3 SPANNER 500 T16 120 SS400 2 do.
FOR THRUST BEARING

4 EYE BOLT - M30 - SS400 4
CASE
JACKING FOR THRUST BEARING

5 400 M24 - SS400 2
BOLT CASE
JACKING FOR HEAT BARRIER

6 100 M16 - SS400 4
BOLT etc.
STAKING FOR LOCK SLEEVE

7 150 OD10 - SKH14 1
TOOL 9317.1, 3
FOR LOCK SLEEVE

STAKING 9317.1
8 120 OD12 - SKH14 1
TOOL
* Needle Dia. : 3.9mm
Q3C0006688- 4/6
POWER PROJECT
Doc. No.: 51006-41400-1058
Item Size
No. L W H
FOR LOCK SLEEVE

STAKING 9317.3
9 120 OD12 - SKH14 1
TOOL
* Needle Dia. : 2.6mm

10 160 OD32 - SKH14 1
TOOL 9317.1

11 160 OD22 - SKH14 1
TOOL 9317.3
WITHDRAWING TOOL
FOR IMPELLER
12 PLATE 27 OD75 - S45C 1
ANDTHRUST
BEARING PLATE
13 PLUG 150 OD25 - S45C 1 do.
JACKING
14 200 M20 - SS400 1 do.
BOLT
SOCKET
15 HEAD CAP 35 M10 - SCM435 2 do.
SCREW
WITHDRAWING TOOL
FOR
16 PLATE T6 OD525 - SS400 1
THRUST BEARING
PLATE
Q3C0006688- 5/6
POWER PROJECT
Doc. No.: 51006-41400-1058
Item Size
No. L W H
WITHDRAWING TOOL
FOR
17 BOLT 300 M16 - SS400 2
THRUST BEARING
PLATE
18 HEX. NUT 13 M16 - SS400 4 do.
DON’T THROW AWAY

THE COVER,
SS400
19 COVER 490 OD981 - 3 BECAUSE THE COVER
/ STPY
WAS DISPATCHED
WITH THE MOTOR.
FOR COVER.
DON’T THROW AWAY
THE RING, BECAUSE
20 RING 25 OD981 - SS400 3
THE RING WAS
DISPATCHED WITH
THE MOTOR.
FOR COVER.
DON’T THROW AWAY
BOLTS, BECAUSE
21 BOLT 350 M16 - SS400 36
BOLTS WERE
DISPATCHED WITH
THE MOTOR.
FOR COVER.
DON’T THROW AWAY
22 HEX. NUT 13 M16 - SS400 72 NUTS, BECAUSE NUTS
WERE DISPATCHED
WITH THE MOTOR.
WITH BELT 4 NOS.

1
DON’T THROW AWAY
CARRIER & BELTS,
23 CARRIER 4000 - 840 SS400 3
BECAUSE THESE
WERE DISPATCHED
WITH THE MOTOR.
T-HANDLED FOR HEX. HEAD BOLT

24 380 400 - S45C 1
WRENCH 9010.1
25 TOOL BOX 750 300 280 - 1 -
Q3C0006688- 6/6
A
B
E
C
D
8
8
7
7
6
6
5
5
4
4
3
3
L&T
2
2
NTPC LIMITED
1
1

F
A
B
E
C
D
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Spare Parts List (Commissioning)

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
0 1/7/2016 1/7/2016 1/7/2016
1 23/9/2016 23/9/2016 23/9/2016
Q3C0006686 - 1/4 1
POWER PROJECT
Doc. No.: 51006-41400-1054
Spare Parts List (Commissioning) Rev. No.: 1
Date: 23/9/2016
Rev
No.
1 REVISED 23/9/2016
Q3C0006686 - 2/4
POWER PROJECT
Doc. No.: 51006-41400-1054
Date: 23/9/2016
Q3C0006686 - 3/4
POWER PROJECT
Doc. No.: 51006-41400-1054
Date: 23/9/2016
Size Q'ty
Additional
Unit 1
Unit 2
Item No. Name of Parts Sketch Material Remarks
L W H
1
1 1 1
SUS304/
1 GASKET OD793.4 ID741.6 4.5 1 1 2 P/N.4113
GRAFOIL
1 1
2 O-RING - ID100 5 NBR 1 1 P/N.4120.5
FOR HP COOLING
RING JOINT
1 1 WATER COOLER INLET
3 OD112.71 ID90.49 15.88 SUS304L 2 2 & OUTLET FLANGE
GASKET
ASME 2500LB
R26
RJ 2''
PURGE WATER MOTOR

1 1
RING JOINT INLET / MOTOR DRAIN
4 OD68.27 ID52.39 12.7 SUS304L 1 1
GASKET
ASME 2500LB
R18
RJ 1''
Q3C0006686 - 4/4
POWER PROJECT
Owner:
NTPC LIMITED
EPC Contractor:
Architect Engineer:
Vendor:

Sub Vendor:
L&T – S&L Job No.: LD16005000

Title: Spare Parts List(Recommended)
Doc./Drg. No.: 51006-41400-1053

51006-41400-1055 Rev No.: 0 Total No. of Pages :8

Checked
L&T-S&L Date Name

Checked
REVISION STATUS
0 8/7/2016 8/7/2016 8/7/2016
Q3C0006689 - 1/8
POWER PROJECT
Doc. No.: 51006-41400-1053
51006-41400-1055
Spare Parts List(Recommended) Rev. No.: 0
Date: 8/7/2016
Rev
No.
Q3C0006689 - 2/8
POWER PROJECT
Doc. No.: 51006-41400-1053
51006-41400-1055
Date: 8/7/2016
Q3C0006689 - 3/8
POWER PROJECT
Doc. No.: 51006-41400-1053
51006-41400-1055
Date: 8/7/2016
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Q3C0006689 - 4/8
POWER PROJECT
Doc. No.: 51006-41400-1053
51006-41400-1055
Date: 8/7/2016

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㻝㻟㼃㻱㻭㻾㻵㻺㻳㻻㻰㻠㻝㻜㻵㻰㻟㻠㻜㻟㻡㻿㼁㻿㻠㻞㻜㻶㻞㻝㻿㻯㻾㻱㼃㻿㻌㼍㼚㼐㻌㼃㻭㻿㻴㻱㻾㻿
㻾㻵㻺㻳㻿㻱㼀㻌㻤㻌㼜㼏㼟㻛㼟㼑㼠㻌㽢㻝㼟㼑㼠
㻔㻼㻛㻺㻚㻌㻥㻟㻝㻣㻚㻟㻘㻌㻥㻝㻠㻜㻚㻝㻞㻘㻌㻡㻡㻜㻜㻚㻢㻕
㻮㻱㻭㻾㻵㻺㻳㻿㼁㻿㻠㻞㻜㻶㻞㻼㻛㻺㻚㻡㻞㻥㻜㻚㻝
㻝㻠㻞㻠㻡㻵㻰㻝㻞㻡㻻㻰㻝㻡㻜㻴㻯㼞㻌㻼㻚
㻝
㻿㻸㻱㻱㼂㻱㻔㼁㻼㻼㻱㻾㻕
㻮㻱㻭㻾㻵㻺㻳㻿㼁㻿㻠㻞㻜㻶㻞㻼㻛㻺㻚㻡㻞㻥㻜㻚㻞
㻝㻡㻞㻠㻡㻵㻰㻝㻞㻡㻻㻰㻝㻡㻜㻴㻯㼞㻌㻼㻚
㻝
㻿㻸㻱㻱㼂㻱㻔㻸㻻㼃㻱㻾㻕
㻿㼁㻿㻟㻜㻠
㻝㻢㻯㻵㻾㻯㻸㻵㻼㻙㻵㻰㻝㻝㻤㻝㻟㻥㻚㻤㻞㻼㻛㻺㻚㻥㻟㻞㻜㻚㻝
㻯㻿㻼
㻿㻼㻾㻵㻺㻳
㻝㻣㻻㻰㻞㻠㻚㻠㻵㻰㻝㻣㻙㻿㼃㻾㻴㻤㻼㻛㻺㻚㻥㻟㻜㻜㻚㻠
㼃㻭㻿㻴㻱㻾
㻿㻼㻾㻵㻺㻳
㻝㻤㻻㻰㻝㻢㻵㻰㻝㻜㻚㻣㻙㻿㼃㻾㻴㻝㻢㻼㻛㻺㻚㻥㻟㻜㻜㻚㻡
㼃㻭㻿㻴㻱㻾
㻿㻼㻾㻵㻺㻳
㻝㻥㻻㻰㻝㻢㻵㻰㻝㻜㻚㻣㻙㻿㼃㻾㻴㻢㻼㻛㻺㻚㻥㻟㻜㻜㻚㻢
㼃㻭㻿㻴㻱㻾
㻿㻼㻾㻵㻺㻳
㻞㻜㻻㻰㻞㻤㻵㻰㻝㻢㻚㻞㻙㻿㼃㻾㻴㻞㻜㻼㻛㻺㻚㻥㻟㻜㻜㻚㻣
㼃㻭㻿㻴㻱㻾
㻸㻻㻯㻷
㻞㻝㻻㻰㻢㻟㻵㻰㻟㻝㻙㻿㼁㻿㻟㻜㻠㻝㻼㻛㻺㻚㻥㻟㻝㻝㻚㻝
㼃㻭㻿㻴㻱㻾
Q3C0006689 - 5/8
POWER PROJECT
Doc. No.: 51006-41400-1055
51006-41400-1053
Date: 8/7/2016

㻸㼃㻴㻺㼛㻚
㻸㻻㻯㻷
㻞㻞㻻㻰㻢㻟㻵㻰㻟㻝㻙㻿㼁㻿㻟㻜㻠㻝㻼㻛㻺㻚㻥㻟㻝㻝㻚㻞
㼃㻭㻿㻴㻱㻾
㻸㻻㻯㻷
㻞㻟㻞㻤㻵㻰㻝㻟㻟㻜㻿㼁㻿㻟㻜㻠㻤㻼㻛㻺㻚㻥㻟㻝㻝㻚㻢
㼃㻭㻿㻴㻱㻾
㻸㻻㻯㻷
㻞㻠㻞㻤㻵㻰㻝㻟㻟㻜㻿㼁㻿㻟㻜㻠㻤㻼㻛㻺㻚㻥㻟㻝㻝㻚㻣
㼃㻭㻿㻴㻱㻾
㻸㻻㻯㻷
㻞㻡㻞㻜㻵㻰㻤㻚㻠㻞㻞㻿㼁㻿㻟㻜㻠㻝㻼㻛㻺㻚㻥㻟㻝㻝㻚㻤
㼃㻭㻿㻴㻱㻾
㻜㻥㻝㻜㻜㻝㻡㻠㻣㻥
㻞㻢㻳㻭㻿㻷㻱㼀㻤㻝㻜㻙㻟㻟㻜㻺㻮㻾㻟㻼㻛㻺㻚㻠㻜㻜㻜㻚㻞㻜
㻞㻣㻳㻭㻿㻷㻱㼀㻞㻜㻜㻙㻞㻜㻜㻺㻮㻾㻟㻼㻛㻺㻚㻠㻜㻜㻜㻚㻞㻝
㻠㼄㻝㻥
㼂㻭㻸㻽㼁㻭
㻞㻤㻳㻭㻿㻷㻱㼀㻙㻵㻰㻥㻜㻻㻰㻞㻜㻜㻟㻼㻛㻺㻚㻠㻜㻜㻜㻚㻞㻞
㻢㻡㻜㻜
㻼㻯㻰㻩㻝㻡㻜㼠㻩㻞
㻞㻥㻳㻭㻿㻷㻱㼀㻻㻰㻟㻜㻵㻰㻝㻡㻝㻺㻮㻾㻟㻼㻛㻺㻚㻠㻜㻜㻜㻚㻞㻟

㻟㻜㻳㻭㻿㻷㻱㼀㻻㻰㻢㻡㻵㻰㻠㻡㻝㻺㻮㻾㻟㻼㻛㻺㻚㻠㻜㻜㻜㻚㻞㻠

㻼㻛㻺㻚㻡㻞㻜㻞㻚㻞
㼀㻱㻾㻹㻵㻺㻭㻸
㻟㻝㻠㻞㻣㻚㻡㻙㻙㻙㻟㻼㻛㻺㻚㻣㻡㻡㻝
㼁㻺㻵㼀
㻔㻖㻝㻘㻌㻖㻞㻘㻌㻖㻟㻕
㻖㻝㼀㼕㼙㼕㼚㼓㻌㼒㼛㼞㻌㼞㼑㼜㼘㼍㼏㼑㼙㼑㼚㼠㻌䠖㻌㻭㼠㻌㼠㼔㼑㻌㼠㼕㼙㼑㻌㼛㼒㻌㼙㼛㼠㼛㼞㻌㼞㼑㼣㼕㼚㼐㼕㼚㼓㻚㻌㻔㼃㼑㻌㼞㼑㼏㼛㼙㼙㼑㼚㼐㻌㼠㼛㻌㼞㼑㼣㼕㼚㼐㻌㼍㼠㻌㼀㼛㼞㼕㼟㼔㼕㼙㼍㻌㼣㼛㼞㼗㻌㼟㼔㼛㼜㻚㻕
㻖㻞㻴㼍㼚㼐㼘㼕㼚㼓㻌䠖㻌㼁㼚㼐㼑㼞㻌㼟㼡㼜㼑㼞㼢㼕㼟㼕㼛㼚㻌㼛㼒㻌㼀㼛㼞㼕㼟㼔㼕㼙㼍㻌㻿㼂㻚
㻖㻟㻿㼠㼛㼞㼍㼓㼑㻌䠖㻌㻿㼑㼑㻌㼛㼡㼞㻌㻻㻌㻒㻌㻹㻌㼙㼍㼚㼡㼍㼘㻚
Q3C0006689 - 6/8
POWER PROJECT
Doc. No.: 51006-41400-1055
51006-41400-1053
Date: 8/7/2016

㻸㼃㻴㻺㼛㻚
㻟㻞㻻㻙㻾㻵㻺㻳㻵㻰㻠㻤㻢㻙㻺㻮㻾㻟㻼㻛㻺㻠㻝㻞㻜㻚㻝㻝
㻟㻟㻻㻙㻾㻵㻺㻳㻵㻰㻡㻜㻠㻙㻺㻮㻾㻟㻼㻛㻺㻚㻠㻝㻞㻜㻚㻝㻞
㻟㻠㻻㻙㻾㻵㻺㻳㻵㻰㻠㻜㻞㻚㻡㻙㻺㻮㻾㻟㻼㻛㻺㻚㻠㻝㻞㻜㻚㻝㻟
㻿㻼㻾㻵㻺㻳
㻟㻡㻙㻵㻰㻝㻜㻚㻞㻻㻰㻝㻤㻚㻠㻿㼁㻿㻟㻝㻢㻥㻜㻼㻛㻺㻚㻥㻟㻜㻜㻚㻞㻜
㼃㻭㻿㻴㻱㻾
㻿㻼㻾㻵㻺㻳
㻟㻢㻙㻵㻰㻝㻜㻚㻞㻻㻰㻝㻤㻚㻠㻿㼁㻿㻟㻝㻢㻟㻢㻼㻛㻺㻚㻥㻟㻜㻜㻚㻞㻝
㼃㻭㻿㻴㻱㻾
㻿㻼㻾㻵㻺㻳
㻟㻣㻙㻵㻰㻝㻢㻚㻞㻻㻰㻞㻤㻿㼃㻾㻴㻝㻞㻼㻛㻺㻚㻥㻟㻜㻜㻚㻞㻞
㼃㻭㻿㻴㻱㻾
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㻟㻤㻙㻵㻰㻝㻣㻻㻰㻟㻜㻿㼁㻼㻢㻟㻼㻛㻺㻚㻥㻟㻜㻜㻚㻞㻠
㼃㻭㻿㻴㻱㻾
㻸㻻㻯㻷
㻟㻥㻞㻣㻝㻞㻚㻡㻟㻜㻯㻝㻝㻜㻜㻟㻼㻛㻺㻚㻥㻟㻝㻝㻚㻞㻜
㼃㻭㻿㻴㻱㻾
㻸㻻㻯㻷
㻠㻜㻞㻜㻤㻚㻡㻞㻞㻿㼁㻿㻟㻜㻠㻢㻼㻛㻺㻚㻥㻟㻝㻝㻚㻞㻝
㼃㻭㻿㻴㻱㻾
㻸㻻㻯㻷
㻠㻝㻞㻣㻝㻞㻚㻡㻟㻜㻯㻝㻝㻜㻜㻢㻼㻛㻺㻚㻥㻟㻝㻝㻚㻞㻞
㼃㻭㻿㻴㻱㻾
Q3C0006689 - 7/8
POWER PROJECT
Doc. No.: 51006-41400-1053
51006-41400-1055
Date: 8/7/2016

㻸㼃㻴㻺㼛㻚
㻲㻻㻾㻌㻴㻼㻌㻯㻻㻻㻸㻵㻺㻳
㻜㻥㻝㻜㻜㻝㻡㻞㻜㻢
㼃㻭㼀㻱㻾㻌㻯㻻㻻㻸㻱㻾
㻾㻵㻺㻳㻌㻶㻻㻵㻺㼀㻵㻺㻸㻱㼀㻌㻒㻌㻻㼁㼀㻸㻱㼀
㻠㻞㻻㻰㻝㻝㻞㻚㻣㻝㻵㻰㻥㻜㻚㻠㻥㻝㻡㻚㻤㻤㻿㼁㻿㻟㻜㻠㻸㻞
㻳㻭㻿㻷㻱㼀㻲㻸㻭㻺㻳㻱
㻭㻿㻹㻱㻞㻡㻜㻜㻸㻮
㻾㻞㻢㻾㻶㻌㻞㻎
㻼㼁㻾㻳㻱㻌㼃㻭㼀㻱㻾
㻜㻥㻝㻜㻜㻝㻡㻞㻜㻢
㻹㻻㼀㻻㻾㻌㻵㻺㻸㻱㼀㻌㻛
㻾㻵㻺㻳㻌㻶㻻㻵㻺㼀
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㻳㻭㻿㻷㻱㼀
㻭㻿㻹㻱㻞㻡㻜㻜㻸㻮
㻾㻝㻤㻾㻶㻌㻝㻎
㻜㻥㻞㻜㻜㻝㻢㻜㻝㻣
㻝㻚㻠㻡㻣㻝㻛㻲㻻㻾㻌㻹㻻㼀㻻㻾㻌㻯㻻㻻㻸㻱㻾
㻠㻠㻳㻭㻿㻷㻱㼀㻙㻥㻡㻝㻝㻡㻳㻾㻭㻼㻴㻚
㻝
㻔㼁㻼㻼㻱㻾㻕㻼㻛㻺㻚㻝㻞㻠
㻜㻥㻞㻜㻜㻝㻢㻜㻝㻣
㻝㻚㻠㻡㻣㻝㻛㻲㻻㻾㻌㻹㻻㼀㻻㻾㻌㻯㻻㻻㻸㻱㻾
㻠㻡㻳㻭㻿㻷㻱㼀㻙㻥㻡㻝㻝㻡㻳㻾㻭㻼㻴㻚
㻝
㻔㻸㻻㼃㻱㻾㻕㻼㻛㻺㻚㻝㻞㻠
㻜㻥㻟㻜㻜㻝㻢㻞㻡㻢
㻺㻻㻺㻙㻲㻻㻾㻌㻼㼁㻾㻳㻱㻌㻯㻻㻻㻸㻱㻾
㻠㻢㻳㻭㻿㻷㻱㼀㻙㻞㻣㻟㻟㻠㻜㻭㻿㻮㻱㻿㼀㻻㻿
㻝
㻼㻛㻺㻚㻢
㻜㻥㻟㻜㻜㻝㻢㻞㻡㻢
㻺㻻㻺㻙㻲㻻㻾㻌㻼㼁㻾㻳㻱㻌㻯㻻㻻㻸㻱㻾
㻠㻣㻳㻭㻿㻷㻱㼀㻙㻝㻝㻠㻝㻣㻡㻭㻿㻮㻱㻿㼀㻻㻿
㻝
㻼㻛㻺㻚㻝㻟
Q3C0006689 - 8/8
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Project KHARGONE SUPER THERMAL POWER PROJECT (2X660MW)
Package STEAM GENERATOR AND AUXILIARIES
Document Title O & M Manual for Boiler Circulation Pump (BCP)
NTPC Document Number 9578-001-102-PVM-W-074
LMB Document Number 51006-41400-1055

NTPC Limited
L&T MHPS Boilers Private Ltd (A Government of India
Enterprises)
Revision 0
NTPC Comments dated

Sr No. Document Reference Description LMB Reply dated 06-11-2017
26-10-2017
1 CC:PE:9578102:21314 Transmittal Comment marked in the document Noted.
Drawing comments
If the normal cooling water to heat barrier is interrupted, then the emergency
cooling water supply from DMCW overhead tank is to be supplied to Heat
barrier. To enable this process, we had provided the Pneumatic ON/OFF
valves at inlet (Tag No: 01PGA02AA729) and outlet (01PGA02AA730) of
Heat barrier. These valves will open automatically to ensure the cooling
Please confirm how the water from water flow to heat barrier.
Emergency cooling
emergency tank is getting circulated in
1 9578-001-102-PVM-W-074 water supply to Heat
the pump. Where is the location of For details, NTPC is requested to the following documents,
barrier
Pneumatic/solenoid valve in this line. a) "9578-001-102-PVM-L-041 - P&ID FOR BOILER WATER
CIRCULATION PUMP SYSTEM"
b) "9578-001-102-PVM-L-041A - BOILER WATER CIRCULATION PUMP
SYSTEM - WRITE-UP / PROCEDURE, S.No. 2.2.6 Heat barrier".
NTPC is requested to note and approve the same.

Project KHARGONE SUPER THERMAL POWER PROJECT (2X660MW)
Package STEAM GENERATOR AND AUXILIARIES
Document Title O & M Manual for Boiler Circulation Pump (BCP)
NTPC Document Number 9578-001-102-PVM-W-074
LMB Document Number 51006-41400-1055

NTPC Limited
L&T MHPS Boilers Private Ltd (A Government of India
Enterprises)
Revision 1
NTPC Comments dated

Sr No. Document Reference Description LMB Reply dated 11-12-2017
28-11-2017
We wish to inform that, the "9578-001-102-PVM-L-041 - P&ID FOR BOILER

Subjected to the approval of the WATER CIRCULATION PUMP SYSTEM" document, had been approved in
1 CC:PE:9578102:22170 Transmittal following document: "NTPC transmittal CC:PE:9578102:7182 dated 22-09-16".
a) Boiler Circulation water P&ID
NTPC is requested to note the above and approve this O&M manual.

O & M Manual For Boiler Circulation Pump (BCP)

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O & M Manual For Boiler Circulation Pump (BCP)

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2 × 660 MW KHARGONE SUPER THERMAL

L&T-MHPS BOILERS PRIVATE LIMITED

L&T – S&L Job No.: LD16005000

Title: O& M MANUAL FOR BOILER CIRCULATION PUMP (BCP)

Doc./Drg. No.: 51006-41400-1055 Rev No.: 02 Total No. of Pages : 245

NTPC Doc./Drg. No.: 9578-001-102-PVM-W-074 Rev No.: 02 Unit Designation: 1 & 2

REVISION SUMMARY SHEET

01 No changes in Document. Customer comments had been responded in CRS. 06/11/2017

02 No changes in Document. Customer comments had been responded in CRS. 11/12/2017

Sl.No Doc. No. Description Page Doc. NTPC Transmittal No.

3.10 41400-1011 PID for Boiler circulation pump 115 4

L&T-MHPS BOILERS PRIVATE LIMITED

TORISHIMA PUMP MFG. CO., LTD.

L&T – S&L Job No.: LD16005000

Title: O & M Manual

Doc./Drg. No.: 51006-41400-1055 Rev No.: 2 Total No. of Pages : 58

NTPC Doc./Drg. No.: Unit Designation: 1 & 2

This document is also applicable for

REVISION SUMMARY SHEET

GLANDLESS HOT CIRCULATION PUMP TYPE

--H L A V-- WET MOTOR TYPE

BCP OPERATION AND MAINTENANCE MANUAL

PRODUCT. NO. PU0114243/PU0114251

TORISHIMA PUMP MFG. CO., LTD

2. Description of Pumping Set 12

3. Delivery and Preservation 13

4. Installation of Pumping Set and Operation 17

5. Preparation prior to Commissioning 24

6. Commissioning and Start-Up 33

8. Pump Operation for Boiler Clean Up 42

9. Dismantling and Reassembly of Pumping Set 44

10. Operational Conditions 53

11. Cause and Remedy of Operational Trouble 54

2 ATTACHMENT 1. Queries related to erection and commissioning

2 ATTACHMENT 2. Annexure of Dwg For Khargone OM Manual

Safety Alerts and Warning Notes

Potential hazard that could result in death or serious injury

Potential hazard that could result in minor or moderate injury

General safety instructions for operation

- Designation Glandless Circulating Pump

1.4 Motor Cooler

- Type Shell and Tube

Design conditions of secondary side

1.5 Purge Cooler

- Type Shell and Tube

Design conditions of secondary side

1.6 Secondary Cooling Water

Cooling Water Quality

Cooling Water Circuit Arrangement

1.7 Life Time of Major Part (for recommendation)

No Major Part Name Part No. Life year

2. Description of Pumping Set

3. Delivery and Preservation

(1)General No.1 to 4 (2)General No.5 (refer to 3.2.2)

3.2.2 Dry Preservation

3.3 Long Time Storage of a Motor

3.3.1 Storage of a Motor before Motor installation

3.3.2 Preservation of a Motor after Motor installation

3.4 Replacement of Terminal Box Silica-gel

4. Installation of Pumping Set and Operation

The details are given in Lifting Plan Drawing (41400-1041).

4.2 Suction Line and Discharge Line

4.3 Motor Cooler and Heat Barrier