TECHNICAL SPECIFICATION

Design, manufacture, inspection, testing and supply of electrically

operated butterfly valves for sea water application
1. SCOPE:

This specification covers design, manufacture, inspection, testing and supply properly
packed of motor operated butterfly valves completes with all accessories as specified herein
under and as required for efficient and trouble free operation for sea water application in
the Madras Atomic Power Station. It is not the intent of this document to specify completely
all details of design, construction, etc. of the equipment. However, equipment shall conform
in all respects to high standards of engineering, design and workmanship.

2. GENERAL SPECIFICATION:
The electrical actuated butterfly valves are intended for outdoor as well as indoor use in the
sea water system pipelines which are used for process water cooling. The nature of duty is
ON/Off service, however, throttling operation is required for certain application like pump
discharge valves where opening up to 10% and closing up to 90% will be encountered
during starting and stopping of pumps for a short period.

3. CODES AND STANDARDS:

The design, material requirement, manufacture, assembly, inspection, testing and
performance of the motor operated butterfly valves covered by this specification shall,
unless specifically stated otherwise, generally comply with one or more of the latest editions
of the following Codes and Standards.
3.1 AWWA C504: American Water Works Associated Standard for Rubber-seated
Butterfly Valves
3.2 IS 1865 GR 500/7 : Standard for DUCTILE (SG) IRON Material.
3.3 ANSI 16.1 : Flange face drilling
3.4 AWWA C504-SHORT BODY: Flange Face to Face to dimension.
3.5 Valve body shall conform to the wall thickness requirements of AWWA C504
and have an integral pad for direct mounting of the gear box.
3.7 IS 325 : Standard for three phase induction motors.
3.8 IS 4029 : Guide for testing of 3 phase induction motor
3.9 ASTM /ANSI Standards for Materials as applicable.
3.10 In case of any contradiction between the aforesaid standards and this technical
specification, particularly the data specification sheets, the stipulations in the data
specification sheets and technical specifications shall prevail and shall be binding on
the tenderer.
4. ANALYSIS OF SEA WATER:
As the valves are indented to use in the sea water application, the supplier should ensure
trouble free operation of valves by taking appropriate design consideration. The analysis of
sea water at our site are given below. All results given below are in parts per million
(except pH and specific gravity), unless otherwise stated:
Physical:
1. a. Silt content (between 5 and 50 micron) 22.4
b. Particle larger than 50 micron 12.8
c. Particle smaller than 5 micron 12.8
d. Total suspended matter 48.0
2. Specific gravity @ 300C / 300C 1.023
3. Total solids 39,310
4. Total dissolved solids 39,208
5. Loss on ignition of total solids 8,720
6. Loss on ignition of dissolved solids 8,670

Chemical (Test conducted on filtered sample):

1. pH 7.9
2. Alkalinity to methyl orange 124
3. Alkalinity to phenolphthalein 5.0
4. Carbon dioxide as CO2 Nil
5. Sulphuretted Hydrogen as H2 1.7
6. Silica as SiO2 1.0
7. Chloride as Cl 17,730
8. Sulphate as SO4 2,562
9. Nitrate as NO3 6.0
10. Iron as Fe 0.02
11. Aluminium as Al 6.4
12. Calcium as Ca 360.7
13. Magnesium as Mg 1,216
14. Oxygen absorbed in 4 hrs. (Tidy’s test) 3.6 mg/lit
15. Total organic matter content (C.O.D.) 51.4 mg/lit
16. Biochemical oxygen demand (5 day @200C) 3.5 mg/lit
17. Chlorine demand:
a. 30 minutes contact 1.8 mg/l
b. 60 minutes contact 2.3 mg/l

18. Site weather condition:

Ambient temperature : 75 - 1200F
Humidity : 85-99 %
5. Technical Data Sheet:

Sl.No Description Valve Nominal Size in mm (Inches)

1050 (42”)
1. Design AWWA C-504, Short Body, Double Flanged End design Butterfly Valve.
2. Operation A.C. Electric Motor Drive for remote operation/ Manual Hand Wheel operated for local
operation. Electric actuator combined with Quarter Turn Gear Box.
3. Flange Face drilling Flange face Drilling (as per ANSI B: 16.1, Class 125) and the holes are off centered to the axis of
( in mm) the disc spindle.

a) OD 1346
b) PCD 1257
c) No. of Holes 36
d) Hole 41
Diameter
e) Minimum
66
flange thickness
4. Flange face to face AWWA C-504, Short body design
distance ( in mm) 305
5. Fluid Handled Sea water ( As per physical and chemical analysis data given in the specification)
6. Flow in M3 /Hr

Maximum 9000
 7. Operating pressure
10.25
in MWC
8. Hydro static Test
150 psi, duration of 10 Minutes
pressure .
9. Seat test pressure . 75 psi, duration of 5 Minutes
10. Design temperature
65
in deg. C
11. Pressure drop when
0.1 Max.
fully open in MWC
12. Frequency of normal
Three operation in a day (One operation means Fully Open and fully Close).
valve operation
13. Opening / closing
time in seconds.
(This is existing 120 Sec.
timing, shall match
with +-10 sec).
Electric actuator and Dear Box shall be of ROTORK make.

Note: the above dimensions are with respect to our existing valves at site, any variation with respect to the valve dimensions shall be notified
in the drawing for approval by the purchaser. However it may be noted that no major changes can be accepted in the technical dimensions
considering interchangeability requirements.
6. MATERIALS OF CONSTRUCTION:
Materials of construction for the various components of butterfly valves to be used in sea water
systems shall be as follows or by equal quality which is acceptable by the purchaser.
SL.No DESCRIPITIN MATERIAL SPECIFICATION
1. Body Ductile(SG) iron with 5mm IS: 1865 Gr.500/7 (latest
thick EBONITE Lining revision) With minimum
5mm thick EBONITE
Lining

2. Disc Ductile(SG) iron with 5mm IS: 1865 Gr.500/7 (latest

thick EBONITE Lining revision) With minimum
5mm thick EBONITE
Lining

3. Drive shaft and Stub Stainless Steel-316 ( OR) ASTM-A-479 Type 316
shaft duplex SS Grade (OR) Duplex SS Grade-
ASTM A 479 UNS
S31803.

4. Shaft Sealing Neoprene O rings/ U Cup Seal or as per the design

code.
5. Seat on body/Disc Preferably hollow Musical node type EPDM seal (OR)
Superior high performance seal as per the design code.
6. Clamping ring Stainless steel- 316 ASTM A473
7. Seat ring Stainless steel-316 ASTM A473
8. Shaft Bearing Bush Leaded bronze/ BS-1400 B2 GRADE C/
Stainless Steel-316 Backed STAINLESS STEEL
PTFE BACKED PTFE (SS 316)
-
9. Key En-97 ( OR ) SS GRADE BS-970 ( OR ) SS GRADE
10. Thrust pad Leaded bronze BS-1400 B2 GRADE C

All other internal hardware’s shall be SS-316 grade or Duplex SS grade material which is
compatible with sea water application and same will be approved by the purchaser in the
technical specification sheet/manufacturer drawing .
7. DESIGN AND CONSTRUCTION FEATURES:
7.1 GENERAL:
7.1.1 The butterfly valves shall be designed and manufactured to confirm to AWWA C504,
latest edition. The features of construction shall generally confirm to short body type.
The valves shall be suitable for installation with the shaft in any position.
7.1.2 Valves shall have the seat ring, disc, clamping ring & rubber seal suitably designed to
ensure trouble free operation.
7.1.3 Valves shall be designed to ensure bubble tight shut off at the design pressure and bi
directional flow. The valve body flanges shall be dimensioned and drilled as specified in
the data specification sheets.
7.1.4 Pipe bore is normally smaller than the valve nominal diameter. Bidder shall check this
aspect and ensure that the valve disc can be freely rotated in such pipeline.
7.1.5 Minimum of double eccentric valves with low torque requirement.
7.1.6 Body, disc and flange faces shall be of 5mm thick ebonite lined. Ensure all internal cast
iron parts shall not come in contact with sea water.
7.1.7 The valve seat shall be in–situ replacement.
7.1.8 The actuator torque shall be minimum 1.25times the required maximum valve torque.
7.1.9 The maximum valve torque requirement shall be worked out considering bi-directional
sealing, Disc differential pressure equivalent to valve rating pressure and hydraulic
forces on disc due to change of direction of flow within one Dia. length upstream and
downstream.
7.2 VALVE BODY:
7.2.1 Cast valve body shall have integral (flat face) flanges dimensioned and drilled as per
technical specification given and two hubs for shaft bearing housing.
7.2.2 Minimum body shell thickness shall be as per the requirement of the applicable table of
AWWA C-504, short body design.
7.2.3 Lifting lugs and eyebolts shall be provided to ensure safe and easy handling of the valves.
Valve body shall have cast marking designating pressure class, test pressure,
manufacturer’s name, number, size and the preferred direction of flow through it.

7.3 VALVE SHAFT:

7.3.1 Valve shaft may be of single piece extending completely through the valve disc or in two
pieces, stubbed into the disc hubs as per the design code.
7.3.2 The shaft diameter shall take in the consideration the maximum differential pressure
across the valve disc when the valve is closed.
7.3.3 The shaft shall be of Stub type design; sealing may be with unique combination of ‘O’
Ring and ‘U’ Cup Seal to prevent leakage from drive end side.
7.3.4 Valve shafts shall have a minimum shaft diameter extending through the valve bearings
and into the valve disc as specified in AWWA Standard specification C-504.

7.4 VALVE DISC:

7.4.1 The valve disc shall be designed with no external ribs transverse to the direction of flow.
7.4.2 The disc shall be designed for maximum differential pressure across the valve as well as
the shock load due to accidental closure of the valve.
7.4.3 The disc shall be contoured to ensure minimum frictional drop when fully open.
7.4.4 The disc shall rotate 900 from full open to tight shut position.
7.4.5 The disc shall be contoured to ensure lowest possible resistance to flow. The disc is
Streamlined Single/ Double eccentrically mounted disc to ensure complete shut off.
7.4.6 There shall be a provision for Disc locking arrangement at Non Driving End to enable
disconnection of gear box and actuator without disturbing the valve position during
service.

7.5 VALVE SEAT:

7.5.1 Rubber seal shall be applied on the disc. The mating seat surface (i.e. seat ring) shall be
of stainless steel, grade-316 or Duplex SS Grade.
7.5.2 The seat ring shall be designed for complete immobility and bubble tight shut off under
all operating conditions.
7.5.3 The seat ring shall be of a design that permits removal and replacement at site and shall
be securely clamped on the body of the valve.
7.5.4 Arrangements for fixing the seat ring and rubber seal (i.e screws, clamps of similar
fixing arrangement) shall be such that obstruction to flow is the least and the material
for such parts shall be rustles type.
7.5.5 In order to prevent galvanic corrosion between C.I / steel body / disc and S.S seat ring /
clamping ring, provision shall be made in the design to eliminate the same.

7.6 VALVE BEARING:

7.6.1 The valves shall be fitted with sleeve type bearings contained in the hub of valve body.
7.6.2 The materials shall be of ‘self lubricated’ type that do not have any harmful effect on
water or rubber and which do not have a coefficient of friction in excess of 0.25 when
run at the maximum bearing pressure.
7.6.3 The bearing shall be provided beyond the shaft seal. The housing for this bearing shall
be rigidly attached to valve body.
7.6.4 Each valve shall be equipped with either one or two thrust bearings set to hold the disc
centered regardless of valve position.
7.7 SHAFT SEALS:
7.7.1 Stuffing box shall be easily accessible for adjustment and replacement of packing
without disturbing any other part of the valve or operator assembly.
7.7.2 Sealing may be with unique combination of ‘O’ Ring and ‘U’ Cup Seal to prevent leakage
from drive end side.

8. ELECTRIC MOTOR OPERATING MECHANISM :

8.1 The Electric motor operated actuator and gear box shall be of ROTORK/ AUMA make
only and confirming to the specification listed below.
8.2 The operator shall include a high torque motor, reduction gearing and limit switches.
8.3 The unit shall be so designed that a torque impulse is imparted to the shaft in both
opening and closing direction to start the disc in motion.
8.4 The motor shall attain full speed before the stem load in encountered.
8.5 A hand wheel shall be provided for manual operation. The hand wheel shall not rotate
during electric operation. The motor shall not rotate during manual operation. When
in manual operation the hand wheel shall be automatically disengaged if the motor is
energized simultaneously from control panel.
8.6 Each motor operating mechanism shall essentially consist of the following components:

1) A.C Electric Motor

2) Motor gear unit
3) Torque clutch
4) Torque Switches
5) Limit Switches.
6) Automatically Disengaging Hand wheel
7) Mechanical position Indicator.
8) Motor contactors and control push button stations will be furnished by the
purchaser.
8.7 The torque rating of the operators shall be selected based on the maximum differential
pressure stated in the valve specification sheet. The actuator shall be capable of
operating the valve at 80% of the supply voltage and the maximum seating or unseating
torque required by the valve shall not exceed the rated torque, calculations justifying
torque and kW rating of the motors in tabular form shall be submitted by the bidders.
8.8 The motors shall be of the high torque squirrel cage induction type suitable for direct-
on-line starting and intermittent duty. The electric supply to the motors shall be of 415
V, 3 Phase, 50Hz, 3 wire systems. In addition, these motors are required to meet the
following variations.
 Voltage variation - ± 10%

Frequency variation - ± 5%

Combined voltage and Frequency variation - ± 10%

Supply voltage imbalance - ± 3%

8.9 During valve operation, it is possible that reverse voltages may be applied even before
the forward direction has come to a stop. In the worst case the applied (reverse) voltage
and induced voltage (due to continued forward motion) and residual magnetism may be
150% to 200% of rated voltage. The motor shall be designed to withstand this condition.
8.10 Motor winding shall be insulated to a minimum of class H insulation as specified in the
latest standard of ANSI C 50.2.
8.11 Characteristic of the motor shall be such the temperature rise does not exceed ANSI C
50.2 limitation, when operating with no pressure difference across the valve for a period
of 15 minutes at rated voltage. The motor temperature shall be sensed by a thermostat
embedded in the motor windings to protect against overheating.
8.12 All motors shall be totally enclosed non-ventilated (TENV) and to same standard of
enclosure as the actuator i.e. ‘0’ ring sealed to IP68 protecting the motor and other
internal electrical elements from ingress of moisture and dust even when the terminal
cover is removed for site cabling. Enclosure must allow for temporary site storage
without the need for on electrical supply connection.
8.13 The actuator gearing shall be totally enclosed and oil bath/grease lubricated. The motor
operated valves shall be capable of being mounted in any position. The structural design
and the lubricating scheme of the operators shall be suitably designed to meet this
requirement.
8.14 All main drive gearing must be of metal construction. The actuator drive shall
incorporate a lost-motion hammer blow feature. The output shaft shall be hollow to
accept a rising stem, and incorporate thrust bearings of the ball or roller type at the base
of the actuator. The design shall be such as to permit the gear case to be opened for
inspection or disassembled without releasing the stem thrust or taking the valve out of
service.
8.15 Moisture proof terminal boxes suitable for armoured / un-armoured, HRPVC / FRLS
insulation cabling connection shall be provided.
8.16 Two earthing terminals shall be provided on the actuator body for solidly grounding the
actuator including the motor.
8.17 The motor operated valves will be located outside containment. The type of actuators
shall be selected suitably for the duties specified and designed accordingly.
8.18 All wiring supplied as part of actuator shall be contained within the main enclosure for
physical and environmental protection. External conduit connections between
components will not be accepted.
8.19 Type test as per IEEE 382 shall be carried out wherever specified in the specification
sheet.
8.20 Each actuator shall be supplied with a start-up kit comprising installation instruction,
electrical wiring diagram and sufficient spare cover screws and seals to make good any
site losses during the commissioning.
8.21 The actuator and Gear box enclosure shall meet the IP-68 protection.
8.22 Valve motor shall be squirrel cage induction type started on direct-on-line at Full rated
voltage. Motor pull-out torque shall be atleast 200% of rated full load torque, capable of
rotation in either direction.
8.23 All motors and gearing shall be adequate to open and close valves under full indicated
un-balanced pressure, the unbalanced pressure being maximum operating pressure or
design pressure as specified, at a sufficient speed necessary to operate to the full extent of
travel in about 30 seconds.
8.24 Centrifugal switch or some such device shall be provided to ensure that the drive motor
does not engage until it has come up to speed. A thrust cushion is to be provided to
absorb kinetic energy of the moving parts when the unit stops as the valve seats solidly.
All the moving parts shall be protected against overload on both power and manual
operations by shear pins ext.
8.25 Each Electric motor operator shall be provided with a standard size hand wheel for
manual operation. The hand wheel shall be automatically declutched when electric
motor is operating, but can be engaged at other times by positioning the clutch lever.
Electric operation shall override manual operation.
8.26 The operator should be furnished with a notching or hammer blow device to loosen
stuck valves or move jammed valves to the required position.
8.27 All motor operators shall be provided with clearly visible local valve position indicators
mounted on the operator assembly itself.
8.28 The torque switch shall function to stop the motor upon actuation by the torque clutch,
to prevent an overload torque when the valve disc is restricted in its attempt to open or
close as follows:
8.28.1 Torque switch in the closing direction to interrupt control circuit if mechanical overload
occurs during the closing cycle or valve is fully closed.
8.28.2 Torque switch in the opening direction to interrupt control circuit if mechanical
overload occurs during the opening cycle or valve is fully open.

8.29 LIMIT SWITCHES:

8.29.1 Each operator shall be provided with adjustable torque switches with one make and one
break contact for limiting the amount of thrust exerted on the valve in both the opening
and closing operations.
8.29.2 Adjustable limit switch contacts which are electrically separate shall also be provided as
follows.
8.29.3 The above limit and torque switches shall be suitable for 1 ampere at both 240 V AC 50
cps and 48 V DC service. The contacts shall withstand 1.5 KV at 50 cps for one minute.
8.29.4 The limit switches shall function to stop the motor when the disc has attained the preset
open or closed positions, and shall have the following contacts configuration.

LIMIT SWITCH REQUIREMENTS:

I. Change over contacts-3 nos. in open position

II. Change over contacts-3 nos. in close position
III. A Torque switch contact shall open on excessive torque in closing cycle
IV. A Torque switch contact shall open on excessive torque in opening
cycle
V. The torque operating setting shall be adjustable from 20% to 120%.
VI. The limit and torque switches shall be standard make. Their contacts
shall be rated for making to brake at 1 A current at 48V DC. It shall
confirm to the latest IS standards.
8.30 All wiring connections from various switches shall be brought out on separate terminal
boards mounted on valve having liberal space for wiring and making connections to
purchaser’s external circuits. All power and control connections shall be of plug and
socket type. Teflon insulated, fire proof, tinned copper, multistrand, flexible wire shall
be used between the micro switch to the terminal board. Cable voltage grade shall be
650 V or more.
8.31 This terminal box shall be water proof and dust tight with suitable conduit entries and
shall be suitable for outdoor use.

9. GEAR BOX:
The gear box shall be of quarter turn worm operated, Packed with lubricant for life time
operation and shall meet IP-68 protection norms.

10. PRE DISPATCH INSPECTION AND TESTING.

a) Pre dispatch inspection shall be carried out by our NPCIL QA. Supplier shall submit
detailed quality assurance plan (QAP) to purchaser for approval after award of PO. The
QA plan shall include chemical and physical test for all major components, directional
checks, hydro test, functional / Performance test. Proof of Design test should have been
 carried out for the configuration of valve being supplied with the same materials of
construction for all major components. This POD should have been certified by Govt./
NPCIL/DAE authorized third party inspection.
b) Manufacture of valve / components shall commence only after approval of drawings
and QA plan. Purchaser reserves the right to carry out any additional tests beyond those
indicated in the approved inspection plan at extra cost.
c) The tenderer shall carryout inspection to establish and maintain quality of workmanship
in his works and that of his sub-contractors to ensure mechanical accuracy of
components, compliance with drawings, identity and acceptability of all material, parts
and equipment. He shall conduct all tests required to ensure that the equipment and
material furnished conform to the requirements of the applicable codes.
d) The purchaser shall be notified well in advance of the fabrication and major shop tests of
the equipment for the purpose of making general inspection and for the progress report.
The purchaser’s representative shall be given access to the shop in which the equipment
is being manufactured or tested and all test records shall be made available to him. The
equipment covered under this specification shall not be dispatched unless the same has
been finally inspected, accepted and shipping release issued by the purchaser.
e) All materials used for manufacture of the equipment covered under this specification
shall be tested quality. Relevant correlating test certificates shall be made available to the
purchaser before the final shop inspection. In case the relevant correlating test
certificates are not available, the supplier shall arrange to carry out the necessary tests
required by the code at his cost, in the presence of purchaser’s representative. However
all the inspection and testing shall be carried out as per the approved QA plan.

f) CASTINGS:
I. Castings material shall be in accordance with IS: 1865 Grade 500/7, latest revision and
of the grades specified.
II. The casting as well as all physical testing of the castings shall be done in the presence of
the purchaser and/or his representatives.
III. Valve disc shall be examined by Magnetic particle inspection/RT in accordance with
ASTM-E-109 and basis for acceptance shall be judged by reference to ASTM-E- 125.
IV. Shafts shall be subjected to UT and visual dye Penetrate test in accordance with ASTM-E-
165. The testing is to be carried out after rough machining (125 micro inches). Any
defect which will not machine out during the final machining shall be fully removed,
inspected by dye penentrant test to ensure that the defect is fully removed and repaired
using an approved repair procedure.
g) FORGINGS/ROLLED COMPONENTS

I. In addition to physical and chemical tests as per relevant codes, surface of the shaft shall
be examined by dye penetrant test/ Ultrasonic test in-accordance with ASTM-E-165 and
basis of acceptance shall be as per ANSI-B 16.34.
II. In addition to physical and chemical tests as per relevant codes, all other forged/rolled
components shall be subjected to magnetic particle testing (except austenitic type) at the
areas of fillet and change of sections. The testing is to be carried out after rough
machining operation (125 micro inches). The testing procedure and acceptance
standard shall be in accordance with ASTM standard as mentioned previously.
III. Any defect that will not machine out during the final machining, will be gouged out
fully, inspected by dye penetrant and/or magnetic particle inspection to ensure that the
defects are fully removed and repaired using an approved repair procedure. Any
indications which prove to penetrate deeper than 2-1/2% of the finished thickness of the
forging shall be reported to the purchaser giving location, length width and depth of
such defects, prior to any repair being done.
IV. The prod method will be used for carrying out the magnetic particle test. The direction of
the fields will be the most suitable one to obtain the clearest of any defect, prior to any
repair being done. All forgings shall be demagnetized after carrying out the test.

h) FABRICATED COMPONENTS:
I. All components which are fabricated from plate or bar stock meet the material
specification as per the standards.
II. The supplier shall furnish the purchaser, mill test reports showing the chemical and
physical properties of the material. In case relevant correlating test certificates are not
available, the supplier shall arrange to carry out necessary tests required by the code at
his own cost.
III. Welding procedure and welder qualification should be done according to ASME section
IX.
IV. 100% D.P. checking on all welded areas to be performed.
V. 10% radiography for all weldments to be done.
VI. The rubber parts used in the valve shall be visually inspected. Shore hardness test of the
rubber parts shall be carried out and certificate of compliance for the rubber
components shall be submitted.

i) HYDROSTATIC BODY TEST:

 Valves shall be subjected to hydrostatic body test as per AWWA C-504 for internal
hydrostatic pressure as indicated in the data specification sheets to check against leakage
through castings, shaft seals etc. and against any permanent deformation. There shall be
no leakage through the metal, the end joints or shaft seal nor shall any parts be deformed
permanently.

j) PROOF OF DESIGN TEST

Test certificates for proof of design as per AWWA-C-504 specification for each class and
size of valves shall be furnished for purchaser’s reference record and verification. Such
test should have been carried out with same design and using same construction
materials for all major components as that of the valves being offered against this tender
and should have been certified by GOVT./NPCIL/DAE approved third party inspection
agency. Carrying out proof of design test after placement of PO / opening of tender will
not be considered.

k) PERFORMANCE TEST
Valve with gear operator shall be shop operated at least 10cycles from fully closed to
fully open condition and reverse, hold at intermediate positions under no flow condition,
to prove the workability of the valve assembly and accessories.

l) SEAT TEST AND AIR LEAKAGE TEST

I. The leak-tightness of the disc shall be tested by subjecting the disc under hydraulic
pressure at the specified hydro seat leak test pressure( equal to pressure rating). The
valve shall be drop-tight under this condition.
II. Air leakage test shall be performed as per AWWA-C504 at the specified ‘Air Leak Test
Pressure’.
III. The valve shall be suitable for leak-tight performances at any pressure from zero to the
hydrostatic test pressure. Valves offered shall be bidirectional for leak-tightness. If not so,
he shall indicate in his offer the pressure up to which the valve will remain leak-tight if
the hydraulic pressure is applied opposite to the preferred direction of sealing. In any
case such difference shall not be more than 50% of the hydrostatic test pressure.
IV. The valve shall be tested for vacuum holding test upto 650mm of HG for the duration of
10 minute.

m) SHOP TORQUE TEST

 One proto type gear operator of each model and torque rating shall be shop tested at a
torque equal to or greater than twice the rated torque in accordance with AWWA C-504
or equivalent and this test shall be witnessed by purchaser representative/QA personals.

I. All operating mechanism shall be completely assembled on their respective

valves and shop tested before shipment.
II. After assembly, each valve shall be shop operated over the full range of Movement in
both directions under no flow conditions to demonstrate that the unit is in working order
and that the torque switches, limit switches and torque clutches operate
satisfactorily.
III. Leakage tests, each of duration not less than 5 minutes, shall be conducted in the
shop with the valves in closed position to demonstrate air tight shut-off with a disc
differential pressure as specified in the specification in accordance with AWWA
standard C-504
IV. With the valve disc is slightly open position, the entire valve shall be subjected to
hydrostatic test in accordance with the AWWA standard C-504. Under this pressure
there shall be no leakage through the body or its bonnet joints, and no part shall be
deformed.
V. Supplier shall furnish to the purchaser certified hydrostatic test certificates and test
reports of physical and chemical analysis of all components of the valves.
VI. Satisfactory completion of these tests or the issue of purchaser’s certificates to that effect
for the purpose of shipment shall not relieve the supplier of his obligations under the
contract, should equipment on further tests at site, be found defective and not to comply
with the specification.
.
11. CLEANING
All manufacturing waste such as metal chips and fillings, welding rods and stubs, waste,
rage, debris etc., shall be removed from the interior of each unit. All loose mill scale,
rust, oil, grease, chalk, crayon, paint marks and other deleterious materials shall be
removed from interior and exterior surfaces. At time of shipment product shall be clean
inside and outside.

12. PAINTING
A shop coat of red oxide paint (approved Indian Standard) shall be applied to all steel
and cast iron exposed surfaces after adequate cleaning as required to prevent corrosion
after release by purchaser for painting and before shipment.

13. DRAWINGS
 Supplier shall submit the following drawings with the proposal and when approved by
the purchaser shall be considered as part of the specification.
a. Dimensioned outline drawing of valve.
b. Longitudinal section of the valve. In this drawing various components of the valve
and its materials of construction shall be tabulated.
c. Drive motor outline dimensioned drawings.
d. Dimensioned outline drawings of gear box and Actuator – in this drawing the
various combination of Gear box Actuator mounting shall be given.
e. Dimensioned drawing of companion flanges-In this drawing ID, OD, thickness,
PCD, Number and size of bolt holes shall be given. Material of construction of the
flanges shall also be clearly indicated.
f. Schematic power and control wiring diagram of valve motor, Limit switches,
torque switches etc.

14. SPECIFIC PERFORMANCE GUARANTEE:

a. The supplier shall guarantee that in closed position and with a disc differential
pressure as specified, the valves shall be airtight.
b. The supplier shall guarantee that the operating mechanism will open and close the
valves under the specified maximum differential pressure.

15. SPECIAL CLEANING PROTECTION AND PAINTING

a) All equipment surfaces shall be smooth and free from burrs and shall be protected
against corrosion and mechanical damage.
b) All steel and cast iron surface shall be thoroughly cleaned to remove all mill, scales, rust
etc. by wire brushing and grit blasting.
c) All internal and external steel and cast iron surface of each valve be given two coats of
red lead primer. Final painting shall be done by the seller as per the approved QA plan as
per the standards.
d) Before the equipments are packed they shall be carefully checked to be sure that all
extraneous matters such as rage, tools, rubbish foreign matters, loose scale and dirt,
welding rod, studs, bolts etc. have been removed. After the interior is cleaned and dried
all opening shall be closed with blank flanges, caps etc. To prevent damage, entry of
water, dirt or any other foreign material.
e) Brass or stainless steel name plate shall be attached to each valve indicating the valve
size, manufactures name, class and year of manufacture.

16. SHIPMENT
a) All parte shall be properly packed, boxed, crated or otherwise protected for preventing
any possible damage during transportation.
b) Flanges shall be drilled as per the specified standard and all exposed surface shall be
protected by fitting suitable wooden blank flanges so that they are not damaged during
transportation.
c) No shipment shall be made unless shipping release is issued by purchaser in writing and
for shipment.
d) Each valve pack shall be identified by tag for numbering by the purchaser.

17. TECHNICAL DATA TO BE SUPPLIED WITH TENDER:

Supplier shall furnish the following technical particulars
a) Valve size in mm :
b) Performance
Flow (Maximum) in m3 / hr. :
Design Pressure in mWC :
Design temperature in OC :
Test pressure in mWC :
Maximum disc differential pressure in mWC:
Pressure in mWC when passing maximum
flow & valve fully open :
Closing time from full open position in
seconds :
Maximum design torque on the shaft in kg.m:
Shaft diameter in mm :

c) Materials of Construction
Supplier shall specify ASTM or IS or BS designation of the materials of construction as
per tender specification / sea water compatible materials.
a. Body
b. Disc
c. Disc seat
d. Retaining segments
e. Drive shaft and stub Shaft
f. Bearing bush
g. Gear casing and internals components.
h. Actuator body and its internal components

d) Electrical Motor actuator and Reduction Gear Box Assembly:

 Supplier shall clearly furnish complete details of electrically operated actuator
mechanism and its internals details, indicating the make, model number, constructional
/ cross sectional drawing and its maintenance and instruction manual / catalogue. The
selected actuator and intermittent gear box shall be confirming to the requirements
given in this specification.

e) WEIGHT:
Supplier shall furnish the weight of each size valve assembly with accessories.

f) DRAWING:
a. Dimensioned outline drawing of valve.
b. Longitudinal section of the valve - In this drawing various components of the valve
and its materials of construction shall be tabulated.
c. Drive motor outline dimensioned drawings.
d. Dimensioned outline drawings of gear box and Actuator – in this drawing the
various combination of Gear box Actuator mounting shall be given.
e. Dimensioned drawing of companion flanges-In this drawing ID, OD, thickness,
PCD, Number and size of bolt holes shall be given. Material of construction of the
flanges shall also be clearly indicated.
f. Schematic power and control wiring diagram of valve motor, Limit switches,
torque switches etc.
18. PROOF OF DESIGN:
Test certificates for proof of design as per AWWA-C-504 specification for the valve size
of 1050mm and above shall be furnished for purchaser’s reference record and
verification. Such test should have been carried out with same design and using same
construction materials for all major components as that of the valves being offered
against this tender and should have been certified by Govt./ NPCIL/DAE approved third
party inspection agency. Carrying out proof of design test after placement of PO /
opening of tender will not be considered.

Annexure-1
GENERAL SPECIFICATIONS FOR SQUIRREL-CAGE INDUCTION MOTORS (UP TO 12 kW) FOR
THE MADRAS ATOMIC POWER STATION
1. SCOPE
This specification covers the general technical requirements for the design manufacture,
inspection, testing and supply up to 12 kW and supplied as prime and auxiliary drives
for and as integral part of the Butterfly valves supplied for the Madras Atomic power
Station. This specification is meant only for guidance of the supplier and is not intented
 to cover all aspects of design and manufacture. The specific requirements are given in
the attached Annexure.
The supply of all cabling, wiring, Switching and electrical control equipment required to
connect the motors to the station electrical system will be special mechanical
construction. This specification does not include special purpose motors with special
operating characteristics and or special mechanical construction.

2. STANDARDS
The motors shall conform to the latest editions of the following standards, unless
specified otherwise in this specification.
2.1 IS-325 Specification for Three-phase Induction Motors.
2.2 IS-1231 Dimensions of Three-phase foot-Mounted Induction motors.
2.3 BS:CP-1014/1963 Protection of electrical equipments for climatic conditions of British
standard specification.

3. DESIGN REQUIREMENTS
3.1 General
3.1.1 Motors shall be designed, Manufactured and equipped with accessories in accordance
with this specification and the applicable standards Materials and components not
specifically stated in this specification and which are necessary for meeting the
requirements of this specification, shall be included in the scope of supply.
3.1.2 The design and workmanship shall be in accordance with the best engineering practices
to ensure satisfactory performance and service life as specified herein.
3.1.3 Design and manufacture of the motors shall be coordinated with the requirements of the
driven equipment- the motor manufacturer shall co-operate fully with the purchaser
and the manufacturer of the driven equipment by furnishing following information
necessary for proper assembly and operation of the unit as a whole.
i. A fully dimensioned outline drawing of the motor.
ii. The relevant motor characteristics viz- speed/torque and speed/current.
iii. The maximum permissible temperature under stalled rotor conditions for cold
and hot motor, when started on full rated voltage.
iv. Weight of motor.

3.2 ENCLOSURE
Motors shall be self-Ventilated unless otherwise specified. Fine mesh screening shall be
provided over air vents and intakes to prevent access of rodents or large insects to the
motor internals. Motors for outdoor service shall be so constructed that exposure to the
weather will not interfere with its proper operation. Motors, which are to be installed in
 inflammable and corrosive atmosphere and hence shall be of the TEFC type as per IS-
325 and as detailed in the particular specification.

3.3 FRAME
The motor frame may be of rigid fabricated steel or a casting. In the latter case, the
material shall be approved by purchaser.

3.4 DIRECTION OF ROTATION

The direction of rotation shall refer to the non-drive end of the machine. All motors shall
be designed for operation in either direction of rotation.

3.5 INSULATION
3.5.1 The insulation class to be adopted for motor windings, except when stated otherwise
shall be in accordance with the following:
Supply voltage Insulation class
415V F
3.5.2 Motor winding shall be given special tropical, fungicidal and ‘power-house’ treatment
for protection against tropical weather conditions, fungus growth and moisture, oil
abrasive and conducting dust and sulphur fumes in combination with weak acid or
alkali fumes respectively that are likely to be encountered in and around the power plant
area. ‘ Power house treatment’ shall comprise an additional treatment to the winding,
over and above the normal treatment generally given to such winding by the
manufacturer. In this, after the coils are placed in slot and all connections are made
entire motor assembly shall be impregnated by completely submerging core and
windings in suitable insulating compound or varnish followed by proper baking. At
least two additional submersions and bakes shall be applied either to the end windings or
to the whole assembly, making total of atleast three submersions and bake treatments.
3.5.3 The supplier shall fully describe the insulation and insulation treatment and its Capacity
to meet without damaging the operating requirements specified.
3.6 TERMINAL BOXES
The terminal boxes shall be fabricated from sheet metal plates with a steel plate cover.
The stator leads shall be brought into the terminal box as insulated cable through a
suitable barrier and terminated in clamp or compression type terminals.
The terminal box shall be suitable for top and bottom entry of cables and shall be
provided with suitable gasket on the covers to make it moisture proof.
Terminal box on motors for outdoor service shall be weather proof. Gaskets of neoprene
of approved equivalent shall be provided at cover joints and also between the box and
 the motor frame. All terminal boxes shall be provided with cable boxes/ cable glands
equipment rating.

3.7 DRIVES
Motors and valve shall be connected by gear drive mechanism. (Through gear box)

3.8 GROUNDING
3.8.1 Provision shall be made on the motors for connecting purchaser’s grounding conductors.
3.8.2 8mm dia hole for motors up to 12KW shall be drilled in the flat surface of the motor
Frame for fixing a suitable high strength bronze threaded post type terminal for
connection of the grounding cable connector. The threaded hole shall be of sufficient
depth to ensure adequate electrical contact between the bolt and the motor frame.
3.8.3 Two independent grounding points shall be provided on each motor frame on opposite
Sides near the bottom. Each grounding device shall be suitable for the purchaser’s
grounding cable as give below:
i. Motors rated 7.5 to 12KW-35 sq. mm stranded copper conductor
ii. Motors rated below 7.5 KW -10sq .mm Stranded copper conductor

3.9 TROPICAL TREATMENT

The stator winding insulation, core punchings and motor internals shall be tropicalised
and given a special treatment of a fungus inhibiting coating as specified in BS: CP-
1014/1963.

3.10 VIBRATION
The motor vibration shall be within the limits specified in IS-325. Tests conforming to
IS-325 for measuring amplitude of vibration shall be carried out when specified.

3.11 BEARINGS AND BEARING HOUSING

The bearing shall be designed to permit motor running in either forward or reverse
directions.
3.12 MOUNTING AND DOWELLING
Unless otherwise specified all horizontal motors shall be foot mounted and vertical
motors shall be of the base mounted type.

3.13 LIFTING FACILITY

Motors weighing more than 25kg.shall be provided with eye bolts, lugs or other devices
to facilitate safe lifting operations.
3.14 BEDPLATES
When a motor is supplied with driven equipment having common bedplate the supplier
shall determine that such bedplate is adequately braced to keep vibration and
misalignment within permissible limits. The bedplates drawing shall be approved by the
motor manufacturer.

3.15 NAMEPLATE AND DIAGRAM OF CONNECTIONS

Each motor shall have nameplate showing all the particulars specified in IS-325 Clause
6. In addition, the following information shall be included in the nameplate:
i. Temperature rise in degrees C at rated load.
ii. Type of bearings and recommended lubricant.

3.16 DIMENSION AND THREADS As per IS-325.

4.0 PERFORMANCE
4.1 SUPPLY VOLTAGE AND FREQUENCY VARIATION
The motors shall operate satisfactorily with the following variation in the supply voltage
and frequency:
Variation in frequency - +/-5%
Variation in voltage - +/-10%
Combined variation of frequency and voltage - +/-10%

4.2 STARTING DUTY

4.2.1 Motors shall be capable of three equally spread starts per hour under normal service
conditions and two starts in quick succession with cold machines at room temperature
4.2.2 Motors shall be designed for direct- on –line, full voltage starting and shall withstand all
stresses and give satisfactory performance when started with their driven equipment
connected under the following operating conditions
4.2.3 The motors shall be capable of starting and accelerating the driven equipment
satisfactorily at a minimum, voltage of 80% of the nominal voltage at the motor
terminals.
4.2.4 Motors shall be suitable for operation without employing starting compensators or other
means for reducing starting current unless specifically asked for.

4.3 LOCKED ROTOR CURRENT

Locked rotor current of motors shall have the lowest value consistent with good
performance and economical design for their torque current class, but this shall not
 exceed 600 percent of full load current. The foregoing maximum permissible values of
current shall be inclusive of tolerances permitted by relevant I.S.

4.4 FAST BUS TRANSFER

Motors shall be capable of withstanding the voltage and torque stresses developed due to
the vector difference between the motor residual voltage and the incoming supply
voltage equal to 150% motor rated voltage during fast changeover of the supply.
Features incorporated in the motor design to comply with this requirement shall be
clearly indicated in the proposal.

4.5 PULL-OUT
Motors shall not pull out of step when the supply voltage drops to 70% of the rated
motor voltage for a short duration of 25 cycles. To meet this requirement, the pull out
torque of the motor at rated voltage shall be atleast 200% of full load torque.

4.6 OVERSPEED
The motors shall be capable of withstanding without mechanical damage atleast 125% of
rated speed.

5.0 OTHER REQUIREMENTS

5.1 Motors shall be capable of satisfactory operation at full loads for ten minutes without
injurious heating for the motor terminal voltage 80% of rated voltage.
5.2 Accelerating time of the motor with rated driven equipment load connected to it shall
not exceed the corresponding safe stall time of the motor even if stalling occurs when
motor is at rated operating temperature.
5.3 TEMPERATURE
The maximum operating temperature of the motor windings under continuous full load
shall not exceed the following:
TEMPERATURE INSULATION PERMISSIBLE TEMPERATURE
MEASUREMENT BY CLASS FOR ALL TYPES OF ENCLOSURES
Thermometer F 1500C
Resistance F 150oC
The temperature rise will depend on the specified ambient temperature.

6.0 SPARE PARTS

The supplier shall recommend a list of spares that are required to be stocked for
maintenance purposes.
7.0 INSPECTION, TESTS AND GUARANTEE
All routine tests mentioned in IS-325 shall be conducted by the manufacturer at his
works in the presence of purchaser’s representatives and six copies of test certificates
shall be furnished to the purchaser for approval. Certificates for type tests are to be
provided.
The purchaser’s Inspector shall at all reasonable times have access to those parts of the
supplier or sub supplier’s works concerned with the manufacture of the motors, for the
purpose of witnessing tests and ascertaining compliance with requirements of this
specification. The purchaser shall also have the right to conduct at his expense any
additional tests or inspection he deems necessary.
Supplier shall furnish material specification certificates for motor shaft and bearing, and
he shall be in a position to correlate these certificates with the actual material used for
the motors.
After receipt of the purchase order, the supplier shall furnish to the purchaser a detailed
schedule of manufacture and delivery to enable purchaser’s inspector to plan visits to the
manufacturer’s works for inspection during different stages of manufacture
The contractor shall supply to NPC representative a complete set of detailed drawings
which will be used in the inspection during construction, which will be retained at the
factory and returned after completion of the contract

8.0 PAINTING AND PACKING

The motor external parts shall be finished and painted to produce a neat and durable
surface which would prevent rusting and corrosion. The equipment shall be thoroughly
degreased, all rust, sharp edges and scale removed and treated with one coat of primer
and finished with two coats of enamel paint.
The motors shall be packed for dispatch to site in strong wooden crates,

9.0 DRAWINGS
The following drawings shall be submitted with the tender
a. Outline dimensions of assembled motor
b. Dimensioned drawing of the terminal boxes showing the method of
terminating the purchaser’s incoming cables.
c. Dimensioned drawing of bearings
d. Schematic, power and control wiring diagram of the valve motor, limit switches,
torque switches etc.
As soon as the purchase order has been issued by the purchaser, supplier shall submit
within 4 weeks for the purchaser’s approval four (4) copies each of certified
dimensioned outline drawings of the motors, terminal boxes and bearings. Outline
 drawings shall show overall and other essential dimensions and details regarding
foundations, conduit boxes. Supplier shall take up manufacture of motors only after the
drawings have been approved by the purchaser.
After execution of the order, six (6) copies of as-built drawings shall be supplied to the
purchaser

10.0 DATA TO BE FURNISHED WITH TENDER

The following information shall be furnished with the tender:
a. Schedule of guaranteed performance figures as per annexure
b. Schedule of supplier’s deviation from this specification
c. Descriptive pamphlets of each type of motor
d. Description of insulation materials used and insulation treatment
e. Description of weather protection features for motors required for outdoor service.
f. List of accessories included in the scope of the supplier’s tender
g. Material specification for motor shaft and bearings
h. All drawings listed

11.0 SPECIFIC REQUIREMENT SHEET -SQUIRREL CAGE INDUCTION MOTORS

a. Voltage : 415V
b. Frequency : 50 C/S
c. Phases : 3
d. Installation : Outdoors
e. Type of Enclosures : TEFC/TESC
f. Class of insulation : Class-H
g. Duty : Periodic / Intermittent
h. Mounting : Vertical/Horizontal
i. Vibration Tests : Required
j. Type Tests : Required
k. Special requirements
i. Bearing
ii. Epoxy-Painting
iii. Vibrations peak to peak amplitude
iv. Coupling
l. Any other special requirements: Closer to sea water. (saline atmosphere)

12.0 TECHNICAL PARTICULARS TO BE FURNISHED

1. Make
2. Frame size size and design code No.
3. Application (driven equipment)
4. KW Rating
5. Rating
6. KW Actually required by driven equipment under specified operating conditions.
7. Rated voltage
8. Frequency
9. Permissible voltage and frequency variation under normal running conditions
10. Minimum voltage required under starting conditions to bring driven equipment up
to rated speed.
11. No. Of Phases
12. Stator winding
13. Connection (stat or Delta)
14. Resistance per phase
15. Resistance between terminal
16. At rated voltage and frequency
a. Full load speed (r.p.m)
b. Full load current (amps)
c. Starting current (Percent of full load current)
d. Starting torque (percent of full load torque)
e. Maximum torque (Percent of full load torque)
f. Full load efficiency (Percent)
g. Full load power factor
h. Starting power factor
17. Starting
a. Accelerating time in seconds (with full load connected)
b. Starting current versus time characteristic
c. Permissible Starting duty cycle
d. Average number of starts permissible during 24 hour period
e. Extra precaution taken in the motor design to meet 150% of nominal voltage
during high speed bus transfers
18. Safe stall-time secs.
a. When motor is at rated operating temperature
b. When motor is at ambient temperature
c. Limiting rotor temperature used to determine stall time(0C).
19. Overload capacity
a. Overload (percent of full load) that can be carried by motor without impairing
overall performance and period for which this overload is applicable.
b. Stator Thermal Time constant
20. Location: Outdoor
21. Insulation
a. Class of insulation
b. Material and treatment of insulation
22. Temperature rise (0 C) over ambient
a. State ambient applicable
a. By Thermometer
b. By winding Resistance
23. Shaft orientation
Horizontal and vertical (shall be suitable for both vertical and horizontal
orientations.)
24. Method of connection to driven equipment
25. Enclosure and ventilation
26. Bearing
a. Type and catalog number
b. Life in hours for actual speed
c. Recommended lubricant
d. Bearing end play (mm)
27. Terminal connectors
a. For stator leads type and number
b. For purchaser’s incoming cable type and number
28. Grounding device
a. Method and number of ground points
b. Location
c. Cable for which grounding connector is suitable
29. Terminal Box
a. Type and number provided
b. Conduit openings for which suitable
c. Whether phases segregated
30. Weight
a. Net weight of complete motor (Kg)
b. List and weight of motor parts weighing 25 Kgs and above.
31. Moment of Inertia (kg-cm2 )
32. Critical speed (r.p.m)
33. Speed torque curve
a. for motor.
b. for driven equipments.