Supply of Slush Pump

# 2 Slush pump, 1600 hp, electric d.c.motor with banded v-belt drive ,triplex single acting, horizontal piston with individual 2(two) piece (separate) forged alloy steel modules and replaceable cylinder liners of various sizes to obtain desired discharge and pressure at rated spm.

1.0 Slush Pump

A) Type of Pump:

Slush pump, triplex single acting, horizontal piston pump with individual 2(two) piece (separate) interchangeable forged alloy steel modules and replaceable cylinder liners of various sizes in steps of 1/2"(15mm) from 7-1/2" to 5" diameter to obtain desired discharge and pressure at rated spm. the pump must be driven by dual end mounted electric d.c.motor with banded v-belt drive, complete with standard accessories mounted on an oil-field type 3(three) runner skidded on a master skid for on shore drilling rig.

B) Capacity of the Pump:

i) Input horse power - 1600 (min) at rated spm.
ii) Discharge at rated spm with replaceable liners and pistons - min. 2700 liters/min (600 imp gpm) at 210 kg/cm2 (3000psi) and min. 1575 liters/min. (350 imp.gpm) at 351.5 kg/cm2 (5000 psi)

Note: Liners to be fitted on the pump at the time of supply should be such to obtain minimum 2700 liters/min (600 Imp. GPM) discharge at 210 kg/cm2 (3000PSI) pressure.

C) Various features of the pump:

i) Fully enclosed fabricated steel plate (ASTM A-36 or equivalent) power end.

ii) Double relieved forged alloy steel Herringbone type main gear.

iii) Double extended pinion shaft with double helix gear.

iv) Crankshaft lobes should be press fitted & keyed onto the shaft.

v) Self-aligning spherical roller pinion shaft bearing.

vi) Double row tapered roller main shaft bearing.

vii) Double row needle bearing at crosshead end.

viii) Cylindrical roller bearing at crankshaft connecting rod end.

Note: Above bearings must be of make Torrington / SKF / FAG/ NTN/ARB.

ix) Provision for manual rotation of the crankshaft externally for maintenance purpose.

x) Individual separate, forged alloy steel (AISI 8630 / 4130 /equivalent), autofrettage, and completely interchangeable fluid end modules having separate valve pots in each module (for both suction & discharge).

xi) Fast change type screwed valve covers.

xii) Two-piece design fast change piston rods with clamp.

xiii) Suction manifold with suction stabilizer assembly and Discharge manifold with discharge pulsation dampener.

xiv) Piston-Liner Cooling / lubrication spray system that includes A.C. 3PH, 50 Hz. Flame proof (Ex-d type) with IP55 protection & insulation type B electric motor suitable for use in hazardous area classification zone-I, gas group IIA & IIB; suitable pump for liner spray; lubricant reservoir with suitable piping connection.

xv) Pump fitted with liners (API 7) held rigidly in place with a two-bolt retention clamp, premium pistons, mission type 4(four) rib valve seats (API 7), center guided valve with polyurethane insert.

xvi) Crankcase Lubrication system should be splash type lubrication.

xvii) Suction connection should be 10" (250mm), ASA-150#, R.J.Flanged.

xviii) Discharge modules should be interconnected so as to make a smooth discharge flow through strainer cross; 5" API 5000#, R.J.Flanged on one end and provide valve & bleed line connection on the other end.

xix) Pump sheaves should be compatible for Gates 8-8VP-3150 power belt.

xx) The pump should be complete with all the components of fluid end and power end, mounted on a sufficiently strong skid (base skid)skidded on a another oil field type skid(mother skid)having standard design for self loading at both ends and base skid should be strongly anchored with the main pump skid (mother skid). The total length of skid should not be more than 7600mm. There should be proper lifting arrangement on the pump also.

xxi) Detailed technical drawing of the base skid and mother skid are to be submitted along with the offer for our approval.

xxii) The dimensions of the complete pump with mother skid should be within 7600 mm long x 2700 mm wide x 2000 mm height and the total package weight must not exceed 28,000kg. Justification is required if the above limiting dimensions can not be met.

xxiii) One complete valve seat puller assembly suitable for above mentioned valve seat and one set of special hand tools for fluid end maintenance must be included with each pump set to be supplied.

xxiv) 2 No additional belt for each pump set to be supplied along with the pump.The belt make and size should be same as offered with the pump.

xxv) Suitable analogue type belt tension meter with complete operation & maintenance manual, 1no. for each pump to be supplied along with the pump.

xxvi) Suitable Stroke Counter Meter should be provided in each pump.

D) Accessories:

The Slush Pump package should be assembled with the following accessories:

i) A high pressure discharge strainer cross assembly complete with the following features:-

a) Suitable Strainer, 5" (125mm).

b) 5" (125mm) API 5000# RJ end connection with weld neck flange (4.063"/104mm
bore) for discharge line, 1no. 1350, 5000 PSI (351.5 kg/cm²) WP forged steel elbow must be supplied welded, one end with the weld-neck flange & the other end with 1no. 4" (100mm) NB X 8" (200mm) long screwed APILP nipple.

C) 4" (100mm), API 5000# RJ flanged connection at the top with studs & nuts for pulsation dampener.

d) 5" (125mm), API 5000# RJ end connection with blind flange for strainer clean out.

e) 5" (125mm), API 5000# RJ end connection with flange having 2" (50mm) APILP
screwed connection for pressure gauge.

ii) A discharge pulsation dampener assembly (Make: Hydril,Model: K-20-5000, Pt. No: 3111330-07011) complete with the following features: -

a) Maximum service pressure: 351.5kg/cm2 (5000PSI).

b) Surge capacity: 75 liters (20 gallon)

c) Bottom connection: 4" (100mm), API 5000# RTJ flanged.

d) Diaphragm: Hydrogenated Nitrile

iii) Charging hose assy. with pressure gauge for Nitrogen gas charging to pulsation dampener.

iv) Pressure gauge of Make: Oteco, Model: 7 having following features:

a) Pressure range: 0-351.5 kg/cm2 (0-5000PSI)
b) Connection: screwed female 2" (50 mm) APILP threaded

v) Manual Reset Relief Valve of Make: Oteco, Type-B or Retsco having following
features: -

a) Pressure range: 105-351.5 kg/cm2 (1500-5000PSI)
b) Connection: screwed female 3" (80 mm) APILP threaded

vi) Bleed line accessories should be included with the following items:

a) 5" (125mm), API 5000# RJ flange with 3" (80 mm) APILP screwed connection. -2 Nos. of which 1 No. is directed to the mud tanks and the other directed towards the power end for bleeding other fluids.

b) Flex seal type 3" (80 mm), 5000PSI (351.5kg/cm²) flanged mud Gate valve (Make:
Oteco or Demco) :-2Nos.

c) Flex seal type 2" (50 mm), 5000PSI (351.5kg/cm²) flanged mud gate valve (Make:
Oteco or Demco):-1No.

d) Nipple, XXS, 3" (80 mm) NB x 6" (150 mm) long, screwed APILP thread both ends:-6 No.

e) Equal Tee, FCS, 3" (80 mm) NB, 5000PSI (351.5kg/cm²), and screwed female APILP thread:-2 No.

f) Reducer, FCS, 3" (80 mm) NB x 2" (50 mm) NB x 6" (150 mm) long, 5000PSI (351.5kg/cm²), screwed male APILP thread: 1 No

g) 3" (80 mm), API 5000# RTJ screwed APILP flange :-2 Nos.

h) 2" (50 mm), API 5000# RTJ screwed APILP flange :-2 Nos.

i) Elbow, FCS, 3" (80mm) NB, 5000PSI (351.5kg/cm²), screwed female APILP thread: -1 No.

vii) Jib crane with trolley installed on each pump to handle fluid end parts.

viii) Hand hoist, ½ ton (500kg), LH, 2.5 m(8ft.) lift for use with Jib Crane.

ix) Api monogrammed ring joint gaskets of required quantity should be provided.

2.0 pump drive and motor skid slush pumps should be dual rear mounted electric motor driven by banded power v-belts.

pump skid must be supplied sufficiently long to accommodate 2 no d.c.motor (to be supplied by oil) with motor supports, tensioning screws, belt guards (two piece detachable type belt guards for easy opening of belts from motor sheaves) to be mounted on the master skid. pumps are to be fitted with suitable sheaves (including hub) at both sides of the pumps. motor sheaves to be supplied to suit the hubs (as per enclosed hub drg.) fitted with motors of oil. pump drive should be complete with 2 no preferably gates make banded 8-8vp-3150 power v-belts for use with d.c. shunt motor.

3.0 Unitization of d.c.motor (d.c.motor will be supplied by oil each slush pump will be driven by 2(two) nos. heavy duty d.c drilling motors. a brief specification of d.c motor is highlighted below, so that the bidder can keep provision and make suitable arrangements on para 2.0 above to match the d.c motors. the bidder has to carryout the unitization and alignment job at our work site at a radial distance of 50 km from duliajan, assam, india.

i) Type and Rating of Motor

a) Armature: 750 V, 1050 Amps (continuous)
b) Shunt Field: 120 V, 55 Amps (continuous)
c) Horse Power: 1000 HP at 1050 RPM (max. RPM: 1300)
d) Torque: 5000 Lbs-ft (nominal)
e) Insulation: #H#
f) Weight of motor with blower: 3500 kg
g) Type: 4903 CX
h) Make: M/s bharat heavy electricals limited, bhopal, india

ii) Motors will be supplied by OIL without sheave but with hub. (dimensional details of the hub is enclosed for supplier's reference).

iii) Foundation pads with tapped holes and jacking bolts should be supplied along with the pump skid for fixing of motors on pump skid (refer enclosed drawing for details of motor foot print). The motor feet hole size is 38 mm and thickness of motor foundation pad should be 42 mm.

iv) All the motors for auxiliary lubrication pump (if any) & liner-flushing pump to be supplied by the Slush Pump supplier should be rated as follows:

a) Voltage: 3 phase, 415volt. 50 Hz.

b) Horse Power (HP): will depend on pump to be supplied but limited to 5 HP for each motor.

c) RPM: will depend on pump offered.

d) Terminal Box: fitted with double compression type FLP gland suitable for cable O.D.- 14 mm.

e) Enclosure: flameproof, suitable for use in hazardous area zone-I, gas group-IIA & IIB.

f) Motors shall be FLP (Ex-d type), with IP55 protection.

g) Motor insulation type B.

h) Motor should conform to IS 2148.

i) Motors must have valid CMRI (India) certification or equivalent certification from competent authority from the country of origin and the bidder has to forward the same along with the offer. Bidder shall confirm categorically during the offer that approval of DGMS (India) for Zone I, Gas group IIA and IIB for the same will beprovided along with the supply.

j) Motors shall preferably be mounted on adjustable pads, so that in case of failure, indigenous make motors (with possibly different frame size) may be installed as replacement.

v) The detailed engineering drawing for the D.C.motor foundation pad on the skid to be provided along with the offer.

4.0 Others:

Following details are to be submitted along with the offer.

i) Material specification and constructional features of the pump.

ii) Complete technical details of the pump, belt (capacity, design, size etc.), dual rear mounted V-belt drive including sheaves, motor skid, base skid & mother skid for pump, V-belt guards, pump and motors for liner flushing, delivery & suction dampener, pressure relief valve, pressure gauge, flex seal mud gate valve etc.

iii) A schematic layout (plan and elevation) of the pump set offered showing outline of skid & mother skid, pump, motor, dual rear mounted motor pump drive and their accessories.

iv) The performance chart of the reciprocating pump indicating all technical calculations such as hydraulic horsepower, volumetric efficiency, mechanical efficiency, rpm, gear ratio etc.

v) If the bidder is other than NATIONAL OILWELL VARCO, USA and G D MACHINERY, Inc, USA, then the bidder has to provide along with offer documentary evidence of supplying minimum 8 nos. of similar pumps(as being offered) with banded V-belt drive for drilling rig application along with performance certificate from the two end users. Certificate from the end user must specify total period of satisfactory operation. The offer must be supported with performance guarantee of the pump for a minimum period of 2(two) years.

vi) Specific confirmation from the bidder for the unitization of D.C. motors with the slush pumps at OIL's work site at a radial distance of 50 KM from Duliajan, Assam, India.

vii) Three sets of list of spares with part no., quantity and unit rate recommended for two years of operation.

viii) Specific confirmation ensuring uninterrupted supply of spares for all items including accessories for a minimum period of 15 years.

ix) During guarantee/warranty period, the supplier has to attend and rectify all defects at site in and around Duliajan, Assam and replace/repair (including supply of spares) all malfunctioning components free of cost to OIL.

x) The following spare parts and tools should be included in the scope of supply. These spare parts are to be quoted separately with individual part numbers and prices thereof. The cost of these spares (AAA & BBB) will be considered for evaluation of the offers. However OIL reserves the right to decide whether to purchase these spare parts along with the pump or not AAA) Fast moving spare parts

a) Liner 7": 30 No
b) Liner 6": 36 No
c) Piston Assembly 7": 48 No
d) Piston Assembly 6": 60 No.
e) Piston Rod complete: 6 No.
f) Valve seat: 25 No.
g) Valve assy. with polyurethane insert: 100 No
h) Valve Insert (polyurethane): 200 No
i) Valve spring: 24 Nos.
j) Valve cover gasket: 200 No
k) Liner gasket, 7": 90 No
l) Liner gasket, 6": 90 No
m) Wear plate gasket: 12 No
n) Wear plate: 6 No
o) Suction module: 3 No
p) Discharge module: 3 No
q) Valve seat puller assembly: 1 No (Type & Make to be specified)
r) Banded power belt: 2 No (Type & Make as offered with the pump) BBB ) Slow moving /Insurance spare parts
a) Crankshaft with bull gear -1 No
b) Rod Connecting -1 No
c) Bearing Eccentric -3 No
d) Bearing Main -2 No
e) Bearing Pinion -2 No

Any other maintenance spares that may be necessary during an initial period of two years should be quoted; however, the same will not be taken for evaluation.

Note: Offer not complying with above points i.e.4.0 (i) through 4.0(x) shall be treated as non-responsive and liable for rejection.

5.0 Terms & Conditions:

5.1 Inspection & Tests:

i) The pump and accessories may be subjected to inspection during assembly at the purchaser's discretion but such inspection shall not relieve the supplier of his responsibility to ensure that the equipment supplied is free from all manufacturing and other defects and conforms to correct specifications.

ii) The complete pump sets will be inspected and performance tested as required by a team of 2/3 engineers from OIL at the supplier's works. The supplier should give inspection call well in advance (at least 3 months).

iii) Except where otherwise agreed the tests called for in this specification shall be carried out in the presence of the purchaser or his representatives appointed for the purpose and to their entire satisfaction. Supplier shall provide all appliances, apparatus, labors etc. necessary for the tests at his cost.

iv) The supplier shall carryout ultrasonography/radiography testing for entire welding zone. The supplier shall also carryout physical & chemical testing of various material used. The supplier shall submit records and certificates of such tests to the purchaser in quadruplicate during the time of pump inspection.

5.2 Hydraulic & Load Testing: Before being despatched from the supplier's works, all vulnerable castings, forgings and valves shall be hydraulically tested to at least 1.5 times their normal working pressure for a period of 30 minutes. The certificates there of shall be made available to the purchaser during the time of pump inspection.

5.3 Packing, Painting & Protection:

i) Packing shall be sufficiently robust to withstand rough handling during ocean shipment and up country journey.All tems shall have their respective identification letters ornumbers painted on them and they shall be suitably packed to provide ease of handling and storage and maximum protection during transport and storage period. Items/item in the crates or boxes shall have a list of items to be written on a piece of tin sheet and nailed it to the wooden box. A duplicate list shall also be included inside.

ii) Internal parts shall be sprayed with inhibitor water splitting preservative and all openings shall be covered with masking tape to prevent ingress of water.

iii) Appropriate external surface of the pump sets shall be treated with one coat of primer and two coats of enamel paints.

iv) Box (es)/packing case(s) shall be waterproof lined.

5.4 Operation and Maintenance Manuals:
Supplier will be required to supply 4 sets of operation and maintenance manuals as well as spare parts manual covering all the items including accessories free of cost.

5.5 After Sales Service:
The nature of after sales service to be provided by the bidder during initial erection and commissioning and also subsequent operation should be clearly stated.

5.6 The country of origin of goods is to be clearly mentioned. In case of mixed origin items, percentage content of origin country wise should be mentioned.

5.7 Any deviation in specifications to those called for vide this enquiry should be mentioned as a separate Annexure.

5.8 Categorical confirmation regarding compliance with the inspection/test procedures and other terms & conditions detailed above is very essential. Offers will be liable for rejection in the absence of such confirmation.

6.0 Commissioning:

Installation and Commissioning of the Pump set shall be carried out by the bidder in the presence of OIL representatives at its fields at Duliajan, Assam (India). Services of qualified and competent personnel from equipment manufacturer is essential during installation and commissioning of the pump sets. Only competent service personnel shall be engaged for installation, testing and commissioning of pump sets. OIL will provide necessary statutory permits in classified areas as and when required.

Installation / commissioning charges should be quoted separately which shall be considered for evaluation of the offers. These charges should included amongst others to and fro fares, boarding/ lodging and other expenses of the commissioning engineers during their stay at Duliajan, Assam (India). All Personal Income and Service Tax etc. towards the services provided by the supplier shall be borne by the supplier and will be deducted at source. Bidders should also confirm about installation/ commissioning in the Technical Bid.