KOC-ME-009 - Rev.2

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STANDARDS PUBLICATION

KOCSTANDARD

FOR

STATIONARY FIREWATER PUMPSETS

DOC.NO. KOC-ME-009, REV. 2

ST ANDARDS TEAM

DOC. NO. KOC-ME-009

Page 1 of 59

REV. 2

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STANDARDS PUBLICATION

KOCSTANDARD

FOR

STATIONARY FIREWATER PUMPSETS

DOC.NO. KOC-ME-009, REV. 2

STANDARDS TEAM

DOC. NO. KOC-ME-009

REV. 2

Page 2 of 59

KOC STANDARD

FOR

STATIONARY FIREWATER PUMPSETS

DOC.NO. KOC-ME-009, Rev. 2

(SUPERSEDES 015-GH-1004)

ISSUING AUTHORITY:

STANDARDS TEAM

,

2

25.12.11

Amendments Approved by STC 86

Task Force (TF-ME/10)

Rev.

Date

Description

Prepared by Tel. 61871

"

~" Snr. Engineer Standards /

\l-

~~ k1r~

~Te~

Leader Standards

Tel. 61871

Tel. 61896

,

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TABLE OF CONTENTS

Page No.

FOREWORD

5

1.0

SCOPE

6

2.0

APPLICATION

6

3.0

TERMINOLOGY 3.1 Definitions 3.2 Abbreviations

7

7

8

4.0

REFERENCE STANDARDS, CODES AND SPECIFICATIONS 4.1 Conflicts 4.2 Order of Precedence 4.3 List of Standards and Codes

8

8

9

9

5.0

ENVIRONMENTAL CONDITIONS

12

6.0

HEALTH, SAFETY AND ENVIRONMENT

12

7.0

MATERIALS 7.1 General 7.2 Proprietary Items

12

12

15

8.0

TECHNICAL REQUIREMENTS 8.1 General 8.2 Operating Philosophy 8.3 Design Requirements

15

15

16

19

9.0

INSPECTION AND TESTING 9.1 Testing Requirements 9.2 Inspection and Testing of Pump 9.3 Testing of Control Panels 9.4 Testing of Battery Charger System 9.5 Testing of Diesel Engine 9.6 String Test of Fire Water Pump Set 9.7 Additional Functional Tests 9.8 Field Acceptance Test

35

35

36

37

37

38

39

40

40

10.0

QUALITY ASSURANCE

41

11.0

MARKING

41

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DOCUMENTATION 12.1 General 12.2 Deliverables

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42 42 42

13.0 SPARE PARTS AND MAINTENANCE DATA

46

14.0 APPENDICES

47

APPENDIX 1 :

CHECK LIST FOR INSPECTION AND TESTING

48

APPENDIX 2: DATA SHEETS FOR FIREWATER PUMPS

49-53

APPENDIX 3:

54-56

DIESEL ENGINE DATA SHEETS

APPENDIX 4: DATA SHEET FOR NOISE LEVEL

57

ACKNOWLEDGEMENT

58-59

SUMMARY OF CHANGES MADE IN REVISION 2 Sr. Clause No. 1. 8.1.3c) 2. 8.3.1 I) 3. Data Sheet

Description Deleted "FM listed I UL approved" Added a "Note". Modified Gland Material from "Plate I Monel 500" to "Plate I Monel 500 I Ni-AI Bronze" in the Materials Column of Appendix 2 Data Sheet for Fire Water Pump

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FOREWORD

This document "KOC Standard for Stationary Firewater Pumpsets" (KOC-ME-009, Rev.2) is intended to provide the minimum basic technical requirements for procurement of Firewater Pumpsets to be installed at KOC's onshore operational facilities within Kuwait. This Standard has been approved by the Standards Team, in consultation with the Standards Technical Committee (STC) for consistent use by KOC Teams as required throughout the corporate engineering and operational functions of Kuwait Oil Company (KSC) in Kuwait. This Standard sets out to achieve the following objectives and benefits: ~

To specify minimum standard requirements for the Firewater Pumpsets that have general applicability for all new construction and will help ensure a consistent and cost effective approach in equipment selection.

~

To utilize experience to avoid repetition of past problems and to consolidate worthwhile and beneficial tec~lnical features in order to minimize the need for clarification and resolution of disputes.

Feedback, comments or suggestions, derived from the application of this Standard at any stage of design, purchase, manufacture, field installation, operation, and maintenance are encouraged, and should be directed to : The Team Leader Standards (Chairman, Standards Technical Committee) Industrial Services Group, KOC P.O. Box 9758, Ahmadi 61008 State of Kuwait

Task Force Responsible for This Standard

The Standards Technical Committee (STC) has entrusted preparation of this Standard to the Task Force No. (TF-ME/10) conSisting of the following members : /VIr. Sanjay Kumar Chou bey Mr. Ali H. AI-Failakawi Mr. Gabriel Popescu Mr. Mukesh Mittal Mr. R. Krishna Kumar Mr. Ahmed Refaey Deraz Mr. A I Aziz AI-Obaidan Mr. Rajesh Pandit

Standards Team HSE (S&EK) Major Projects (Fluor) Fire Team Design Team Utilities Team Utilities Team Opns. Tech . Svcs. (EK)

TF Leader Member Member Member Member Member Member Member

Tel. 61871 Tel. 22025 Tel. 61763 Tel . 66048 Tel. 61152 Tel. 68549 Tel. 66647 Tel. 22343

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1.0

SCOPE

1.1

This KOC document "KOC Standard on Stationary Firewater Pumpsets" (KOC­ ME-009, Rev.2) is based on "Standard for the Installation of Stationary Pumps for Fire Protection"(NFPA 20) 2007 edition as the main reference standard; and supersedes the "KOC Engineering Group Specification for Firewater Pumpsets" (015-GH-1004).

1.2

This Standard specifies minimum technical requirements for design, procurement, selection of materials, assembly, inspection and testing of skid mounted stationary Firewater Pumpsets (main pumps, jockey pumps and related components. Their quantities shall be decided by the KOC Controlling Team) to be procured for installation at onshore operational facilities of Kuwait Oil Company in Kuwait.

1.3

This Standard does not cover the following categories of Firewater Pumpsets : a) Onshore drilling rigs generally have manifold for foam injection and do not have jockey pumps . This Standard is not applicable to such fire water pumping systems at onshore drilling rigs. b) Firewater Pumpsets to be used in non-hazardous areas (residential buildings, offices, sports complex, warehouse / stores etc.), which are situated in the areas outside the KOC operational areas. The KOC Controlling Team shall refer NFPA 20 and other applicable references from this Standard and decide the pump details based on the factors including : (i) Flow and pressure requirements, (ii) Driver(s) and power supply sources, (iii) Other technical requirements specific to that location. c) Portable firewater pumpsets.

1.4

Unless otherwise specified, the firewater pump shall be of the horizontal centrifugal type.

1.5

Project specific requirements shall be further specified as necessary in KOC data sheets, project specifications and in the purchase documents.

2.0

APPLICATION

2.1 All materials, components and equipment for the Firewater Pumpsets shall be new and of premium quality conforming to the requirements of this Standard and other international standards, recommended practices and specifications referred herein. 2.2

This Standard covers the technical requirements of the diesel engine drivers for "main" firewater pumps. Technical requirements of electrical motor(s) covered in this Standard is for jockey pumps.

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2.3

Exceptions or deviations from this Standard along with their merits and justifications shall be brought to the attention of KOC's Controlling Team for their review, considerations and amendment by the Standards Team, (if required).

2.4

Compliance with this KOC Standard does not itself confer to the Vendor I the Manufacturer immunity from legal or statutory obligations.

3.0

TERMINOLOGY

3.1

Definitions In addition to the definitions provided in Chapter 3 of NFPA 20, following definitions shall also apply:

3.1.1 Fire Pump Pump that is dedicated as provider of water supply at desired flow and pressure for fire fighting and protection services in KOC facilities. 3.1.2 Inspection Conformity evaluation by observation and judgement accompanied as appropriate by measurement, testing, gauging or otherwise comparing the product with the applicable requirements. 3.1 .3 KOC Controlling Team Any KOC Team authorized to initiate a request for procurement and supply of materials. equipment and related services for KOC . 3.1.4 Manufacturer An authorized manufacturer that manufactures the equipment covered by this Standard and has been qualified into KOC List of Approved Manufacturers (LAM). 3.1.5 Proprietary Item Functional component or part of an equipment. designed and developed by the Manufacturer without disclosing intrinsic details of manufacturing (and usually. has been patented). 3.1.6 Test Technical operation that consists of the determination of one or more characteristic or performance of a given product, material, equipment. physical phenomenon, process or service according to a specified procedure. 3.1.7 Vendor An organization or body approved by KOC. who can manage with full responsibility the design. material selection. manufacturing. assembly. inspection and testing, certification and all other technical requirements of pumps. motors. diesel engines etc. as per the KOC contract requirement. the purchase order and this Standard.

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Abbreviations API ASME ASNT AWS CSWIP DCS FM HSE ISO ITP KOC LAM LCR LPC MRB MSDS NDE NFPA NSS O&M PAU PIM PMI PQR RP RT SPL UL VPIM WPS

American Petroleum Institute American Society for Mechanical Engineers American Society of Non-Destructive Testing American Welding Society Certification Scheme for Welding and Inspection Personnel Distributed Control System Factory Mutual Health, Safety and Environment International Organization for Standardization Inspection and Test Plan Kuwait Oil Company (K.S.C.) List of Approved Manufacturers Local Control Room Loss Prevention Council (UK) Manufacturer's Record Book Material Safety Data Sheet Non-Destructive Examination National Fire Protection Association Suction Specific Speed Operating and Maintenance Pre Assembled Unit Pre Inspection Meeting Positive Material Identification Procedure Qualification Records Recommended Practice Radiographic Test Sound Pressure Levels Underwriter's Laboratory Vendor Pre Inspection Meeting Welding Procedures Specifications

4.0

REFERENCE STANDARDS. CODES AND SPECIFICATIONS

4.1

Conflicts

4.1.1 All the related standards and codes specified in contract I work instruction I purchase order as appropriate shall be complied with, as applicable to the particular Contract. 4.1.2 In the event of conflict between this Standard and the standards, codes and I or specifications referred herein I purchase I commercial requirements or the technical requirements specified in the Contract, the subject shall be brought to the attention of KOC Controlling Team for review, consideration and resolution or amendment by the Standards Team (if required) . 4.1 .3 However, it shall be noted that in case of conflicts, the most stringent requirement shall usually be applied.

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Order of Precedence

For order of precedence, the following sequence shall apply:

4.3

a)

Kuwait Government's Rules and Regulations,

b)

Purchase Order and Contract Specifications,

c)

Project Data Sheets and Drawings,

d)

This KOC Standard (KOC-ME-009),

e)

International Codes and Standards,

f)

The Manufacturers Standards and Specifications.

List of Standards and Codes

The latest editions of the following standards, codes and specifications shall apply: 4.3.1 National/International Codes and Standards AGMA 9000

Flexible Couplings-Potential Unbalance Classification ­ Revision of 515.02

ANSI HI 1.1-1.5

Centrifugal Pumps For Nomenclature, Definitions, Applications and Operation

ANSI HI 2.1-2.5

American National Standard for Vertical Pumps (for Nomenclature, Definitions, Applications and Operation)

ANSI HI 9.1-9.5

Pumps: General Guidelines (for Types, Definitions, Application and Sound Measurement)

API 610

Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries

API 682

Pumps Shaft Sealing Systems for Centrifugal and Rotary Pumps

API RP 686

Recommended Practices for Machinery Installation and Installation Design

ASME 815.1

Safety Standard for Mechanical Power Transmission Apparatus

ASME 831.3

Process Piping

ASTM A488

Qualification of Procedures and Personnel for Welding of Steel Castings

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ASTM A609

Practice for Castings, Carbon, Low-Alloy and Martensitic Stainless Steel, Ultrasonic Examination thereof

ASTM B148

Standard Specification for Aluminum-Bronzes Sand Castings

BS ISO 3046-1

Reciprocating Internal Combustion Engines : Performance Declarations of Power, Fuel and Lubricating Oil Consumptions and Test Methods: Additional Requirements for Engines for General Use

BS PD 5304

Guidelines for Safety of Machinery

BS 5514

Reciprocating Internal Combustion Engines - Part 4: Performance, Speed Governing-ISO 3046-4

BS EN 60529

Degrees of Protection Provided by Enclosures

ISO 1940-1

Mechanical vibration - Balance Quality Requirements for Rotors in a Constant (Rigid) State - Part 1: Specification and Verification of Balance Tolerances

ISO 2954

Mechanical Vibration of Rotating and Reciprocating Machinery. Requirements for Instruments for Measuring Vibration Severity

ISO 3046

Reciprocating Internal Combustion Engines : Performance - Parts 1 to 6

ISO 10438

Petroleum, Petrochemical and Natural Gas Industries­ Lubrication, Shaft Sealing and Control-Oil Systems and Auxiiliaries - Parts 1 to 4.

ISO 15550

Internal Combustion Engines -Determination and Method for the Measurement of Engine Power- General Requirements

NFPA20 (2007 Edition)

Standard for the Installation of Stationary Pumps for Fire Protection

OSHA 29 CFR 1910.219

Mechanical Power Transmission Apparatus

ANSI / UL 448

Centrifugal Stationary Pumps for Fire-Protection Service

ANSI / UL 508

Standard for Safety Industrial Control Equipment

4.3.2 KOC Standards KOC-E-001

KOC Standard for High Voltage Induction Motors

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KOC-E-004

KOC Recommended Practice for Selection, Installation and Maintenance of Electrical Equipment in Hazardous Areas

KOC-E-008

KOC Recommended Practice for Design, Selection and Installation of Electric Cables, Cable Systems and Wiring

KOC-E-010

KOC Standard for Low Voltage Induction Motors

KOC-E-012

KOC Standard for DC Power Supply Units

KOC-E-020

KOC Recommended Practice for Electrical Installation on Packaged Equipment

KOC-E-023

KOC Standard for Electrical Power Cables and Wiring

KOC-E-024

KOC Recommended Practice for Earthing and Bonding

KOC-G-004

KOC Standard for Packing, Marking and Documentation

KOC-G-007

KOC Standard for Basic Design Data

KOC-G-009

KOC Standard for Spare Parts and Maintenance Data

KOC-I-001

KOC Standard for Instrumentation and Control Design

KOC-I-002

KOC Standard for Instrument Installation

KOC-I-011

KOC Standard for Instrument Cables

KOC-L-028

KOC Recommended Practice for Plant Layout

KOC-L-030

KOC Standard for Plant and Equipment Noise Control

KOC-MP-010

KOC Standard for Piping Material Classes

KOC-P-001

KOC Standard for Painting and Coating of External Metal Surfaces

KOC-Q-014

KOC Standard for Project QA/QC ReqUirements

4.3.3 KOC 015 Series of Specifications 015-DH-1003

Rectangular Tanks

015-GH-1002

Special-Purpose Gearboxes

015-JH-1903

General Instruments

015-JH-1909

Instrumentation for Package Equipment

015-WH-1003

Inspection of Castings for General Pressure Service

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4.3.4 Other KOC References KOC HSE

KOC HSE Guidelines on Hearing Conservation

4.3.5 Project Specifications This Standard also makes reference to other specifications which should be designated by the Controlling Team in KOC, in absence of any other KOC Standard and Recommended Practices, on a project specific addendum sheet. Any addition I change to this Standard shall be specifically mentioned in Purchase Order, Contract Specifications, Project Data Sheets and Drawings. 5.0

ENVIRONMENTAL CONDITIONS

5.1

Environmental conditions in Kuwait are severe. Refer to "KOC Standard for Basic Design Data" (KOC-G-007) which provides detailed design information regarding the environmental, Site and the utility supply conditions prevailing throughout the KOC facilities at Kuwait.

5.2

The Firewater Pumpsets supplied by the Vendor shall be suitable for instantaneous starting and operation for both intermittent short periods of operations of less than six (6) hours as well as for performing long term continuous operation in the environment mentioned above.

6.0

HEALTH, SAFETY AND ENVIRONMENT

6.1

The Vendor shall ensure that Firewater Pumpsets supplied by him comply with the KOC HSEMS procedures, HSE guidelines and regulations for protection of KOC personnel, adjacent equipment, property and environment during operation and maintenance of the equipment.

6.2

All applicable safety requirements of Occupational Safety and Health Administration (OSHA) Standard 29 CFR 1910.219 and BSI BS PO 5304 shall be considered in design, manufacture, and assembly of the packaged equipment covered by this Standard.

6.3

Gaskets and other packing material shall not contain asbestos.

6.4

The Vendor shall provide Material Safety Data Sheets (MSDS) for rust preventives and other chemicals contained in Firewater Pumpsets. One (1) copy of each MSDS shall be shipped with the packaged equipment.

6.5

Other HSE deliverables have been specified in clause 12.2.3 of this Standard .

7.0

MATERIALS

7.1

General

7.1.1 KOC firewater pumpsets usually handle brackish water. The water composition shall be provided in the data sheet. The Vendor I the Manufacturer shall select the suitable

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material and shall confirm to KOC the suitability of selected material with respect to the water to be used in service. 7.1.2 As a minimum, the pump material requirement for brackish water shall be specified as below: a) Casing and Impeller : Nickel Aluminium Bronze ASTM B148 alloy No. C95800. b) Shaft and Sleeves : Monel K 500 UNS No. 5500. c) Minor parts not identified (nuts, gaskets, washers, keys an so forth) shall have corrosion resistance equal to that of specified parts in the same environment. 7.1.3 Castings requiring major weld repairs shall be rejected . Minor repairs shall be brought to the attention of KOC and they shall be repaired only after obtaining the prior approval of KOC (KOC reserves the right to reject the request for minor welds repairs). Nickel aluminium bronze repairs shall be accepted by KOC only in accordance with ASTM 8148 Clause 8. Welding procedure shall be submitted to KOC for approval before such repair. Any minor weld repair shall be heat treated. 7.1.4 Castings shall not be plugged, filled or impregnated. Internal pockets for casting purposes shall be considered pressure-containing parts. Provisions shall be made to drain the stagnant water from such cavities during maintenance operations. However, impeller internal cavities as a result of the cored pattern may be allowed to be filled, if considered necessary by the Manufacturer. 7.1.5 Casing bolts shall not be sealed with teflon tape or similar. 7.1.6 Paper based gaskets requiring time for "water soaking to become effective" shall not be used. 7.1.7 Baseplate a) Pump sets shall be supplied with base structures suitable to support complete pump, driver, local control panels and auxiliary equipment. All welding shall be continuous. b) The baseplate shall have a drip tray and 'flanged drain connection. c) Two earthing points shall be provided on the baseplate and they shall be located diagonally opposite to each other, in accordance with KOC Project standard drawing entitled "Earthing Clip." d) Jack screws shall be provided on base plate both for the pump and for the driver. 7.1.8 Couplings a) Only flexible, spacer type couplings shall be used for main fire pumps. Lubricated type couplings and the elastomeric couplings "in shear" shall not be used.

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b) The maximum torque shan be limited to 80% of the coupling rating. c) The spacer piece shall be positively constrained from flying out in the event of failure of the flexible d)

preferred shaft to hub fit is Interference fit / according to the AGMA 9000 and keys I keyways shall be according to AGMA 9000 preCision class A However, the Manufacturer shall propose the most one with adequate justifications and submit to KOC for approval. Coupling hubs shall have tapped puller holes regardless the shaft to hub fit.

f) Flanged forged stub shaft ends shall be used for the diesel engine. 7.1.9

Guards a) Guards shall the personnel. b)

provided on all the moving parts which could be hazardous to

coupling guards shall be removable and made of non-sparking Guards shall comply with BSI BS 5304.

c) These guards shall be sufficiently rigid to withstand when a force equivalent to a 100 kg mass is applied to the guard. 1.10 Piping, Valves and Ancillaries a) Pipework scope shall defined by the KOC Controlling Team. Pipework shall be designed and supplied by the Vendor in accordance with 831.3, NFPA 20 and KOC-MP-010 "KOC Standard for Piping Material . The suction and discharge piping shall be insulated from pumps by using suitable insulation kit in order to maintain cathodic protection for longer periods. Complete insulation kit shall be supplied by the Vendor. b) Engine piping shall be according to the Manufacturer's standard. Threaded connections shall not be used on fuel (diesel) piping and eqUipment. All piping connections to engine, the exhaust, shall be via steel braided flexible The and of such hoses shall kept optimum. c} Teflon tape shall not be used for threaded jOints. Where it is necessary, only a suitable liquid thread sealant shall d} All small bore tubing shall be adequately supported and protected from the possible damages. e) All drain and venting pipes shall

flanged and routed to the edge of the skid.

f) In addition to the requirements of clause 11 of NFPA 20, the circulation relief valve shall have an independent drain with visible discharge. Water shall be directed to proper drainage or away from the firewater pump and its

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surrounding area. Also, the circulation relief valve shall effectively remove the heat and shall allow the pump to run with no discharge for at least 30 minutes. 7.1 .11 Strainers a) The inside parts of strainers shall be made of Monel K400. Strainers' bodies shall be of corrosion resistance metals suitable for the pumped fluid. External body (housing) of carbon steel or other suitable metallurgy shall be allowed . It shall have corrosion resistance phenollic epoxy resin internal lining. b) Strainers shall be supplied along with the Firewater Pumpset by the Firewater Pumpset Manufacturer, only if specified in the purchase order. 7.2

Proprietary Items

7.2.1 The Vendor shall clearly specify the proprietary items he intends to use and shall obtain KOC approval. 7.2.2 Unless otherwise spedfied in purchase order, data sheet or by written instructions, the proprietary items may be allowed to be used (though not preferred) subject to prior approval of KOC . 7.2.3 Some of the parts of the diesel engine including the radiator may be proprietary items and shall be allowed to be used after obtaining KOC approval. 8.0

TECHNICAL REQUIREMENTS

8.1

General

8.1 .1 Firewater Pumpsets shall be located in an area of Facility with a hazardous area rating : "Unclassified" or as decided by KOC and shall be designed after assessing the fire water distribution requirements of the KOC facility being protected . The KOC-L-028 "KOC Recommended Practice for Plant Layout" shall be referred for the pump location and layout. The vent and drain from the pump(s) shall be terminated to a main drain inside the pump house. 8.1.2 Firewater Pumpsets shall be built according to NFPA 20 and UL 448 and shall be UL listed / FM approved . The installation of the pumps shall be governed by API 686. Alignment readings shall be documented with and without piping. The deviation shall be limited within API 686 or the Manufacturer's standard . The most stringent one shall be applied in case of conflict. 8.1.3 Each Pumpset shall consist of, but not be limited to the following : a) Skid-mounted, horizontal centrifugal firewater pump (diesel engine-driven) complete with: i. Couplings and coupling guards,

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Fuel supply system for the diesel engine including the fuel day tank,

iii . Complete system for diesel engine, including piping harnesses or cooling I flushing I draining I coolant reservoir tank, lubrication, air intake system and spark arrestor I silencer. iv. Automatic high pressure management system at discharge piping of pump to safeguard the pressure surge at the downstream of pump due to closure of valve at the farthest end after the fire is extinguished. It shqll also serve as safeguard to piping in case of automatic starting of the firewater pump. v. Battery operated engine starting system , with back-up hydraulic starting system, vi. Local control panel (designed as per NFPA requirements), vii. Local instrumentation and monitoring equipment. b) One (1) free-standing remote control panel for the Firewater Pumpset(s) and it shall be located within the auxiliary control room . 2

c) Skid mounted, fixed-speed, electric motor-driven jockey pumps. Jockey pumps shall be built according to NFPA 20 and UL 448, and as per the requirements specified in the purchase order. d) Skid cabling shall be fire-resistant . e) Skid-mounted junction boxes shall be made of stainless steel with IP 55 rated enclosures. f)

Automatic air release valve , circulation relief valve, test flow meter and pump suction I discharge pressure gauges in accordance with NFPA 20 requirements shall be mounted on the pipe work within the PAU .

g) Special tools for maintenance purposes, as necessary. 8.1.4

Painting All equipment, structurals and piping shall be painted in accordance with " KOC Standard for Painting and Coating of Metal Surfaces - New Construction" (KOC-P -001) and shall have a finish red color. '

8.1 .5 The Vendor representative shall impart technical training to KOC's operations and maintenance personnel in Kuwait.

8.2

Operating Philosophy

8.2 .1 General This clause is included in this Standard to ensure that the Vendor and the approved Manufacturer of the equipment are aware of the manner in which the equipment will be used by KOC .

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a) Under normal conditions, the pressure in water ring main is maintained by the jockey pump. Minimum one (1) jockey pump shall be provided as working pump and minimum one (1) jockey pump shall be provided as stand-by pump. Additional quantities shall be decided by the KOC Controlling Team. b) If the jockey pump should fail, alarm (local + remote both) shall occur and immediately (Le. simultaneously) the standby jockey pump shall automatically start. c) If header pressure drops to a receives a signal to start.

point. then the nominated main fire pump

d) If the nominated main fire pump running signal (pressure switch) has not been received within seconds, then the standby main firepump will start. e)

pump operation shall conform to NFPA 20, chapter 14 (covering accept­ ance testing, performance and maintenance).

8.2.2 Basic Operational

uirements

a) One (1) "working" jockey pump shall provided to always maintain the pressure the facility ring main system and minimum one (1) jockey pump of equal rating shall be provided as "stand by". The power supply for jockey switchboard which is normally fed on main pumps shall be from power supply and backed-up by an emergency generator in the event of loss of main power supply. b) Appliance / equipment needing electricity, battery system / control panel etc. shall have completely separate power systems incapable simultaneous impairment. c)

fighting shall be required to provide an adequate, reliable source of firewater for firefighting in all deSignated operational areas and for fire training purposes via automatically operated, horizontal centrifugal firewater pump/so

d)

pump(s) shall meet the capacity at the specified discharge pressure as indicated in the datasheet Fire water pump(s) capacity shall ensure comply with the following statement: "KOC requirement is that main fire pump(s) shall have rated capacity meeting the maximum fire water demand in worst case of fire scenario and simultaneously maintain a minimum pressure of 150 psig {when flow equivalent to the maximum fire water demand of the protected facility is discharged by the fire water pump(s)} at the hydraulically farthest point in the firewater ring main. Hydraulically farthest pOint shall be measured from the location of fire water pumps".

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DOC. NO. KOC-ME-009

e) The firewater pump/s shall always be held ready state, and shall be available for instant startup. When at rest, those parameters affecting readiness to operate shall continuously monitored and if a fault situation occurs, the fact shall be annunciated at the local and remote control panels and at the Distributed Control System (DCS). A local firewater pump control panel shall situated on each pump skid. 8.2.3 Normal Start Main firewater pumps shall start automatically at a pre-set water pressure in the header. Main firewater pumps shall also be able to started automatically or manually either remotely or locally, from local or remote control for testing purposes or for emergency situations. Main firewater pumps shall also meet the minimum requirements as described below: a) When a leak in header or fire I hazardous situation occurs in operational area, the firewater pump shall automatically. Details shall conform to NFPA 20 in particular with respect to interlocking of the local and remote of each pump set in order to prevent simultaneous starting of Firewater Pumpsets. b) Due to varying operation scenarios, the design shall based on the most severe option. Scenarios shall include starting the pump when the discharge valve is fully opened, partially opened or closed and the main being pressurized anywhere between atmospheric pressure and discharge pressure of an already operating fire pump. Emergency Manual a) The Firewater Pumpsets shall be capable of being started manually while the controller is completely out service. The driver shall be equipped with manually operable direct-start switches allowing power from the batteries to starter motor. b) The diesel engines shall backup starting method.

provided with a hydraulic starting system as a

8.2.5 Test Running Flow meters and a test circuit shall be provided to allow routine fire pump running tests under local control. The firewater pump shall return water to the firewater storage tanks. The flow meter shall be to accommodate 175% of the firewater pump rated capacity. The flow measurement device shall ULlFM listed. 8.2.6 Shutdown a) Shutdown of each Firewater Pumpset shall local control panel only.

carried out manually from the

b) In normal operation (when pump is in "automatic" or "manual" modes), the fire pump shall shut down automatically only if diesel engine overspeeds. All other malfunctions shall annunciate an alarm only.

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Design Requirements

8.3.1 Specific Requirements of Firewater Pump a) Firewater Pumpsets shall be designed and assembled such that equipment and components can be integrated into a Pre-Assembled Unit (PAU). The pump shall be manufactured using the metric systems . All dimensions of the pump shall also be written in SI units. b) Pumps shall be suitable for parallel operations and they shall be sized, designed and constructed in accordance with requirements of NFPA 20 and UL 448 except where amended by this Standard . c) Pump shall be suitable for both intermittent short periods of operation of less than six (6) hours and for continuous operation . d) Pump shall be suitable for remote and automatic starting without the operator intervention. e) Pumps shall operate under positive suction head at all times. Margin between Net Positive Suction Head Available (NPSHA) and Net Positive Suction Head Required (NPSHR) shall be greater than one (1) metre over the entire specified operating range up to 150% rated flow. f) For rated flows above 150 m3/hr (660 USGPM), pumps shall be single stage

centrifugal, horizontal, between bearings, axially split casing type with minimum of double suction . End suction pumps may be used for rated flows up to 150 m3/hr (660 USGPM). g) Glands shall be packed with a graphite based packing material with good self lubricating qualities such that the integrity of packing is preserved during start up of the pumps and should have suitable anti-corrosion additives to prevent pitting of the shaft sleeve. While pump is running , the packing lantern rings shall be supplied with an adequate flow of water to preserve the packing integrity. h) The pump shall always be maintained fully primed . Pump shall be able to start with fully open discharge valve. Pump casing shall be fitted with an automatic air release valve on the casing . The automatic air release valves shall keep the pump and system free of air accumulation in order to minimize both corrosion and risk of damage to pump on startup. i) Circulation Relief Valve shall be provided as per clause 5.11 of NFPA 20. These valves shall be sized to allow the pump to be safely run at no discharge for at least thirty (30) minutes. j) Minor gland leakage shall be piped and routed to the drain and shall not be

allowed to drip onto base tray.

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k) Pump Performance (i) Unless otherwise specified in the purchase order, pump shall be designed such that performance shall have a relatively flat performance characteristic curve. Pumps having higher drooping performance characteristic curves shall not be accepted. (ii) The Performance Envelope shall be as defined as per the Table 1 of this Standard as follows: Table 1 : Pump Performance Envelope

0%

< 120% Rated Head

100%

100% Rated Head

150%

> 65% Rated Head

I) Suction specific speed (NSS) determined at best efficiency point (BEP) for the maximum impeller diameter of the casing shall not exceed 10,000, calculated using the formula given in API 610 Annex. "A" and based on metric units {flow rate in m3/h, NPSHR in metres (m) and rotational speed in RPM}.

2

Note: Pump with Suction Specific Speed higher than 10.000 shall require specific approval by KOC. m) Pump pressure retaining components shall be hydrotested at 1.5 times the maximum casing design pressure, irrespective of the fire main design pressure. n) Pump bearing shall be designed that bearing temperature do not exceed 80°C while the ambient shade temperature is 55°C. 0) Fire pump package shall be capable of starting and operating on intermittent basis and independently of any external supplies.

8.3 .2 Specific ReqUirements of Jockey Pumps a) The jockey pumps shall be capable of frequent start and stop as required to maintain the pressure. They shall also be able to run continuously. b) The rated flow of each jockey pump shall be the stated flow plus the specified minimum continuous flow. c) The jockey pumps shall be fitted with a mechanical seal. d) The jockey pumps shall be electrical motor driven . e) Flexible, spacer type, non lubricated couplings shall be used for the jockey pumps.

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8.3.3 Specific Requirements of Diesel Engine Drivers a) General i. Diesel engine drivers for main firewater pumps shall conform to the NFPA 20 requirements. ii

Oil reservoirs, housings enclosing moving parts, shaft seals and parts shall be designed to prevent the ingress of dust and moisture during operation and periods of idleness.

iii. All eqUipment shall be designed to permit rapid and economical mainte­ nance . Major parts shall be shouldered or dowelled to ensure accurate alignment on assembly. iv. Diesel engines shall be supplied with an adequate air intake filtration system suitable for dusty environment described in KOC-G-007. v. Diesel engine cylinders shall be provided with removable liners. vi. Accessible hot parts of the diesel engine exhaust system shall be suitably insulated for personnel protection. b) Diesel Engine Rating i. Under any of the facility conditions specified, the diesel engine shall be capable of continuous operation at the rated power and speed and at any speed within the speed range specified. The engine governor shall be factory set and shall be tamper-proof. ii. The engine continuous net brake power, fuel consumption, lubricating oil consumption and overload power shall be declared at standard reference conditions in accordance with IS015550 and BS 5514 Part 1 (ISO 3046/1). iii. Appropriate "rerating" to the diesel engine performance rating shall be made for the combination of the highest expected air temperature, highest humidity and lowest atmospheric pressure. iv. Engines shall be of the 4-cycle, and shall have a site conditions continuos power rating of not less than 110% of the maximum power demand at rated speed . The maximum power demand is the sum of: • Maximum pump absorbed power including test tolerances, • Transmission losses, • Auxiliary power take-off. v. The continuous rating shall have a 10% overload capacity.

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vi. The engine speed shall not exceed the requirements specified in the Table 2 of this Standard. Table 2 - Engine Rating and Speed Limits

Engine Rating

Maximum Allowable Speed

Up to 1500 kW

1800 RPM

1500 kW onwards

1000 RPM

c) Torsional Vibration and Critical Speeds

i. Each engine, coupling, driven unit, shall be so designed to ensure that complete installation starts, operates and stops free from torsional vibration and oscillation. ii. First lateral and torsional critical speeds for complete train shall be at least 10% above engine trip speed. iii. If this is impractical, dampers shall be provided to limit shaft stresses due to torsional vibration to 24 N/mm2 throughout the operating range up to 110% of rated speed. iv. As part of the design of the diesel-driven Firewater Pumpsets, an analysis verifying the critical speed shall be carried out by the Vendor. The Vendor shall provide all data necessary for KOC and an independent certifying authority shall review the analysis. v. The torsional analysis shall be submitted to KOC for approval. As a minimum, the torsional analysis shall include the following : • A complete description of the method used in the analysis; • A graphic display of the rotor system torsional frequencies showing predominant forcing "frequencies; • A torsional mode shape diagram of the rotor system; • A graphic display of the rotor system showing the stations used in the analYSis and the torsional stiffness and inertia used at each station. d) Flywheels Flywheels shall be of the solid type arranged to facilitate barring over of the engine.

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e) Engine Fuel System

i. Each engine shall be supplied with a complete fuel oil system which shall include, but not be limited to the following: • Water and sediment trap with cleanout drain, • Shaft-driven fuel feed pump with pressure relief valve, • Fuel feed pump suction strainers and fuel pump discharge filters, • Shaft-driven fuel injection pumps, • Guards on protecting pipe for all exposed fuel lines, • Fuel day tank.

ii. The fuel day tank shall supply fuel for 24 hours minimum continuous operation at rated power. The tank shall be separate from the Firewater Pumpset and shall be located at a minimum distance of eight (8) metres from the pump set skid . The tank shall be complete with the following: •

Supply and return connections to the engine fuel system,

•

Fill connection,

•

Manual fill connection : a valve and a suitable approach to enable manual filling,

•

Instrument connections for a level gauge, low-and high-level alarms,

•

Vent connection with flame / spark arrestor,

•

Cleanout point,

•

Valved drain connection,

•

Overflow connection shall be discharged to the location as directed by KOC.

•

The fuel tank shall be constructed of suitable metallurgy and shall be tested for leaks. The design and construction of the tank shall be in accordance with 015-0H-1003 "KOC Engineering Group Specification Rectangular Tanks" or as agreed by KOC. Tank shall be painted in accordance with KOC-P-001 "KOC Standard for Painting and Coating of External Metal Surfaces".

•

Level gauge / sight tube shall be installed at diesel tank. Sight glass shall have isolation valves with vent and drain. The Manufacturer shall either design impact resistance sight glass or provide a suitable impact protection for this.

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There shall be a level transmitter / level switch on the diesel tank connected to the DeS .

iii. Fuel feed pump suction strainers shall be duplex type with replaceable cartridge elements and full-flow change-over valve. The nominal filtration of the filter shall be as recommended by the approved Manufacturer of the engine for satisfactory continuous operation of the engine fuel system and shall be capable of protecting the fuel pump from any entrained particles (sand, dust etc resulting from the ambient conditions), that may be present in the fuel oil. The filter elements shall be capable of easy removal when the engine is running without breaking any fuel line connections, or allowing the ingress of air to the fuel system. The fuel pump discharge filters shall be of the duplex type with ten (10) microns nominal filtration (i.e. the efficiency of the filter on particles that are ten (10) microns or larger in diameter, shall not be less than 90%, throughout the life of the element) with replaceable cartridge elements and full-flow transfer valve . The clean filter pressure drop shall not exceed 0.35 bar at the normal operating conditions. A differential pressure gauge and alarm shall be supplied for each pair of duplex filters. iv. Where required or recommended by the approved Manufacturer of the engine, a diesel fuel break tank shall be furnished alongside the engine to prevent fuel leakage through the injectors at standstill. •

A normally open, manually operated valve shall be installed in the fuel line to the engine. If the diesel tank is in the same room with the engine, the valve shall also be operable from the outide.

•

No shut-off valve shall be installed on the fuel return line.

•

Fuel lines between the fuel pump and injectors shall be double skinned, seamless tubing with fuel leak monitor and alarm.

•

All flexible hoses shall be flame resistant type .

f) Engine Lubrication System i.

Engine shall be suitable for starting under all conditions without the need for engine pre-lube and shall not need rundown lubrication.

ii. Each engine shall be equipped with dedicated lubrication system and shall not be shared with other parallel operating units.

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iii. The engines shall be supplied with a complete pressure lubrication system which shall include, but not be limited to, the following equipment : •

Shaft-driven positive displacement oil pump with external pressure relief valve.

•

Oil cooler with thermostatically controlled bypass valve. The lube oil coolers shall be sized for continuous rating.

•

Lube oil shall be maintained at a higher pressure than the cooling medium to prevent leakage of cooling medium into the oil.

•

An integral oil reservoir shall be provided with level indication, fill filter, vent and drain connection with a valve.

•

Duplex-type oil filters with ten (10) micron nominal filtration (Le. the efficiency of filter on particles that are 10 microns or larger in diameter shall be no less than 90% for the life of elements), replaceable cartridge elements and full flow change over valve. The clean filter differential pressure shall not exceed 0.35 bar at normal operating conditions. The filters shall be equipped with a differential pressure gauge and alarm at local and remote control panel. Filter element shall be such that it can be easily removed when engine is running, and without breaking any lube oil line connections .

g) Air Intake and Exhaust System The engine shall be supplied with an intake and exhaust system which shall include, but not be limited to, the following : i.

Intake Air Filter with Rain Hood The air filter shall be designed to ensure that the engine condition does not deteriorate due to ingress of sand, dust and other airborne contaminants. Air filter shall include at least two stages of filtration, the primary stage being a cyclone-type filter followed by a secondary filter of a replaceable media type. The filter shall be guaranteed to remove at least 95% of all particles of two (2) microns and larger, and 100% of all particles of ten (10) microns and larger from air for combustion. Intake filter shall be equipped with a differential pressure indicator and alarm. The housing and all structural components of the air filter shall be constructed of 316L stainless steel.

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ii. The Manufacturer shall be responsible to meet noise level limitation specified in KOC-L-030 or in data sheets / purchase order. If required, he shall design and provide a suitable Intake air silencer. iii. An automatic shut off valve actuated by the engine over-speed shall be fitted in the air intake manifold. Operation of this valve shall be independent of external power sources and shall also be capable of manual operation. iv. Turbocharger (if fitted, or required) v. Exhaust silencer shall be fitted with a flame / spark arrestor and rain cap. vi. Inlet and exhaust flexible connections, as required. vii. Exhaust system shall be insulated for noise reduction requirements and to limit surface temperature to 60°C at 45°C ambient. Where this is impractical regarding temperature, additional wire mesh hand protection shall be used, spaced such that the maximum temperature of the protection guard is 60°C at 45°C ambient. h) Engine Starting Diesel engines shall not require any preparation for start up and shall be capable of immediate start up to rated duty. Each engine shall be provided with two starting systems. The primary system shall be electric based on the use of the batteries. The secondary (back up) starting system shall be hydraulic type as described in sub clause 8.3.3 I) of this Standard. The secondary start system shall initiate automatically when the engine fails to start even after all the primary starting system cranking cycles are completed. The secondary start system shall comply with NFPA 20 11.2.5.3.2 conditions. Both primary and secondary systems shall be capable to start the engine when coupled to the pump. All starting systems shall be of proven reliability and certified by the Vendor. i) Primary Starting System

i. For diesel engines rated at 1000 kW and below, the method of starting shall be by electric starter motor powered by battery systems in accordance with NFPA 20. ii. For diesel engines rated at above 1000 kW, the method of starting shall be electric, provided that the Manufacturer of the engine demonstrates that the proposed engine has proven successful experience with this method of starting . Otherwise, the starting method shall be by direct air injection from air receivers . The method of starting engines rated above 1000 kW shall require KOC approval.

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iii. A permanently mounted

of starting instructions (including a prestart check list) shall be provided close to or at the pump set local and remote control panels. instructions shall be written in English language and shall be and

iv. Primary starting need to of this Standard.

or

capable of successive without the as specified in following

j) Battery Starting _.... ".:T/;un Battery starting system shall consist of, but not be limited to, the following items: i. Two (2) of nickel-cadmium type batteries shall supplied. Each set shall have twice the capacity, at maximum ambient temperature condition, sufficient maintain cranking speed through a three (3) minute attempt-to-start cycle, which is six (6) consecutive cycles of 15 seconds of cranking and 15 seconds of rest. Thus, each battery set shall have capacity for 12 such consecutive cycles.

In operation, these two of batteries shall be used alternately, with change-over being automatic. In the event a battery failing during cranking period, the healthy battery shall be brought in automatically provide power for all remaining cycles. on a continuous float charge, with charger Batteries shall normally maintaining batteries in a fully charged condition, at the same time supplying any continuous standby (inert) load. Each unit shall be rated for 125% of the maximum expected load. ii. Batteries, battery chargers and associated distribution equipment shall mounted on the pump set skid in an enclosure with a degree of protection not less than I according to EN 60529 or as agreed by KOC. Enclosures shall constructed from folded and welded mild sheet not than two (2) mm thick. The enclosure height shall not be greater than 2200 mm from grade and shall permit front access only. The enclosure shall equipped with a pair of removable eye bolts for lifting purposes. Individual hinged access doors shall be key lockable handle.

by means of a

type

A mechanical interlock shall be provided between the enclosure door and the main AC supply isolating switch so that access can only obtained in the "off' position. Cable access shall be via suitably sized three (3) mm thick gland plates. The main switch operating handle shall be provided with on I off indication and pad-lockable in the "off" position.

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Internally, the units shall be provided with IP 2X protection in accordance with BS EN 60529. The batteries shall stand on trays, and the enclosure shall be resistant to attack by the electrolyte media . Neoprene gaskets shall be used. Suitable anti-vibration mountings shall be used between the above enclosure and the pumpset skid. iii. Batteries shall be adequately secured against displacement, excessive temperature, vibration, mechanical damage or flooding with water. They shall be readily accessible for servicing . Batteries shall be nickel-cadmium alkaline type and it shall be possible to replace faulty battery cells without disturbing the remaining cells. The containers shall be of restricted breathing type. Vents shall be of a design that prevents the escape of electrolyte. Vent covers shall be of a non-flame propagating material. The cell container shall be of translucent plastic material to give a visual indication of electrolyte level, the material shall be non-flame propagating and mechanically shock resistant. Inter-cell connections shall be provided and shall be insulated or provided with protective cover to prevent inadvertent short circuiting. iv. Batteries shall be protected against the effects of over-voltage, under voltage and overcharging in accordance with the recommendations of the approved Manufacturer of the batteries. v. The battery chargers shall be of the automatic solid-state type with constant voltage and current limiting characteristics. Manual boost and float charge facilities shall be provided. The charger shall be able to operate satisfactorily with the batteries disconnected. Boost charging shall only be used where the battery characteristic permits. vi. The RMS value of the ripple on the DC output voltage , with the battery connected, shall not exceed 5% or the value recommended by the approved battery Manufacturer, whichever is lower. The charging voltage level shall be adjustable to within 2:. 10% of nominal voltage. vii. The battery charger shall be provided with the following control I metering I indications I protections in the local control panel as rninimum :

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• AC supply on / off switch, • Charge-indication lamps . • DC voltmeters to measure charger input and output voltage, • DC ammeter with zero at mid-scale to measure battery current, • DC ammeter to measure charger output current, • Fuses to protect battery charger circuits , • Battery fuse switch, • AC supply failure detection, • Earth fault DC system detection, • Charger failure detection, • Low battery volts detection , • Low battery voltage alarm with remote indication capability. viii. Batteries shall be furnished in a dry condition with the electrolyte liquid in a separate container. Electrolyte shall be added at the time the engine is put into service and the battery shall be given a conditioning charge . ix. Batteries shall be charged from the following : • A set-mounted alternator whilst unit is running . • Dual mains battery chargers (i.e. separate charger for each set of batteries) when the unit is at standstill. Each charger shall be sized to restore a fully discharged battery to 100% capacity within eight (8) hours maximum and shall be suitable for initial charging of the batteries. Battery charging shall be current limited such that isolation during cranking is not necessary and the charging system shall be effectively controlled by diode steering such that the alternator charger and mains charger are compatible. • All changeover relays shall be provided . • Electrical power supply shall be as specified on equipment datasheets. x. In addition to starting from the local and remote control panels, it shall be possible to start the engine by means of a manual switch directly connected to the battery. xi. Refer to "KOC Standard for DC Power Supply Units" (KOC-E-012) for details of battery charger.

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Direct Air Injection Starting System It shall be installed only if specified in data sheets / purchase orders. The direct air injection starting system shall consist of, but not be limited to the following : i. One (1) electric motor-driven air compressor, ii. One (1) diesel-driven air compressor, iii. Two (2) air receivers with a capacity sufficient to maintain cranking speed through a six (6) minute cycle of 15 seconds crank followed by 15 seconds rest for 12 consecutive cycles. Each air receiver shall have the capacity for six (6) consecutive cycles. All air receivers shall be in accordance with Engineering Group Specification "Pressure Vessels" (015-CH-1 001). iv. All necessary piping, valves, instruments, knockout pots, cabling, controls etc. necessary for the safe operation of the system and its automatic control.

I) Back-up Hydraulic Starting System i. The hydraulic starting system shall be capable of a minimum of six (6) discrete start attempts. ii. Hydraulic starting system shall be supplied complete with an engine driven charging pump, hand-charging pump, one (1) accumulator pack for each start attempt, hydraulic motor, necessary manual controls, instrumentations and relief systems. Accumulator packs shall be capable of being isolated from one another during start attempts and hand-recharging activities. iii. Hydraulic starting system piping shall be made of stainless steel. iv. The engine-driven charging pump shall be sized to completely charge the accumulator in not more than 15 minutes at rated speed. v. An alarm shall be provided to annunciate at the local and remote control panels when the accumulator pressure falls to a critical level. m) Engine Cooling System i. Engine cooling shall be achieved by an air blast radiator with air flow away from the diesel engine and the fan mounted on the engine shaft. ii. A closed cooling system shall be provided with connections for filling the system, checking coolant level, taking samples of coolant and adding make up water when necessary. The system shall be deSigned to allow for complete drainage from engine and all ancillary equipment and for complete venting.

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radiator shall the proprietary item to suit the cooling requirement of diesel engine. The Manufacturer shall be responsible for its design and performance.

iv. Radiators shall be to achieve stable conditions at the rated output with the worst ambient conditions specified and a fouling factor of 0.0004 m2 °CfW on the coolant side. v. The cooling system shall contain anti-freeze coolant. vi. If specified in the data sheets I purchase order, the engine shall be provided with thermostatically controlled jacket water heater and if necessary, circulating pumps ensure optimum starting engine temperature. vii. Cooling water flexible hoses shall be flame resistant type and certified by Vendor. n) Speed and Load Governing

i. Engine shall be supplied with a direct driven over speed governor.

ii. The governor shall be in accordance with the relevant classification of BS 5514, Part 4 or as specified on the data I purchase order. iii. Fuel pumps shall be restricted to prevent delivery of more fuel than the engine can accept without overloading.

0) Safety Devices

All auxiliary systems shall 8.3.4

fitted with relief devices.

Motors a) Motors shall comply with "KOC Standard for High Voltage Induction Motors" (KOC-E-001) and "KOC Standard for Low Voltage Induction Motors" 010) as applicable. b) All jockey pumps shall be essentially motor driven and shall be rated least 15% greater than maximum pump absorbed power including tolerances at rated speed. c) All electrical equipment shall be suitable for the classification zone, gas group and temperature class of the installation area as specified on the equipment data sheets. d) The earthing and bonding of engines, pumps and rnotors shall be as per KOC-E-024 "KOC Recommended Practice for Earthing and Bonding". All material shall be supplied by the Vendor.

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e) The electrical cabling I wiring shall be done according to KOC-E-008 "KOC Recommended Practice for Design, Selection and Installation of Electric Cables, Cable Systems and Wiring". All material shall be supplied by the Vendor. 8.3.5 Control Panels and Instrumentation a) Control panel shall conform to NFPA 20, 015-JH-1903, 015-JH-1909 and "KOC Standard for Instrumentation and Control system design"(KOC-I-001). i) The new controller shall ii)

compatible with existing KOC system.

Common control panel shall provided in case of multiple fire water pumps. The indication shall also be hooked up to the DCS I LCRI respective water section control room or as decided by KOC.

iii) Termination of cables shall be clearly specified in a separate

Iv) Incoming and outgoing cables (for both electricals and Instrumentations) shall be from bottom only. b) There shall be a local control panel for Firewater Pumpset Where more than one pump is supplied, a sequence interlock to initiate pump start-up shall be supplied. c) Local and remote control panel enclosures shall be suitable for classification (zone, gas group and temperature class) of installation area as specified in the package data d)

Controls and control panels shall be completely piped and wired such that pump are completely integrated safe and operable packages requiring minimal interconnection the Facility.

e) Anti-vibration mountings shall be furnished between baseplate. f)

panel and the

a minimum, the following functions shall be provided on the local and control panels: i.

I Stop (only on local control panel):

ii. Battery selector; iii. Panel heater on I off; iv. Annunciator test button; v. Alarm acknowledge button and vi. Weekly test start I stop;

button;

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vii. Main isolation; viii. On / Off manual selector; ix. Manual emergency start button. g) All control wiring for automatic controller shall be mounted on engine and terminated . h) The instrument cabling shall be supplied according to " KOC Standard for Instrument Cables" (KOC-I-011). All material shall be supplied by the Vendor. i) As a minimum, the following alarms and indication shall be provided at the local and remote control panels as given in Table 3 of this Standard: Table 3 - Minimum Alarms and Indications

FUNCTION

Power supply (3-phase and 1-phase) failure Starting battery volts low (or air pressure low) Amps charging (duplex) Chargerihigh and low) Space heater on/off Engine jacket heater on/off Run-hour meter Engine speed 110% overspeed alarm 120% overspeed trip Engine jacket temperature high Engine coolant level low Engine oil pressure low Engine fuel level low Air intake manifold temperature if turbo-charged Air intake valve closed Exhaust~as temperature hi9h Fuel inlet pressure gauge Fuel filter differential pressure Engine oil inlet temperature high Engine oil filter differential pressure high Engine oil level low Pump available Pump running Pump failed to start Weekly start due Common fault

INDICATOR

ALARM

x x x x x x x x x x x x x x x

R R R R

x x x x x x R R x R

R R R R R R x x

x x R

R

R (Table continued to next page ... .)

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(Table continued from last page ...... ) Pressure recorder (note) Controller on automatic Jockey pump running/stopped Jockey pump failed to start

x

R R x

R

LEGEND: I Indication A Alarm

x Provide R Repeat Signal to DCS at Main Control Room

NOTES: a) Pressure transmitter on firewater pump discharge with recorder shall be located at the main control room. b) In addition to switch inputs, alarm and trip circuits shall also be provided. c) The diesel engine logic shall initiate immediate start of the engine in the event of failure of local or remote control panels, or the battery/ air receiver dips to minimum start level. d) Stopping of a fire pump shall only manually be possible from the local control panel. Remote stop facility shall not be provided. e) A manual start / stop push button shall be provided on the local control panels. Only a manual start button shall be provided on the remote panel.

f)

When the start button is pushed , it shall cause the local or remote control panel to open or close all circuits as required to automatically start the engine by performing the following minimum functions: i. Turn on fuel supply. ii. Crank engine in series of crank-rest cycles. iii. Disconnect starting system upon engine start. iv. Engine shall remain in operation until manually or automatically shutdown. v. If engine fails to start after completion of the sequence, the controller shall disconnect the starting circuit and give alarm to indicate failure to start.

g) Engine shall automatically shut-down in the event of engine over speed. The shut - down shall close both the fuel supply and air intake valves. h) Each local and remote control panel shall have an audible alarm mounted on the panel. The sound of the alarm shall be sufficiently high to be audible over the noise of the running engine. A mute facility shall be provided for the audible alarm . The mute shall automatically be canceled and alarm reset when the fault is cleared. In addition, a flashing beacon, clearly visible from the pumps, shall be provided .

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i)

The control system shall be designed to allow system start from external sources.

j)

An indication shall be provided at the local and remote control panels for jockey pump running I stopped conditions.

k)

The weekly start facility shall not be automatic as defined in NFPA 20, clause 12.5.2.7. Weekly start due shall be indicated on the local and remote control panels and at the DCS. It shall be the operator's option as to when to start the test run. It shall not permit the operator to cancel the indication without having the pump run for a minimum of one (1) hour.

I)

During the weekly test run, all parameters which are normally only alarm- functions shall be tested as trip functions to inform the operator if any of the parameters are operating at trip setting.

m)

If during a weekly test run a fire signal is received by the system, the system shall automatically revert from a control aspect to normal operation. The operator shall align all valves from weekly test run to normal pOSition.

8.3.6 Noise and Vibration a) Noise levels for all equipment and ancillaries shall not exceed the limit stated on the equipment data sheets. Where necessary to meet the specified noise level for the pump set, suitable noise-attenuating devices shall be provided by the Manufacturer. Noise control measures shall be taken to meet the "KOC Standard on Plant and Equipment Noise Control"(KOC-L-030). b) Anti-vibration mounts shall be provided between equipment and skid. c) All piping connections to engine, except the exhaust, shall be via steel braided flexible hoses. The extent and length of such hoses shall be kept optimum. d) Pump vibration level shall comply with ANSI I HI 9.6.4, which shall apply either for electric, or diesel driven pumps. Maximum RMS vibrations values (unfiltered) at pump bearing shall not exceed 5.6 mm/sec for motor driven main pumps and 10 mm/sec for pumps driven by diesel engine with radiator. 9.0

INSPECTION AND TESTING

9.1

Testing Requirements

9.1.1

QA/QC work shall be in accordance with "KOC Standard for Project QAlQC Requirements"(KOC-Q-014). The Manufacturer shall prepare the ITP and submit to KOC for approval well before the Vendor Pre Inspection Meeting (VPIM).

9.1.2 Pumps, Diesel engines, Control panels and Battery chargers systems shall be tested at respective Manufacturers workshops before being incorporated in the pumpset.

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9.1.3 Vibration readings of motors in uncoupled and in coupled condition shall be taken and recorded. 9.1.4 A String Test shall be carried out at the approved Vendor workshop. 9.1.5 "NO LOAD" and "FULL LOAD" currents of the motors of jockey pumps shall be taken and recorded. 9.1.6 Field Acceptance Test shall be carried out after installing fire water pump at Site. 9.2

Inspection and Testing of Pump

9.2.1 a) Positive Material Identification (PMI) shall be done for casing, impellers and other alloy materials. b) All castings shall be examined by dye penetrant tests as per KOC Engineering Group Specification "Inspection of Castings for General Pressure Service" (015 WH-1003). 9.2.2 All pressure containing parts shall be hydrostatically tested for thirty (30) minutes at 1.5 times design pressure. Pump pressure retaining components shall be hydrotested at 1.5 times the maximum casing design pressure, irrespective of the fire main design pressure. 9.2.3

RT shall be carried out on casing and casing joints. Seepage or leakage shall not be allowed. Any leakage shall be cause for rejection .

9.2.4 Any weld repair shall be subject of prior approval by KOC and shall be inspected by KOC appointed / authorized Inspector before a second subsequent test in accordance with clause 4.3.3 of 015-WH-1 003 and with ASTM B 148-93a. 9.2.5 Performance and NPSH tests shall be conducted as per API 610. The tolerances shall comply with API 610. 9.2.6

Tests shall be extended as required to demonstrate the characteristics specified in clause 6.2 of NFPA 20.

9.2.7 Pumps shall be driven by an electric motor and as far as possible tests shall be conducted at the rated pump speed. 9.2.8 Tests shall be conducted at the following points: (a) Shut Off, (b) Minimum flow required by the data sheet; (c) Listed capacity; (d) Rated capacity; (e) 150% rated capacity.

JI

DOC. NO. KOC-ME-009

I

Page 37 of 59

I

REV. 2

9.2.9 If, any of the above two points are too close, the Manufacturer shall propose another appropriate point and submit to KOC for approval. 9.2.10 Head, Efficiency, Absorbed Power, Required NPSH values and Vibration level at each of above mentioned points shall be measured and recorded . 9.2.11 Vibration readings for drivers in uncoupled condition and vibration readings of main pumps I jockey pumps in coupled condition shall be taken and recorded . Pump vibration spectrum, bearing temperatures level and "Performances versus Capacity" curves shall also be plotted at each of the points as mentioned in clause 9.2.8 of this Standard. 9.2.12 If the test can not be carried out at the rated speed, the results shall be converted to reflect at rated speed except for the NPSH test results. A NPSH test shall be conducted at rated speed after incorporating the pump into the pumpset. 9.2.13 If it is necessary to dismantle the pump after the shop test for the sole purpose of machining the impeller(s) diameter(s) to meet tolerance on differential head, no performance retest will be required , unless the reduction in diameter exceeds 5% of the original diameter. However a mechanical run test shall be required. The diameter of the impeller at the shop test together with the final diameter of the impeller shall be recorded on a certified shop test curve showing the operating characteristics on test before and after the modification.

9.3

Testing of Control Panels All control panels shall be functionally tested at the works of the approved Manufacturer of the panel and during mechanical run test of the complete pumpset.

9.4

Testing of Battery Charger System The battery charger systems shall be subjected to the following tests:

9.4.1 Insulation resistance test of all circuits (except semiconductor component). 9.4.2 The following measurements shall be carried out at 0%, 50% and 100% of full-load direct current and shall be repeated at plus (+) 10% and minus (-) 10% of the nominal supply voltage. The measurements shall be carried out in the rectifier float - charge operating mode and in the boost charge operating mode. The measurements shall comprise of: a) Input phase voltage and frequency, b) Input phase current, c) Input power, d) DC output voltage,

Page 38 of 59

DOC. NO. KOC-ME-009

2

Output power,

f) Output voltage ripple,

g) DC output current.

9.5

Testing of Diesel Engine

9.5.1 Diesel engines shall be

as

nor'ITI'::,rI

by KOC as below:

a) At the Works of approved Manufacturer of the engine. procedure shall be submitted to KOC for approval.

engine

b) Vibration readings of diesel engines in uncoupled and in coupled condition shall be taken and recorded in "NO LOAD" and in "FULL LOAD" conditions respectively. 9.5.2 Hydrostatic

a)

containing

shall be

according to the code they have been

designed. b) The fuel oil day tank shall be subjected to a leakage test with paraffin or fuel oil kept for a period of one (1) hour minimum. 9.5.3 Diesel Engine Performance Test

a)

Diesel shall be against a dynamometer to demonstrate full fuel consumption. load power, the 10% overload capability and

b)

shall be carried out with all contract dependent auxiliaries installed on engine.

c)

All engines shall receive a four (4) hour loaded shop running test with minimum of (3) hours rated power and a minimum of 30 minutes 110% rated power.

d)

All tests shall be carried out using the radiator, heat exchangers, filters, governor and

e)

Oil having characteristics identical to the oil specified, shall allowed to

f)

Only that fuel, which has been specified for conducting the

g) h)

used.

shaH be

shall be in accordance with ISO 3046-1 and ISO 1 Measurements and measuring points shall be in accordance with engine group number as defined in ISO 3046-1 and 15550 List A of Table

DOC. NO. KOC-ME-009

i)

I

Page 39 of 59

I

REV. 2

The engine group number as per ISO 15550 Table 5 shall be clearly stated on the "Engine Test Procedure".

9.5.4 Diesel Engine Functional Tests a)

Functional test shall meet the requirements of C1-C5, C7-C8 as per ISO 15550 as minimum .

b)

The operation of the over-speed protection system shall be demonstrated mechanically or hydraulically without the use of external power.

c)

Change over of duplex filter cartridge elements shall be demonstrated while machine is running.

9.5.5 Acceptance Criteria a) During the test, all parts of engine and control equipment shall be required to operate satisfactorily and without excessive heating, vibration or display of other unfavorable characteristics. b) Permissible deviations shall be according to Table 4 of ISO 15550 except for power (no negative tolerance shall be allowed), and for fuel consumption plus four (+ 4) % deviations shall be permissible. 9.5.6 Diesel Engine Test Report Engine acceptance test report shall be issued in accordance with ISO 15550 clause 9 and shall include the statement of results, the declaration of power, the declaration of fuel consumption, the declaration of fuel specific consumption and the declaration of lubricating oil consumption in accordance with ISO 3046-1 and ISO 15550 and the report of functional test carried out. The Vendor shall submit the reports to KOC. 9.6

String Test of Fire Water Pump Set

9.6.1

Each complete fire pump set shall be fully assembled, with all the auxiliaries connected, and given a full load four (4) hours mechanical run test at the rated pump conditions.

9.6.2 The coolant and air intake temperature shall be adjusted to correspond with the maximum ambient temperatures on Site. 9.6.3 After bringing the engine to the normal operating temperature the pump shall be operated for three (3) hours at rated capacity and rated speed, and for one (1) hour at 150% rated capacity and rated speed. 9.6.4 Every 15 minutes at least the following recordings shall be made for : a)

Engine and pump speed,

b)

Cooling water temperatures (at the inlet and the outlet of all radiators / heat exchangers),

II

c)

Vibrations on pump

2

Page 40

DOC. NO. KOC-ME-009

engine bearings

Vibration instrument shall comply with 2954. Measurement point shall be the same as the individual component test. Vibration levels shall be no more same 110% those recorded during component tests at condition, d}

Temperature on pump and engine bearings,

e)

oil pressure,

f)

consumption, Engine exhaust temperature,

h)

Fire pump head

capacity.

9.7 9.7.1

starting system for pump shall be fully tested. Starting systems shall be capable starting the pump in the absence of any external power. Electric and time to

12 electric starting attempts shall and the duty point shall be recorded for

starting time start.

9.7.3 Hydraulic back-up system: Six (6) hydraulic starting cold attempts shall made. starting time and time to the duty point shall be recorded for each start. Engine protection: The coolant flow shall restricted and the engine seen to the point high temperature. The oil shall dropped (by the means temporary valve) the engine seen to trip at low oil pressure. 9.7.5 Overs peed system functioning shall

at a

demonstrated to the KOC representative.

Emergency sllut-down buttons and the functioning in presence of the KOC representative.

control panel lamps shall

9.7.7 KOC Controlling Team may specify some additional tests and shall be the purchase order data-sheets.

in

9.8 9.8.1

Field Acceptance according to the pump installation.

9.8.2

Test Report shall be issued and the results shall certified pump curve as per 14.2.4.2 of NFPA 20. For the deviations if any, with respect to conducted.

14.2.7 of NFPA

compared with factory

project specifications, are-test

DOC. NO. KOC-ME-009

9.8.4 Acceptance

Page

shall include the following

2

of 59

as minimum:

a) Demonstrations of the adequacy of pump and ability to deliver water in accordance with the Manufacturer's certified head capacity shop characteristic curve. b} Operation of the pump under various conditions to ascertain satisfactory performance under all expected conditions. c)

operations of the controlling and alternative power supply equipment (when supplied) to demonstrate satisfactory operation under all expected conditions from either automatic or manual operation of the controller.

d) Any faults, or other performance problems during documented before final acceptance is Acceptance Test shall be remedied granted. out to demonstrate that a pressure 150 9.8.5 Field Acceptance shall be is available the hydraulically most fire hydrant of the facility the rated flow of the fire pump. 9.8.6 Each pump shall at

for four (4) hours of continuous running after installation

9.8.7 The Vendor shall take the vibration readings during the field acceptance readings documented and submitted to KOG.

These

9.8.8 Other parameters like bearing temperatures, engine temperature, fuel pressure, lube oil pressure and battery ampere shall also recorded I documented at half an hour interval during the 10.0 QUALITY ASSURANCE 10.1

The Manufacturer shall operate quality systems to ensure that requirements of this are achieved. The quality systems shall be based on ISO 9000 of Standards. The Manufacturer shall demonstrate compliance by providing a copy of the accredited certificate a copy his quality manual.

1

Verification the Manufacturer's quality system is normally a part of Qualification Procedure KOG and therefore, not detailed in Standard.

10.3

Vendor I Manufacturer shall comply with the guidelines given in "KOG Standard for QA I QG ReqUirements" (KOG-Q-014).

11.0 Packing, marking, and shipping documentation shall comply with "KOG Standard for Packing, Marking and Documentation" (KOG-G-004).

DOC. NO. KOC-ME-009

12.0

DOCUMENTATION

12.1

General

I

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I

REV. 2

12.1.1 All correspondence, instructions, data sheets, drawings, calculation or any other written information shall be in English language. In case of dual languages, one language shall be English. 12.1.2 All dimensions, units of measurement, phYSical constants etc. shall be in SI units, unless otherwise specified. (Pipe sizes shall be shown in inches). 12.1.3 In addition to hard copies, all final documents such as speCifications, data sheets, and drawings shall be provided in the approved electronic software format (Latest versions of MS Word, Excel and AutoCad). Calculations shall be submitted in widely used software forms agreed upon by KOC. 12.1.4 Documents shall be comprehensive and customized. "Typical" documents shall not be accepted. 12.1.5 If however commercial documents providing data for several similar products are used for minor components, then the concerned product shall be clearly identified. 12.1.6 Documents shall contain all the necessary data to ensure correct installation, operation and maintenance of fire pumps and also for their integration into the fire fighting system. 12.1.7 Also, the documents containing internal clearances, tolerances and fitting classes shall be provided for the parts requiring dismantling during maintenance and for the wear parts (bearings, couplings, sleeves, wear rings, etc.) to permit correct maintenance practices.

12.2

Deliverables

12.2.1 Test Certificates and "as-built" Data Sheets and drawings of all pieces of equipment, appurtenances, and materials shall be submitted to KOC for review and approval before packing I shipment of equipment and supplies covered by this Standard. 12.2.2 The Vendor shall supply detailed technical information as well as the "Operation & Maintenance" (O&M) manual of each component of the PAU to KOC. 12.2.3 HSE related deliverable shall include the following as minimum: a) The Vendor shall provide KOC with the Operating and l\IIaintenance (O&M) manuals. The O&M manuals shall contain installation, operating and maintenance instructions. These instructions shall be given in sufficient details to allow KOC and the Contractor to train their personnel in safe installation, operation and maintenance of the equipment being supplied, including all necessary safety precautions.

II

DOC. NO. KOC-ME-009

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Page 43 of 59

I

REV. 2

b) The Vendor shall provide the list of HSE warning signage recommended to be displayed at the equipment's installed location to ensure safe operation and maintenance. 12.2.4 The Vendor shall submit to KOC for review and approval all test certificates, documents and data sheets (filled) for all equipment and materials, including, but not limited to the following:

Main Firewater Pump The electronic (soft) copies on CD-ROM shall also be provided by the Vendor. a) ITP of main pump, b) Pump + Engine Data sheet, c) Pump Performance Curve, d) Pump Cross Sectional Drawing with bill of materials and clearances, e) Pumpset Outline Drawing, f) Casing Relief Valve Data, g) Air Release Valve Data, h) Pressure Relief Valve Data, i) Pump Speed - Torque Curve, j) Coupling Drawing with Fitting Tolerances, k) Engine De-rating Calculations, I) Engine Speed - Torque Curve, m) Engine Outline Drawing, n) Engine Torsional Analysis, 0) Muffler Drawing & Flexible Exhaust Drawing, p) Muffler Insulation and Support Drawings, q) Hydraulic Starter Drawing, r) Noise Level Data Sheet, s) Foundation Load Calculations, t) Foundation Drawings, u) Fuel Tank General Arrangement Drawing, v) Lubrication List, w) System P& 10, x) Philosophy of Operation, y) UUFM name plate drawings for major components , z) Manufacturer's Record Book (MRB).

Jockey Pump The electronic (soft) copies on CD-ROM shall also be provided by the Vendor. a) b) c) d) e)

f)

ITP of Jockey pump,

Pump + Electric Motor Data sheet,

Pump Performance Curve,

Pump Cross Sectional Drawing with bill of materials and clearances,

Mechanical Seal Drawing,

Pump Outline Drawing,

JI

44 of 59

NO. KOC-ME-009

h)

i) j) k) I)

m) n) 0) q) r) s)

t) u) v) w) x) y) z) aa)

REV. 2

and Moments, Nozzle Allowable Motor outline Drawing, Pump + Motor Torque Coupling Drawing with Fitting Tolerances,

Lubrication List,

for Pre Commissioning Commissioning, spare parts for 3 years UUFM name plate. drawing, Load Calculations, G.A Drawing. Wiring Schematic Controller Field Connections, Electrical Load List, and Test Plan (lTP). Painting Specification and Procedure, Pump Procedure, Material and Mill Certificate, Pump Report + Certificates, Manual, Installation Operating and Record Book (MRB).

Procedures: The electronic (soft) copies on CD-ROM shall

be provided by the Vendor.

a) Inspection and Plan (ITP), b) Quality Control Plan, c) NDE nrl"lf'QI"I

d)

Records + Qualified

e)

f) g) h) Battery i) Engine j) Diesel Tank Control & Leak Test Procedure k) Diesel Tank Leak Procedure, I) String Test I-'roceaul m) Field Test ACI:eOta Procedure, Specification and n) Surface preparation, 0) Packing I-Jrr,f'Qf'11 p) Preservation I-Jrl"lt"cl"l

IJrf"lt"Q/'"l

Electrical and Instrumentation. electronic (soft)

on CD-ROM shall also be provided by the Vendor.

a) Complete Document Index, b) Control Panel G.A Drawing, c) Battery Calculation,

DOC. NO. KOC-ME-009

I

Page 45 of 59

I

REV. 2

d) e) f) g) h) i)

Electric Load List, Control Panel Wiring Schematic Diagram with Earthing details, Instrument Index, Control Logic Flow Chart and Logic Diagram, Control Panel Input / Output List, Control Panel Wiring Schematic Diagram with Details, j) Control Panel Field Connection Schematic, k) Control Logic Diagram,

Drawings: The electronic (soft) copies on CD-ROM shall also be provided by the Vendor. a) b) c) d) e) f) g) h) i)

System P&ID, List of instruments, Electrical load list, Main firewater pump general arrangement drawing and foundation loads drawing, Main firewater pump cross sectional drawing with clearances and material bill, Main firewater pump drawing for nozzle loads, Main firewater pump UL / FM name plate drawing, Diesel engine data, Main firewater pump controller data (which includes G.A. drawing, wiring schematics and field connection diagram), j) Nickel Cadmium battery data, and calculation k) Hydraulic starter drawing, I) Coupling data, m) Muffler data, n) Data for the flexible exhaust (made of SS 316), 0) Air release valve, p) Casing relief valve, q) Pressure gauges, r) Pressure relief valve, s) Jockey pump and motor data sheet, t) Jockey pump G.A. drawing, u) Jockey pump mechanical seal drawing, v) Jockey pump controller data (which includes G.A. drawing, wiring schematics and field connection diagram), w) Jockey coupling data, x) Engine torsional analysis.

12.2.5 Test Reports and Certificates: a) b) c) d) e) f)

PMI reports and Material certificates , Certified mill test reports for all pressure containing materials, Dimensional outlines, fabrication drawings and structural attachment details, NDE report, Welding Procedures Specification (WPS), Procedure Qualification Record (PQR) and Nondestructive Examination (NDE) records, Welder's performance qualification certificates,

II

DOC. NO. KOC-ME-009

Page 46 of 59

REV. 2

g) Impeller balancing certificate, h) curves or tables for the pumps showing power and capacity versus discharge and operating limitations, i) Testing procedures for: pump, control panel, battery charger, diesel engine, string test, field acceptance and for all other procedures as instructed by KOC or specified in the purchase order, j) Calibration Certificates, k) Pump Report + Certificates, I) String Report + m) Jockey pump performance curve, n) Jockey pump-motor curves I Compliance statement, 0) Controller Report + Certificates, p) Control Report + Certificates, q) Battery Report + Certificates, r) Engine Report + Certificates, s) Diesel engine performance and functional test report, t) Day tank certificates and test reports as per 015-DH-1 003, u) Field acceptance report+ Certificates, v) Compliance certificates, w) All other tests reports and certificates as instructed by KOC or specified in purchase 12.2.6 Other Documents: a) MRB b) Release notes, Dispatch dossier, d) Spare parts list as per clause 13.0 of this Standard, e) Operating and Maintenance (O&M) manuals, which shall include the following as minimum: (i) Pre-commissioning and Commissioning details and Procedures, (ii) The Manufacturer's recommended routine visual inspection I PM checklists for daily I weekly I fortnightly I monthly I quarterly I biannually and annually as appropriate. 12.2.7 Other documents either specified in purchase order or required by the KOC Controlling Team shall also be submitted by the Vendor KOC. 13.0 13.1

The Manufacturer shall comply with the requirements of "KOC Standard for Spare Parts and Maintenance Data" (KOC-G-009).

13.2

The Manufacturer shall submit a list to KOC, clearly segregating the following spares' Insurance spares,

b)

Maintenance

II

DOC. NO. KOC-ME-009

13.3

1

Page 47 of 59

1

REV. 2

The Manufacturer shall supply to KOC the following as minimum : a)

Pre-commissioning and Commissioning Spare Parts,

b)

Touch-up paint,

c)

Oils and coolant for first (initial) fill,

d)

Filter elements, gaskets and packing materials.

13.4

If specified in the purchase order, the Manufacturer shall supply operational spare parts and consumables for three (3) years reliable operation .

13.5

The Manufacturer shall submit to KOC a " Comprehensive list for five (5) years spares and Consumables".

14.0

APPENDICES

14.1

The Appendices of this Standard include: a) Check List for Inspection and Testing, b) Data Sheets for Firewater Pumps, c) Data Sheets for Internal Combustion Engine (Diesel Engine) , d) Data Sheet for Noise Level

14.2.

Though the Check-List and Data Sheets of this Standard have been marked with a selection (X), the KOC Controlling Team shall be allowed to make and incorporate case specific changes, if any and re-select (X). The KOC Controlling Team shall also be allowed to expand the Data Sheet by making case specific additions.

14.3.

The referenced standards shall be used for making any more data sheets viz. for electrical motors.

14.4.

Centrifugal Fire Pump Acceptance Test Form may be referred from NFPA 20 and customized (therefore it is not repeated in this Standard) .

II

DOC. NO. KOC-ME-009

I

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REV. 2

APPENDIX 1: CHECK LIST FOR INSPECTION AND TESTING

@ KUWAIT OIL COMPANY

PREPARED BY:

EQUIPMENT NUMBER:

DATE: PART I

PROJECT DATA: I. PROJECT NUMBER: . 2. PROJECT TITLE: 3. SHOP ORDER NUMBER: -----. . --..----.. .-.--- ­-- . -­-......---.. -.-­ ------.-=-=-c::------­---.----.----..-.-----..­ . -.---.. -.- - .­.......-­---.­ ......... ... --.- ----.. .----.. ­- - - ­ 4. ENGINEERING REQUISITION NUMBER: -- 5~-PURCiiASE OIDiER NUMBER~-- - --- -- ----------·---- --·--- - -·----- ·· ·----- - . ­. --.-----------.---­---.­--------.-..­- -----­--------------- ­ 6. SUPPLIER:

MATERIALS: PART 2

EXCEPTIONS & JUSTIFICATIONS: PART

3

INSPECTION AND TESTING: I. MANUFACTURER'S SHOP INSPECTION: • REQUIRED 2. SUPPLIER'S SHOP INSPECTION: • REQUIRED 3. KOC SHOP INSPECTION: • REQUIRED 4. PRE-INSPECTION MEETING: • REQUIRED 5. SUPPLIER'S/MANUFACTURER'S QA MANUAL: • APPROVAL 6. INSPECTION & TEST PLAN: • APPROVAL 7. PRODUCTION & INSPECTION SCHEDULE: • APPROVAL

PART 4

PART

5

I

DOCUMENTATION: I. COMPLETED DATA SHEETS AT ENQUIRY STAGE: 2. MANUFACTURING PROCEDURE: 3. INSPECTION & TESTING PROCEDURES: 4. SHOP REPAIR PROCEDURES: 5. COMPLETE BILL OF MATERIALS 6. MATERIAL TEST CERTIFICATES: 7. OPERATING & MAINTENANCE MANUALS: 8. "AS-BUILT" DRAWINGS: 9. PACKING, MARKING AND DOCUMENTATION:

o APPROVAL

0 0 NOT REQUIRED 00 NOT REQUIRED 0 0 NOT REQUIRED 00 NOT REQUIRED o U INFORMATION o U INFORMATION o U INFORMATION

• INFORMATION

o APPROVAL

• INFORMATION

• APPROVAL • APPROVAL

o INFORMATION

• APPROVAL o APPROVAL

o INFORMATION

• APPROVAL

o INFORMATION

• REQUIRED

o NOT REQUIRED

• REQUIRED

o NOT REQUIRED

o INFORMATION

• INFORMATION

ISSUED FOR QUOTATION REV.

BY

CHECKED

APPROVED

DATE

REVISION

PAGE 49 of 59

DOC. NO. KOC-ME-009

~

REV. 2

II

APPENDIX 3

@

-

ITEM

JOB NO.

KUWAIT OIL COMPANY (K.S.C.)

PURCHASE ORDER NO.

-

SPECIFICATION NO.

RRE WATER PUMP DATA SHEET

PAGE

Q

1 APPLICABLE TO :

0

PROPOSALS

DATE

REVISION NO.

0

PURCHASE

1

--­

- - ­ BY

._.­

AS BUILT

Kuwait Oil Company

2 FOR

-

5

OF

-­

SERIAL NO.

3 SITE

-

-

NO. REOUIRED

Firewater Pumf>s

4 SERVICE

NO. STAGES

5 MANUFACTURER

-

PUMP SIZE & TYPE

6 NOTES:

INFORMATION BELOW TO BE

7

COMPLETED:

0

0

BY PURCHASER

--­

BY MANUFACTURER

-

GENERAL

8 9 PUMPS TO OPERATE IN (PARALLEL)

-

NO . MOTOR DRIVEN

NO. ENGINE DRIVEN PUMP ITEM NO.

-

11 GEAR ITEM NO . 1

-

MOTOR ITEM NO.

ENGINE ITEM NO .

-

12 GEAR PROVIDED BY

_.

MOTOR PROVIDED BY

ENGINE PROVIDED BY

13 GEAR MOUNTED BY

-

MOTOR MOUNTED BY

ENGINE MOUNTED BY

-

14 GEAR DATA SHT. NO'S

-

DRIVER DATA SHT. NO: S

ENGINE DATA SHT. NO:S

-

10

YES

Refer P&IO

PUMP ITEM NO.

REMARKS : 1) FIREWATER PUMP SHALL COMPLY TO KOC-ME-009, NFPA 20 and UL 448. 15 2) ALL MATERILAL SHALL BE FM I UL approved/listed

OPERATING CONDITIONS

16 17

0

18 19 20 21

22

SITE AND UTILITY DATA (CONTO)

CAPACITY, RATED, m3/h

COOLING WATER:

OTHER

0 0 0 0

23 D

MIN RETURN

SUCC. PRES,MaXIRated

Bara

DISCHARGE PRESSURE

Bar a

DIFFERENTIAL PRESSURE m

0

KW

~ INTERMITIENT (STARTS/DAY

CONT.

Lp

MAX ALLOW

INSTRUMENT AIR : MAM.lIN PRESS

--­ m

NPSHA

HYDRAULIC POWER

0

Ber

--­

Bar

DIFF. HEAD

24 SERVICE:

--­

--­ Bor

WATER SOURCE

)

0 0

25 REMARKS:

I

._ ­-

Ber

LIQUID

TYPE OR NAME OF LIQUID

Brackish Waler ref Sheet 5

PUMPING TEMPERATURE NORM.

- ­-

'C

MAX.

- .'C

MIN.

'C

26 Sae Note 4 on page 5

0

27

SITE AND UTILITY DATA

26 LOCATION: 29

0

INDOOR

30

0

OUTDOOR

0 0 0

31

0

GRADE

32

0

AREA CLASSIFICATION

0 0 0

HEATED UNHEATED MEZZANINE

: ZONE

PARTIAL SIDES SUN

-

SPECIFIC HEAT

0 0

--­ -

: UNCLASSIFED

33

SPECIFIC GRAVITY

0 0 0

UNDER ROOF

GROUP

0 0

VISCOSITY

36

37

0 0 0

ELEVATION

SEE PAGE 6 OF 6

CHLORIDE CONCENTRATION

See Page 5

ppm

H2S CONCENTRATION

See Page 5

ppm

0

40

0 0

OTHER

0 0 0

FUMES

UTILITY CONDITIONS:

42

MIN

43

MAX

DRIVERS

-­ - ­ Bar -

45

47

HERTZ

48

PHASE

HEATING

49 COOLING WATER:

OTHER

IMPELLER DIA. RATED

-­ MAX.

RATED POWER

kW

0 0 0

--­

- - ­ MIN.

mm

--­

EFFICIENCY

%

-­

MINIMUM CONTINUOUS FLOW

--­

m3/h

m3/h

STABLE

MAX HEAD RATED IMPELLER

m

MAX POWER RATED IMPELLER

KW

NPSH REQUIRED AT RATED CAP.

0

SUCTION SPECIFIC SPEED

0

MAX. SOUND PRESSURE LEVEL

REMARKS:

(FT)

--­ - ­ --­ mH20 10,000 Max.

dBA

Ref: 015-NH-1104 (Plant & Equip Noise)

dBA

-­

Not Available

TEMP., INLET

-­

'C

51

PRESS. NORM

--­

Bar

Date

·C

SIOOWN

--­ --­

50

Rev.

·C

-­ --­ --­

- ­-

--­

--­ --­

CONTROL

0

rpm

THERMAL

--­ ...

Bar

·C -­ Bar -­ --­ --­

DRIVERS

46 VOLTAGE

HEATING

--­ ­---­ - ­ ·C -

Bar '­ --­

44 ELECTRICITY:

53

0

0

FLAMMABLE

PERFORMANCE

PROPOSAL CURVE NO.

REF: KOC·G·OO? (BaSic Design Crileria)

41 STEAM

52

'C

100/50

~ DUST

38 UNUSUAL CONDITIONS: 39

·3/55

MAXIMIN

o

TOXIC

0

RANGE OF AMBIENT TEMPS : MINIMAX. RELATIVE HUMIDITY: %

-­

'C

Bar

CORROSION I EROSION CAUSED BY

m

55

MAX. TEMP.

cP@

Vapour Pres.

34 SITE DATA: 35

@ kJlkg.K

By

--­

MAX. RETURN

Checked

..

_

Approved

'C

.-

Bar Description

Data sheet Number

DOC. NO. KOC-ME-009

@

PAGE 50 of 59

I

KUWAIT OIL COMPANY (K.S.C.)

ITEM NO.

REVISION NO. PAGE

0

I

CONSTRUCTION

ANSI SIZE

4

RATING

FACING

POSITION

RF

Side

5 SUCTION 6 DISCHARGE

RF

­

7 BAL. DRUM

.

8

...

9 0

...

SERVICE

_.

NO.

Side

0 0 0 0 0

LUBRICATION

Non lubricated

LIMITED ENO FLOAT REQUIRED SPACER LENGTH

--­

mm

SERVICE FACTOR DYNAMIC BALANCED

AGMA BALANCE CLASS

DRIVER HALF COUPLING MOUNTED BY

...

...

~

12 VENT

FLANGE WNALVE

14 TEMP GAUGE

-

0

DRIVER MFR.

D

CLEARANCE

D

0

CLASS 1

HUB TO ENGINE SHAFT FIT

INTERFERENCE

PURCHASER

AGMA 9002

HUB TO PUMP SHAFT FIT

INTERFERENCE

FLANGE WNALVE

13 PRESS. GAUGE

0

PUMP MFR.

• •

TYPE

SIZE

...

BY

...

11 DRAIN

{J5 WARM·UP

--­

5

...

OTHER CONNECTIONS

10

DATE 2 of

COUPLINGS: (CONTINUED)

MAIN CONNECTIONS:

3

I

c JOB NO.

ARE WATER PUMP DATA SHEET

2 0

REV. 2

II

CLASS 2

c:=J

AGMA 9002

CLEARANCE

0

CLASS 1

CLASS 2

.­

REMARKS:

...

FeJexible spacer type required. "In share" coupling are not acceptable

c:=J

Non·Sparking type coupling guard required

MATERIAL

...

16 CASING MOUNTING:

0

17

•

18

0 0

19

20

0 0 0

CENTERLtNE FOOT VERTICAL

0 0 0

NEAR CENTERLINE SEPARATE MOUNTING PLATE SUMP

0 0 0 0 0 0 0

IN·LINE

21 CASING SPLIT: •

22

0

AXIAL

RADIAL

23 CASING TYPE:

0 0 0

24 25 26

2

0 0 0

SINGLE VOLUTE BARREL STAGGERED VOLUTE

DOUBLE VOLUTE DIFFUSER VERTICAL DOUBLE CASING

29

0

BETWEEN BEARINGS

0

OVERHUNG

OPEN

II

CLOSED

0 0

0

MONEL K500

COUPLING HUBS COUPLING SPACER COUPLING FLEXIBLE ELEMENTS BASEPLATE

I

VERTICAL LEVELING SCREWS

REQUIRED

HORIZONTAL POSITIONING SCREWS Gland I Mat'l

'late I MONEL K 500

REQIRED I Ni AI Bronze

Noles:

-

I)Ea~hln9

Clips per Siand. Draw. KOC·E·024 2) UNS C 95800

AS PER REQUIREMENT OF ASTM 8 148

33

PRESSURE

CW

SLEEVE

3) CASING AND IMPELLER CASTINGS TO BE HEAT TREATED

CASING PUMP DESIGNED FOR MAX. ALLOWABLE WORKING

0

MONEL K500

DOUBLE

32

35

NiAIBronze(Note 2) MONEL

DIFFUSERS

BEARINGS AND LUBRICATION

SUCTION PRESS. REGIONS OF MULTISTAGE OR DOUBLE

34 ROTATION:

IMPELLER

SINGLE

30 CASE PRESSURE RATING: 31

NiAIBronze ( NOle 2)

SHAFT

0

27 IMPELLER MOUNTED: 28·

BARREUCASE

CASEIIMPELLER WEAR RINGS

BEARING: (TYPE I NUMBER)

(VIEWED FROM COUPLING END)

0

0

RADIAL

I

o

THRUST

I

CCW

36 MAX ALLOWABLE PRESSURE Bar g

LUBRICATION

40 SHAFT DIAMETER AT SLEEVE

mm

41 SHAFT DIAMETER AT COUPLING

mm

0 0 0 0 0

42 SHAFT DIAMETER BETWEEN BRGS.

mm

0

OIL HEATER REQ'D

43 SPAN BETWEEN BEARING C.L.

mm

0

OIL PRESSURE TO BE GREATER THAN COOLANT PRESSURE

44 SPAN BETWEEN BEARING & IMPELLER

mm

REMARKS

37 AT @15'C

AT NORM. PUMP. TEMP

--­

38 HYDRO TEST PRESSURE· Bar.g 39 SHAFT:

45 REMARKS:

FLOOD PURGE OIL MIST

0 0

PURE OIL MIST

0

API.o14

0

STEAM

RING OIL

CONSTANT LEVEL OILER PRESSURE

o

API.610

OIL VISC., ISO GRADE

0

ELECTRIC

BEARINGS TEMPERATURE SHALL REMAIN

OPERATING CONDITIONS

COUPLINGS

47

DRIVER·PUMP

48

0 50 0 51 0

FLINGER

0 0

BELOW AT BOC AT 55C AMBIENT TEMPERATURE IN ANY

46

49

GREASE

MAKE MODEL TYPE

REVISON

Data sheel Number

I

DOC. NO. KOC·ME·OO9

(@

PAGE 51 of 59

II

KUWAIT OIL COMPANY (K.S.C.) JOB NO.

ARE WATER PUMP DATA SHEET

ITEM NO. DATE

REVISION NO. PAGE

3 of

•

MANUFACTURER

40 TYPE

sO

__

5.. .. ._

- BY

CONTROL PANEL AND INSTRUMENTATION

PACKING

1 2 PACKING DATA: 3D

REV. 2

II

•

NFPA 20 COMPLIANT

0

YES

NO

DEVIATIONS

SIZE. AND NO. RINGS

6 0 PACKING INJECTION I 7[] PACKING INJECTION REQUIRED

0 0 9 8

FLOW

m3/h

Bar.g

LANTERN RING

10 NOTE:

•

1. Piping and Valves furnished per 015 - LH - 1001

DEVIATIONS

110 12 • 13 • 140

•

KOC 015-1004 COMPLIANT

SLEEVE MATERIAL

Monel K 500

GLAND MATERIAL

Monel K 500

0

YES

--­ NO

-

,5°

16 GLAND TAPS: 17

0

(FOR LANTERN RINGS)

0

FLUSH (F)

o o

,80 VENTM 19

0

QUENCH (Q)

o

DRAIN (D)

BARRIER (B)

0

OTHER

COOLING (C) HEATING (H)

20 PACKING FLUIDS REQUIREMENT

•

21 • 22 23

AVAILABLE FLUSH LIQUID: PUMPED FLUID PACKING FLUSHING PLAN

0 0

Pumped Liquid

0

TUBING

•

PIPE

CARBON STEEL MONEL

24 25

AUXILIARY PIPING

26

27 • 28 • 29 30 • 3'

VENT(V)

YES

MONEL

DRAIN (D)

YES

MONEL

AUTOMATIC AIR RELEASE

DIAMETER

0

0 0

VISIBLE DRAIN MATERIAL

PRIMER FINISH COAT

BASEPLATE SURFACE PREPARATION SSPC-SP- 10 PRIMER FINISH COAT

0 0

ALL AUXILIARY PIPING SHALL FLANGED AND ROUTED TO

36 THE EDGE OF THE SKID

FLEXIBLE ELEMENT TO BE PROVIED ON THE SUCTION

Cl III

LINE

REMARKS

STRAIN RELIEF

39 • 40 41 42

0

°

DIAMETER

44D

e soe 49

DOMESTIC

•

SHIPMENT EXPORT

•

EXPORT BOXING REQ'D

OUTDOOR STORAGE MORE THAN 6 MONTHS REF: KOC-G-004

(PaCking, Mar1