Mechanical Pump Test Run Procedure Manual Mechanical Pump Test Run Rev 0-28-04 10

WORK METHOD MANUAL

PROCEDURE NO:

CONSORTIUM

WMM-MCOTR-110

ONSHORE CONSTRUCTION

REVISION NO.: 0

REKMAL

MECHANICAL PUMP TEST RUN PROCEDURE

FOR PETRONAS CARIGALI SDN BHD KUALA LUMPUR

CONSORTIUM REKAYASA INDUSTRI MALAYSIA AND SIMFONI TEMASEK REV NO. 0

DATE

PREPARED BY NAME

27 . 04 . 10

Iwan

SIGN

REVIEWED BY

DATE

NAME

27.04.20

Sholeh

SIGN

DATE 29.04.10

APPROVED BY NAME Redy

SIGN DATE N

PCSB REVIEWED BY NAME

SIGN

DATE

APPROVED BY NAME

SIGN

DATE

PROCEDURE NO:

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CONSORTIUM

REVISION NO.: 0

ONSHORE CONSTRUCTION

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REKMAL

TABLE OF CONTENTS

SECTION

DESCRIPTION PAGE

1

PURPOSE

3

2

SCOPE

3

3

REFERENCE

3

4

DEFINITIONS

3

5

PROCEDURES

3

ITEMS TO BE TESTED PRE-REQUISITE CHECK PUMP RUNNING PROCEDURE ACCEPTANCE CRITERIA TEST SCHEME AND CHECK LIST

3 4 5 6 7

5.1 5.2 5.3 5.4 5.5

APPENDICES APPENDICES 1

:

List

of

the

Pumps

which

require

mechanical running test APPENDICES 2

:

Mark-up P&ID for Pump Mechanical

Running (Test Loop), 230 kbd only. APPENDICES 3

: Operation Log Sheet.

APPENDICES 4

: Vibration Monitoring Sheet

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APPENDICES 5 : MCC-29, Electric Motor-Driven Centrifugal

Pump, Checksheet APPENDICES 6 :

and Testing Record Step by step

for mechanical run test

procedure

1.

PURPOSE This document generally covers the Mechanical Running Test Procedure

for Pumps with electric motor drivers for MCOT

Rejuvenation Project Phase 2. Test procedure for each pump will have checklist describing procedure for running the specified pump.

2. SCOPE This procedure shall be applied to all electric-driven motor pumps utilized in MCOT Rejuvenation Phase 2 Project, from 230 kBD Plan, MCD-1, and MCD-2.

3. REFERENCE I.

Testing and Precommissioning Plan Procedure, Doc. No.

PSP-MCOTR-18A, II.

Detailed Testing and Precommissioning Plan Procedure,

Doc. No. PSP-MCOTR-18B, III.

API 610 9

IV.

Carigali Standard Procedure, CSP-T-20, Guideline for

th

edition.

Testing & Precommissioning Procedure.

4. DEFINITIONS PCSB :

Petronas Carigali Sdn Bhd

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Rekmal

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:

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Rekayasa Industri Malaysia Sdn Bhd

5. PROCEDURES 5.1

ITEMS TO BE TESTED

Pump listed in the Appendices-1 shall be given a mechanical running test during precommissioning stage. The test will be conducted with the proper fluid source, such as utility water or the process product as the pumping liquid.

5.2

PRE-REQUISITE CHECK

The prerequisite check shall be made on the following items before the mechanical running test is performed : 5.2.1 Documents i. MCC – 29, Electric Motor Driven Centrifugal Pump, Checksheet and Testing Record. ii. MCC – 04, Coupling Alignment Record Sheet iii. Pump Alignment Sheet iv. Operation Log sheet v. P & ID 5.2.2 Equipment Statutory All equipment as stated in P&ID 5.2.3 HSE Requirement i. Fire Extinguisher ii. Safety barricade surrounding area pump to be tested 5.2.4 Tools i. ii. iii. iv.

Vibration analysis. Temperature Infrared Ray (TIR) Tachometer F key or F tool

5.2.5 Man Power i. Inspector Rotating

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ii. iii. iv.

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Operator Electrical and Instrument Supervisor Mechanical

5.2.6 Check list activity i.

Final pump alignment must be completed

ii.

Motor no-load run (solo-run) test has been completed.

iii.

Make sure coupling has been installed properly

iv.

Coupling

guard

is

installed

and

securely

fastened v.

Ensure suction strainer are installed

vi.

All spring support lock on the pipe system line are removed

vii.

The

unit

must

have

a

safety

barricade

surrounding prior the mechanical running test is performed. viii.

Ensure that the pump mechanical running test lines (test Loop) has been checked as per mark-up P&ID.

ix.

Ensure the fire extinguisher is presented near the unit

x.

Make sure that vessel or Sump has been filled with the liquid at normal level.

xi.

Make sure mechanical seal pump is manually being water flushed before the pump start running. For vertical barrel pump, ensure liquid has been filled into the barrel with the vent line in open condition.

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Just before the running test for the units driven by electric motor, the motor to be run for a moment to check for correct shaft rotation of the pump unit.

xiii.

Measuring tools and accessories are required to be set properly

xiv.

Operation log sheet are ready to be filled in.

xv.

Person in charge for the mechanical running from all discipline related are ready on their position, for data recording and any response required.

5.3

PUMP RUNNING PROCEDURE

Pump will have a step-by-step procedure for running. These procedures will be provided as a checklist prior to run the unit. Each items listed on the step-by-step procedure to be confirmed or mutually agreed by REKMAL and PMT , refer to Appendices 6.

5.4

ACCEPTANCE CRITERIA

Mechanical running test shall be conducted as general for 24 (twenty four) hours running continuously and log operating data every two hour intervals, this will be done after the oil temperature on the bearing housing are stabilized. For pump without the recycle lines can be tested depend on working avaibility of the inventory / process liquid.

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During the running test, the following requirements shall be met. 5.4.1 VIBRATION Unless otherwise specified by vendor. Unfiltered vibration levels measured on the bearing housings shall not exceed the value given below: •

For centrifugal pump which follow the API 610 9th Edition.

Max. unfiltered vibration : 3.0 mm/s (0.12

in/s) RMS. •

Vertical Suspended pump which follow the API 610 9th Edition. Max. unfiltered vibration : 5.0 mm/s ( 0.2 inch/s) RMS.

Note : 1.

Vibration readings will be taken on the upper

bearing housing of the motor for vertical pumps with rigid couplings and on the top pump bearing housing for vertical pumps with flexible couplings. 2.

Vibration limits at flow rate other than the rated

flow should be discussed with MCOT if required and mutually agreed upon. 3.

All the vibration check and recording will be done

as per API 610 Ninth edition section 5.9.3

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PROCEDURE NO:

5.4.2 BEARING

TEMPERATURE

(Recheck

Page 8 of 17

to

Vendor

recommendation) All pumps, motors

shall operate within the following bearing

temperature limits (as per API-610 para. 5.10.2, unless otherwise specified by manufacturer •

For pressurised system, oil outlet temperature below 70 0C (160 0F)

•

For ring oiled or spash system, oil sump temperature below 820C (180 0F)

5.4.3 Reliability Running mechanical test run, pump shall continuously run for 24 hours without any interruption, especially for pump with minimum flow facilities.

5.5

TEST SCHEME AND CHECK SHEET

Test scheme (by marked up P&ID) and check sheet to be prepared and submitted (attached) when issue application for the testing of respectively pump. These document will be part of Test Report, refer to check sheet MCC-29.

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REKMAL

APPENDICES 1 LIST OF PUMPS WHICH REQUIRE MECHANICAL RUNNING TEST No.

Equipment no.

1

P-4260

2

P-4265

3

P-4270

4

P-4240 A

5

P-4240 B

6

P-4250 A

7

P-4250 B

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

P-1620 A P-1620 B P-1410 P-1420 P-1430 P-1000 P-2000 P-1200 P-6900 P-6910 P-6940 P-4275 P-4280 P-4310 P-4320

Note :

Name Produced Water Transfer Pump Produced Water Transfer Pump Produced Water Transfer Pump IGF V-4220 Recirculation Pump IGF V-4220 Recirculation Pump IGF V-4230 Recirculation Pump IGF V-4230 Recirculation Pump Slop Oil Transfer Pump Slop Oil Transfer Pump SLPS Booster Pump SLPS Booster Pump SLPS Booster Pump Fast Loop Pump Skid Jet Mix Pump Skid Crude Pump Oily Water Pump Oily Water Pump Oily Water Pump Produced Water Recirculation Produced Water Recirculation Sand Wash Transfer Sand Wash Transfer

Remark With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow With minimum Flow

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Pump system with minimum flow facility can be tested for 24 hours

REKMAL

and agreed by all parties

APPENDICES 1 (continued) LIST OF PUMPS WHICH REQUIRE MECHANICAL RUNNING TEST No.

Equipment no.

23

P-4330

24 25

P-1610 A P-1610 B

26

P-6585 A

27

P-6585 B

28

P-6585 C

29 30 31 32 33 34 35 36 37 38 39 40

P-6520 A P-6520 B P-6520 C P-6540 A P-6540 B P-6540 C P-6595 A P-6595 B P-6320 A P-6320 B P-5748 A P-5748 B

41

P-5749

Note :

Name Jet Pump of Sand Washer System Slop Oil Sump Pump Slop Oil Sump Pump Effluent Discharge Sump Pump Effluent Discharge Sump Pump Effluent Discharge Sump Pump TPI-2 Sump Pump TPI-2 Sump Pump TPI-2 Sump Pump TPI-2 Water Pump TPI-2 Water Pump TPI-2 Water Pump Storm Water Sump Pump Storm Water Sump Pump Relief Liquid Pump Relief Liquid Pump Closed Drain Sump Pump Closed Drain Sump Pump Closed Drain Sump Rain Water Pump

Remark Non electric-driven motor Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow

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Pump system without minimum flow facility will be tested as required

REKMAL

and agreed by all parties.

APPENDICES 2 MARK-UP PID FOR PUMP MECHANICAL RUNNING (TEST LOOP) FOR 230 KBD ONLY

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APPENDICES 3 OPERATION LOG SHEET

Page 12 of 17

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APPENDICES 4 VIBRATION MONITORING SHEET

Page 13 of 17

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REKMAL

APPENDICES 5 ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP CHECKSHEET AND TESTING RECORD

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APPENDICES 6 Step by step Start up Procedure

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