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

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CONSORTIUM
PROCEDURE NO: 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
PCSB
REVIEWED BY
NAME SIGN DATE
DATE
PREPARED BY
NAME SIGN DATE
27.04.20
REVIEWED BY
NAME
Sholeh
APPROVED BY
NAME
Redy
APPROVED BY
NAME SIGN DATE
SIGN
DATE
29.04.10
27 . 04 . 10
Iwan
SIGN DATE N
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PROCEDURE NO: WMM-MCOTR-110 REVISION NO.: 0
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TABLE OF CONTENTS
SECTION
DESCRIPTION PAGE
1 2 3 4 5 5.1 5.2 5.3 5.4 5.5
PURPOSE SCOPE REFERENCE DEFINITIONS PROCEDURES ITEMS TO BE TESTED PRE-REQUISITE CHECK PUMP RUNNING PROCEDURE ACCEPTANCE CRITERIA TEST SCHEME AND CHECK LIST
3 3 3 3 3 3 4 5 6 7
APPENDICES APPENDICES 1 APPENDICES 2 : : List of the Pumps which require
mechanical running test Mark-up P&ID for Pump Mechanical Running (Test Loop), 230 kbd only. APPENDICES 3 APPENDICES 4 : Operation Log Sheet. : Vibration Monitoring Sheet
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APPENDICES 5 : MCC-29, Electric Motor-Driven Centrifugal and Testing Record Step by step for mechanical run test APPENDICES 6 :
Pump, Checksheet 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. Detailed Testing and Precommissioning Plan Procedure, API 610 9
th
PSP-MCOTR-18A,
II.
Doc. No. PSP-MCOTR-18B,

III. IV.
edition.
Carigali Standard Procedure, CSP-T-20, Guideline for Testing & Precommissioning Procedure.
4. DEFINITIONS PCSB : Petronas Carigali Sdn Bhd
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ONSHORE CONSTRUCTION Rekmal :
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REKMAL
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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ONSHORE CONSTRUCTION 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 Motor no-load run (solo-run) test has been completed. Make sure coupling has been installed properly Coupling fastened guard is installed and securely
ii. iii. iv. v. vi.
Ensure suction strainer are installed All spring support lock on the pipe system line are removed The unit must have a safety barricade
vii.
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. 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.
xi.
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xii.
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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. Measuring tools and accessories are required to be set properly Operation log sheet are ready to be filled in. Person in charge for the mechanical running from all discipline related are ready on their position, for data recording and any response required.
xiii.
xiv. xv.
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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ONSHORE CONSTRUCTION 5.4.2 BEARING TEMPERATURE (Recheck
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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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APPENDICES 1 LIST OF PUMPS WHICH REQUIRE MECHANICAL RUNNING TEST

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Equipment no. P-4260 P-4265 P-4270 P-4240 A P-4240 B P-4250 A P-4250 B 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 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
Note :
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Pump system with minimum flow facility can be tested for 24 hours and agreed by all parties
APPENDICES 1 (continued) LIST OF PUMPS WHICH REQUIRE MECHANICAL RUNNING TEST

No. 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Equipment no. P-4330 P-1610 A P-1610 B P-6585 A P-6585 B P-6585 C 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 P-5749 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
Note :
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Pump system without minimum flow facility will be tested as required 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
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APPENDICES 4 VIBRATION MONITORING SHEET
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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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PROCEDURE NO: WMM-MCOTR-110