method manual mechanical pump test run

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REKMAL

CONSORTIUM

WORK METHOD MANUALPROCEDURE NO:

ONSHORE CONSTRUCTION

WMM-MCOTR-110

REVISION NO.: 0

MECHANICAL PUMP TEST RUN PROCEDURE

FOR

PETRONAS CARIGALI SDN BHD

KUALA LUMPUR

CONSORTIUM REKAYASA INDUSTRI MALAYSIA AND SIMFONI

TEMASEKPCSB

REV

NO.DATE PREPARED BY REVIEWED BY APPROVED BY REVIEWED BY APPROVED BY

NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE

0 27 . 04 . 10 Iwan 27.04.20 Sholeh 29.04.10 Re!



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TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1 PURPOSE 3

2 SCOPE 3

3 REFERENCE 3

4 DEFINITIONS 3

5 PROCEDURES 3

5.1 ITEMS TO BE TESTED 35.2 PRE-REUISITE C!EC" 45.3 PUMP RUNNING PROCEDURE 5

5.4 ACCEPTANCE CRITERIA #5.5 TEST SC!EME AND C!EC" LIST 7

APPENDICES

APPENDICES 1 $ L%&' of '(e P)*+& ,(%( e/)%e

*e(a0%a )00%0g 'e&'APPENDICES 2 $ Ma-)+ PID fo P)*+ Me(a0%a

R)00%0g Te&' Loo+6

23 89 o0:.

APPENDICES 3 $ O+ea'%o0 Log S(ee'.

APPENDICES 4 $ ;%8a'%o0 Mo0%'o%0g S(ee'



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APPENDICES 5$ MCC-2<6 Ee'% Mo'o-D%=e0 Ce0'%f)ga

P)*+6 C(e&(ee' a09 Te&'%0g Reo9

APPENDICES #$ S'e+ 8: &'e+ fo *e(a0%a )0 'e&'

+oe9)e

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 checlist descri!ing

procedure for running the specified pump.

2. SCOPE

This procedure shall !e applied to all electric"driven motor

pumps utili#ed in MCOT Rejuvenation Phase 2 Project$ from 2%&

'( Plan$ MC("1$ and MC("2.

3. REFERENCE

I. Testing and Precommissioning Plan Procedure$ (oc. )o.

P*P"MCOTR"1+,$

II. (etailed Testing and Precommissioning Plan Procedure$

(oc. )o. P*P"MCOTR"1+'$

III. ,P- 1& / th edition.

IV. Carigali *tandard Procedure$ C*P"T"2&$ 0uideline for

Testing Precommissioning Procedure.

4. DEFINITIONS

PC*' Petronas Carigali *dn 'hd



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Remal Reayasa -ndustri Malaysia *dn 'hd

5. PROCEDURES

5.1 ITEMS TO BE TESTED

Pump listed in the ,ppendices"1 shall !e given a mechanical

running test during precommissioning stage.

The test will !e conducted with the proper fluid source$ such as

utility water or the process product as the pumping li3uid.

5.2 PRE-REUISITE C!EC"

The prere3uisite chec shall !e made on the following items

!efore the mechanical running test is performed

4.2.1 (ocumentsi. MCC 5 2/$ 6lectric Motor (riven Centrifugal

Pump$ Checsheet and Testing Record.

ii. MCC 5 &7$ Coupling ,lignment Record *heetiii. Pump ,lignment *heetiv. Operation 8og sheetv. P -(

4.2.2 63uipment *tatutory,ll e3uipment as stated in P-(

4.2.% 9*6 Re3uirementi. :ire 6;tinguisherii. *afety !arricade surrounding area pump to !e

tested

4.2.7 Toolsi. <i!ration analysis.ii. Temperature -nfrared Ray =T-R>iii. Tachometeriv. : ey or : tool

4.2.4 Man Poweri. -nspector Rotating



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ii. Operator

iii. 6lectrical and -nstrument *upervisoriv. Mechanical

4.2. Chec list activity

i. :inal pump alignment must !e completed

ii. Motor no"load run =solo"run> test has !een

completed.

iii. Mae sure coupling has !een installed properly

iv. Coupling guard is installed and securelyfastened

v. 6nsure suction strainer are installed

vi. ,ll spring support loc on the pipe system line

are removed

vii. The unit must have a safety !arricade

surrounding prior the mechanical running test

is performed.

viii. 6nsure that the pump mechanical running test

lines =test 8oop> has !een checed as per

mar"up P-(.

i;. 6nsure the fire e;tinguisher is presented near

the unit

x. Mae sure that vessel or *ump has !een filled

with the li3uid at normal level.

;i. Mae sure mechanical seal pump is manually

!eing water flushed !efore the pump start

running. :or vertical !arrel pump$ ensure li3uid

has !een filled into the !arrel with the vent line

in open condition.



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xii. ?ust !efore the running test for the units driven

!y electric motor$ the motor to !e run for a

moment to chec for correct shaft rotation of

the pump unit.

xiii. Measuring tools and accessories are re3uired

to !e set properly

xiv. Operation log sheet are ready to !e filled in.

xv. Person in charge for the mechanical running

from all discipline related are ready on theirposition$ for data recording and any response

re3uired.

5.3 PUMP RUNNING PROCEDURE

Pump will have a step"!y"step procedure for running. These

procedures will !e provided as a checlist prior to run the unit.

6ach items listed on the step"!y"step procedure to !e confirmed

or mutually agreed !y R6@M,8 and PMT $ refer to ,ppendices .

5.4 ACCEPTANCE CRITERIA

Mechanical running test shall !e conducted as general for 27

=twenty four> hours running continuously and log operating data

every two hour intervals$ this will !e done after the oil

temperature on the !earing housing are sta!ili#ed. :or pump

without the recycle lines can !e tested depend on woring

avai!ility of the inventory A process li3uid.



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(uring the running test$ the following re3uirements shall !e met.

5.4.1;IBRATION

Bnless otherwise specified !y vendor. Bnfiltered vi!ration

levels measured on the !earing housings shall not e;ceed

the value given !elow

• :or centrifugal pump which follow the ,P- 1& /th

6dition. Ma;. unfiltered vi!ration %.& mmAs =&.12

inAs> RM*.

• <ertical *uspended pump which follow the ,P- 1&

/th 6dition. Ma;. unfiltered vi!ration 4.& mmAs = &.2

inchAs> RM*.

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 reuired and mutuall!

agreed upon.

3. "ll the vibration check and recording will be done

as per "#$ %&' (inth edition section ).*.+



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5.4.2BEARING TEMPERATURE (Recheck to Vendor

recommendation)

,ll pumps$ motors shall operate within the following !earing

temperature limits =as per "#$,%&' para. ).&'.2- unless otherwise

specified b! manufacturer

• :or pressurised system$ oil outlet temperature !elow

&&

C =1&&

:>

• :or ring oiled or spash system$ oil sump temperature

!elow +2&C =1+& &:>

5.4.3Re%a8%%':

Running mechanical test run$ pump shall continuously run for 27hours without any interruption$ especially for pump withminimum flow facilities.

5.5 TEST SC!EME AND C!EC" S!EET

Test scheme =!y mared up P-(> and chec sheet to !e

prepared and su!mitted =attached> when issue application for

the testing of respectively pump. These document will !e part of

Test Report$ refer to chec sheet MCC"2/.



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APPENDICES 1

LIST OF PUMPS ?!IC! REUIRE MEC!ANICAL RUNNING

TEST

No. E"#$%&en' no. Na&eRe&a()

1 P*42+0P(o#,e Wa'e( T(an-e(

P#&% W$'h &$n$&#& /low

2 P*42+P(o#,e Wa'e( T(an-e(

P#&%W$'h &$n$&#& /low

P*4270P(o#,e Wa'e( T(an-e(

P#&%W$'h &$n$&#& /low

4 P*4240 AIG/ V*4220 Re,$(,#la'$on

P#&%W$'h &$n$&#& /low

P*4240 BIG/ V*4220 Re,$(,#la'$on

P#&%W$'h &$n$&#& /low

+ P*420 AIG/ V*420 Re,$(,#la'$on

P#&%

W$'h &$n$&#& /low

7 P*420 BIG/ V*420 Re,$(,#la'$on

P#&%W$'h &$n$&#& /low

P*1+20 A Slo% O$l T(an-e( P#&% W$'h &$n$&#& /low

9 P*1+20 B Slo% O$l T(an-e( P#&% W$'h &$n$&#& /low

10 P*1410 S3PS Boo-'e( P#&% W$'h &$n$&#& /low



1 P*1000 /a-' 3oo% P#&% S)$ W$'h &$n$&#& /low

14 P*2000 e' M$5 P#&% S)$ W$'h &$n$&#& /low

1 P*1200 6(#e P#&% W$'h &$n$&#& /low

1+ P*+900 O$l! Wa'e( P#&% W$'h &$n$&#& /low

17 P*+910 O$l! Wa'e( P#&% W$'h &$n$&#& /low1 P*+940 O$l! Wa'e( P#&% W$'h &$n$&#& /low

19 P*427 P(o#,e Wa'e( Re,$(,#la'$on W$'h &$n$&#& /low

20 P*420 P(o#,e Wa'e( Re,$(,#la'$on W$'h &$n$&#& /low

21 P*410 San Wa-h T(an-e( W$'h &$n$&#& /low

22 P*420 San Wa-h T(an-e( W$'h &$n$&#& /low

No'e $



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Pump system with minimum flow facility can !e tested for 27 hours

and agreed !y all parties

APPENDICES 1 o0'%0)e9LIST OF PUMPS ?!IC! REUIRE MEC!ANICAL RUNNING

TEST

No. E"#$%&en' no. Na&eRe&a()

2 P*40e' P#&% o San Wa-he(

S!-'e& Non ele,'($,*($en &o'o(

24 P*1+10 A Slo% O$l S#&% P#&% W$'ho#' &$n. low

2 P*1+10 B Slo% O$l S#&% P#&% W$'ho#' &$n. low

2+ P*+ AEl#en' D$-,ha(8e S#&%

P#&%

W$'ho#' &$n. low

27 P*+ BEl#en' D$-,ha(8e S#&%

P#&%W$'ho#' &$n. low

2 P*+ 6El#en' D$-,ha(8e S#&%

P#&%W$'ho#' &$n. low

29 P*+20 A TPI*2 S#&% P#&% W$'ho#' &$n. low

0 P*+20 B TPI*2 S#&% P#&% W$'ho#' &$n. low

1 P*+20 6 TPI*2 S#&% P#&% W$'ho#' &$n. low

2 P*+40 A TPI*2 Wa'e( P#&% W$'ho#' &$n. low

P*+40 B TPI*2 Wa'e( P#&% W$'ho#' &$n. low

4 P*+40 6 TPI*2 Wa'e( P#&% W$'ho#' &$n. low

P*+9 A S'o(& Wa'e( S#&% P#&% W$'ho#' &$n. low

+ P*+9 B S'o(& Wa'e( S#&% P#&% W$'ho#' &$n. low

7 P*+20 A Rel$e 3$"#$ P#&% W$'ho#' &$n. low

P*+20 B Rel$e 3$"#$ P#&% W$'ho#' &$n. low

9 P*74 A 6lo-e D(a$n S#&% P#&% W$'ho#' &$n. low

40 P*74 B 6lo-e D(a$n S#&% P#&% W$'ho#' &$n. low

41 P*7496lo-e D(a$n S#&% Ra$n

Wa'e( P#&%W$'ho#' &$n. low

No'e $



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Pump system without minimum flow facility will !e tested as re3uired

and agreed !y all parties.

APPENDICES 2

MAR"-UP PID FOR PUMP MEC!ANICAL RUNNING TEST LOOP

FOR 23 "BD ONL@



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APPENDICES 3

OPERATION LOG S!EET



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APPENDICES 4

;IBRATION MONITORING S!EET



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APPENDICES 5

ELECTRIC MOTOR DRI;EN CENTRIFUGAL PUMP

C!EC"S!EET AND TESTING RECORD



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APPENDICES #

S'e+ 8: &'e+ S'a' )+ Poe9)e

method manual mechanical pump test run

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