DOCUMENT NO.

PT Caltex Pacific Indonesia

REV.

SP-ME-ME-002
DATE :

1
1
OF

October 9, 2001
Nurhasan Nurhasan Shawn

SHEET :

22

SPECIFICATION

PREPARED BY CHECKED BY APPROVED BY

NHS NHS SPD

ABOVE 500 HP CENTRIFUGAL PUMPS SPECIFICATION (API)

PT. CALTEX PACIFIC INDONESIA

REV

DATE

PAGES

DESCRIPTION

PREPD

CHKD

APPD

0 1

10/9/01 15/5/02

ALL ALL

ISSUED FOR IMPLEMENTATION CPI SPEC REVIEW TEAM (TRB, TOTO, FIB, SKMT, BBA, TJG, MIRS)

NHS Team

NHS Team

SPD Team

TABLE OF CONTENT 1. GENERAL .......................................................................................................................... 3 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7. 2. Scope........................................................................................................................ 3 Terminology.............................................................................................................. 3 References................................................................................................................. 3 Conflicting Requirements ........................................................................................... 4 Definitions ................................................................................................................ 4 Vendor Responsibilities.............................................................................................. 4 COMPANY Responsibilities ....................................................................................... 5

BASIC DESIGN .................................................................................................................. 5 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 2.10. 2.11. General..................................................................................................................... 5 Pressure Casings....................................................................................................... 6 Nozzles and Miscellaneous Connections...................................................................... 6 Rotating Elements...................................................................................................... 6 Wear Rings ............................................................................................................... 7 Mechanical Shaft Seals.............................................................................................. 7 Dynamics.................................................................................................................. 8 Bearings and Lubrication........................................................................................... 8 Lubrication ............................................................................................................... 8 Materials .................................................................................................................. 9 Drivers ..................................................................................................................... 9

3.

ACCESSORIES................................................................................................................. 10 3.1. 3.2. 3.3. 3.4. Couplings and Guards............................................................................................. 10 Baseplates/Skids...................................................................................................... 10 Instrumentation....................................................................................................... 11 Piping..................................................................................................................... 14

4.

FABRICATION................................................................................................................. 14 4.1. 4.2. General................................................................................................................... 14 Casting................................................................................................................... 14

5. 6.

COATING AND PAINTING............................................................................................. 15 INSPECTION AND TESTS............................................................................................... 15 6.1. General................................................................................................................... 15

PT. CALTEX PACIFIC INDONESIA

Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

6.2. 6.3. 7. 8. 9.

Inspection ............................................................................................................... 15 Testing.................................................................................................................... 16

PREPARATION FOR SHIPMENT................................................................................... 18 INSTALLATION , START UP AND COMMISSIONING................................................ 20 VENDORS GUARANTEE............................................................................................... 20 9.1. 9.2. Mechanical............................................................................................................. 20 Performance ........................................................................................................... 21

10.

INSTRUCTION TO VENDOR.......................................................................................... 21

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1:

Project Specific Clarifications & Requirements

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

1.

GENERAL 1.1. Scope 1.1.1. This Specification covers the minimum performance requirements for heavy duty electric motor-driven, single or multistage, horizontal or vertical, general refinery services. Generally, this specification is applicable to pumps which meet any of these conditions: 1) require reliability, 2) are greater than 500 BHP, 3) operate at equal or greater than 3600 RPM, 4) operate at greater than 250 F, 5) are required to pump with low NPSHA, 6) pump flammable stocks, or 7) pump hazardous or corrosive stocks.

1.1.2.

1.2.

Terminology In this specification, the following words and terms shall have the meanings hereby assigned to them, unless noted otherwise. 1.2.1. COMPANY Refer to PT. CALTEX PACIFIC INDONESIA, as the user and owner, the authorized representative of COMPANY or COMPANY third party inspection. 1.2.2. CONTRACTOR Refers to company selected by COMPANY, which may be responsible for the detailed engineering design, material and equipment procurement, and construction as specified in Contract, Scope of Work, or Work Order. 1.2.3. Vendor Refers to company selected by COMPANY or CONTRACTOR, which is responsible for the purchase agreement or purchase order of the goods/services specified in this specification. Note : ? ? For EPC (Engineering, Procurement and Construction) project purposes: The terminology shall have the meanings as above. ? ? For Direct Procurement by COMPANY purposes: Vendor shall also be responsible as CONTRACTOR.

1.3.

References 1.3.1. Related Specification PP-PC-GG-003 PP-PC-GG-004 SP-EL-EE-006 SP-IN-II-002 SP-ME-ME-025 Shipping and Traffic Instruction Packing and Marking Instruction Induction Motor 200 HP and above Instrument with Package or Mechanical Unit Coating and Painting Specification

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

PP-QC-GG-003 PP-QC-GG-006 1.3.2. Code and Standard

Inspection and Test at Shop Welding Procedure

The publications listed below form parts of this specification. Each publication shall be the latest editions and addendum in effect on the date of this specification is issued for construction unless noted otherwise.
? ? API-610 ? ? API-670

Centrifugal Pumps for General Refinery Services Non-contacting Vibration and Axial Position M onitoring Accelerometer-Based Vibration Monitoring Systems Lubrication, Shaft-Sealing, and Control Oil Systems for Special Purpose Applications. Quality Standards for Steel Castings and Forgings and for Valves, Flanges and Fittings, and Other Piping Components. Magnetic Particle Examination Method. Quality Standards for Steel Castings and for Valves, Flanges and Fittings, and Other Piping Components Radiographic Examination Method. Quality Standards for Steel Castings and for Valves, Flanges and Fittings, and Other Piping Components Radiographic Examination Method - Liquid Penetrant Examination Method.

Systems
? ? API-678 ? ? API-614 ? ? MSS-SP-53

? ? MSS-SP-54

? ? MSS-SP-93

? ? NACE MR0175 National Association of Corrosion Engineers

1.4.

Conflicting Requirements Should conflicts exist between this specification and other referenced documents, the following order of precedence shall govern : ? ? Purchaser order ? ? Data sheets ? ? This specification ? ? Other referenced specifications ? ? Approved for Construction Drawings

1.5.

Definitions (Addition to paragraph 1.4.12 of API-610) Suction specific speed shall be calculated at the best-efficiency flow with the maximum impeller diameter as defined in paragraph 2.1.1 of this specification, and paragraph 2.1.1 of API 610.

1.6.

Vendor Responsibilities Vendor is responsible for supplying complete units which perform to this specification at the job site. Vendor is also responsible for assuring that its subvendors (e.g., motor, coupling, variable frequency motor-speed controller, pressure lubrication system) and

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

supplie rs meet their obligations as stated by Vendor. Pump Vendor shall assume unit responsibility. Unit responsibility refers to the responsibility for coordinating the technical aspects of the equipment and all auxiliary systems included in the scope of the purchase order. 1.7. COMPANY Responsibilities COMPANY responsibilities include: 1.7.1. 1.7.2. 1.7.3. 1.7.4. 1.7.5. Earthwork necessary for installation of the pump(s) and driver(s). Procurement and installation of the Vendor-designed foundation(s) based on 1000 psf soil bearing capacity. Transportation within Indonesia and installation of the pump(s) and driver(s) on the foundation(s). Design, procurement and installation of suction and discharge piping. Design, procurement and installation of electrical power, control or instrumentation items up to terminal connections on the driver or variable frequency motor-speed controller, as applicable. Prompt review and return of drawings submitted in accordance with paragraph 5.1 of this specification.

1.7.6.

2.

BASIC DESIGN 2.1. General 2.1.1. (Addition to paragraph 2.1.1 of API-610) Pumps that have a suction-specific -speed (Nss) greater than 11,000 are not acceptable. The proposed pump shall not exceed its maximum horsepower requirement at any point in the stated operating range. (Addition to paragraph 2.1.4 of API-610) Impelle r diameters shall not exceed 95% of the maximum diameter. (Addition to paragraph 2.1.11 of API 610) Parallel operation design is required. Curves shall continuously rise to 110% to 120% of the rated head at shut off. (Addition to paragraph 2.1.13 of API-610) COMPANY desires pumps which will not produce noise which may cause hearing impairment, speech interference, or be a public nuisance. Pump Sound Pressure Levels (SPL) at any location 3 feet from the pump and its connecting piping shall not exceed the following values: Octave Band Center Frequency (HZ) 31 63 125 250 Maximum SPL dBA (ref 0.0002 microbar) 100 96 92 90

2.1.2. 2.1.3. 2.1.4.

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

500 1000 2000 4000 8000

90 90 90 90 90

Vendor shall provide evidence of compliance with noise limits for all pumps and motors. This requirement may be satisfied by submitting certified noise test data obtained at Vendor's plant or noise test data obtained on a unit of identical design and construction running under rated load conditions in an existing plant. 2.1.5. 2.1.6. 2.1.7. (Addition to paragraph 2.1.14 of API-610) High energy pump dynamic heads shall be limited to 650 feet per stage. (Exception to paragraph 2.1.17 of API-610) No cooling water is available. (Addition to paragraph 2.1.29 of API-610) The pump and driver will be installed inland, out-of-doors in Sumatra, Indonesia. Site conditions are shown on the data sheets.

2.2.

Pressure Casings 2.2.1. (Exception to paragraph 2.2.3 of API-610) The maximum allowable working pressure shall apply to all parts referred to in the definition of pressure casing (see paragraph 1.4.19 of API 610 ). The Splitter with the function to prevent turbulence effect when the pumping fluid flow to the rotating element. The placement of splitter may be on the casing or impeller element zs per specified on the data sheet.

2.2.2.

2.3.

Nozzles and Miscellaneous Connections 2.3.1. (Exception to paragraph 2.3.1.3.2 of API-610) Flat-faced flanges are not acceptable on casings other than cast iron. Flat-Faced cast iron case flanges shall be supplied with mating flat-faced carbon steel (ASTM A105) pipe flanges of equal or greater operating and hydrostatic test pressure ratings. (Addition to paragraph 2.3.2.10 of API-610) Tapped connections (NPS 3/4 minimum) shall be provided to insure complete draining of horizontal pump casings and case-to-bearing bracket. Casing vents (NPS 3/4" minimum) are required unless the pump has a self-venting nozzle design. All tapped nozzles and piping shall be fabricated from 316SS pipe.

2.3.2.

2.4.

Rotating Elements 2.4.1. 2.4.2. (Addition to paragraphs 2.5.1 of API 610) Repelling vane construction is not acceptable. (Exception to paragraph 2.5.4 of API 610) Impellers for multistage pumps shall be individually secured against axial movement in either direction along the shaft. Interference fits alone are not considered adequate axial mechanical restraint.

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

2.5.

Wear Rings 2.5.1. 2.5.2. (Addition to paragraph 2.6.4 of API-610) Materials of construction for multistage pump close clearance parts shall resist galling. (Addition to paragraph 2.6.4.1 of API-610) When the deflection of multistage pump components unavoidably equals or exceeds the running clearances, materials of construction for these close clearance parts shall resist galling. The galling resistance shall be at least equivalent to materials such as cast iron and bronze. Materials of less galling resistance are not permitted. Hardfacing over corrosion-resistant base metal is one acceptable method of providing adequate galling resistance. Final material selections shall be subjected to COMPANY review. (Addition to paragraph 2.6.6 of API-610) All actual, assembled running clearances shall be measured and documented and be available for COMPANY review prior to performance testing.

2.5.3.

2.6.

Mechanical Shaft Seals 2.6.1. (Addition to paragraph 2.7.1.2 of API-610) Hydraulically balanced seals shall be furnished and installed. These seals shall provide 12 months of zero leakage minimum. Vendor is responsible for assuring a reliable seal design. Acceptable manufacturers are: BW/IP, Durametallic, Flexibox and John Crane (BW/IP is preferable). (Addition to paragraph 2.7.1.7 of API-610) Flush 316SS, vent and drain connections shall be provided in the gland plate. These connections shall lead to the seal chamber. (Addition to paragraph 2.7.1.12) The mechanical seal chamber shall operate at a minimum of 25 psi above the pumped fluid's normal vapour pressure to preclude entry of air. Pumps with inboard and outboard bearings shall have cartridge mechanical seals. Bellow materials shall be AISI 316 stainless steel as a minimum when hydrogen sulfide or chlorides are present, bellows materials shall be hastelloy C. Gasket materials shall be viton as a minimum. For stuffing box temperatures above 400?F (204?C), gasket materials shall be graphite foil. Gasket materials shall be kalrez when hydrogen sulfide is present. Seal face material shall be tungsten carbide against carbon steel faces shall not be overlay construction. All mechanical seal parts (including external and plates) shall be, as a minimum, 300-series stainless steel suitable for the liquid being pumped. When hydrogen sulfide or chloride are present, the material shall be hastelloy C. All seal piping shall be, as a minimum, inch outside diameter (OD), 316 stainless steel tubing with 316 stainless steel tube fittings. All parts of the flushing system shall be at least of quality equal to the pump casing materials.

2.6.2.

2.6.3.

2.6.4. 2.6.5.

2.6.6. 2.6.7.

2.6.8.

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

2.6.9.

(Addition to paragraph 2.3.3.11 of API 610) Vendor shall verify that possibility install tap pressure gauge on the chamber after throat bushing to prevent of the mechanical seal leakage.

2.7.

Dynamics 2.7.1. (Addition to paragraphs 2.8.1.2 of API-610) For systems with a wet lateral critical speed below the maximum continuous running speed, critical speed amplification factors shall be measured during coast down. Critical speeds shall be test-stand confirmed and lateral critical speed vibration analysis are required. (Addition to paragraph 2.8.4.1 of API-610) Dynamic balancing of the rotating element shall be done after the addition of each major component. Balance correction shall only be applied to the element added. Final assembled rotor balance of pumps shall be documented per Specification MNS-REF-022, Standard Procedure for Determination of Residual Unbalance. All impeller and rotor balancing shall be documented. Documentation shall be submitted to the COMPANY. 2.7.3. (Addition to paragraphs 2.8.4.7 and 2.8.4.8 of API-610) Filtered vibration measurements shall also be made and the results recorded for frequencies of twice running speed and at any dominant sub-synchronous frequencies (defined as greater than 10% of the running frequency amplitude). (Exception to paragraph 2.8.4.13 of API-610) During the factory performance test, Vendor shall demonstrate that the pump can operate from the quoted minimum continuous stable flow to 110% of rated flow without exceeding the specified vibration limits of API-610 paragraphs 2.8.4.7. or 2.8.4.8.

2.7.2.

2.7.4.

2.8.

Bearings and Lubrication 2.8.1. (Addition to paragraph 2.9.1.1 of API-610) Reworked or reconditioned bearings are not acceptable. Recommended antifriction bearings Manufacture are FAG and SKF. (Addition to p aragraph 2.9.1.7 of API-610) Replaceable thrust collars shall be provided when axial position or thrust pad temperature monitoring systems are not installed. (Addition to paragraph 2.9.2.2 of API-610) Trico Optomatic oilers shall be provided. The Pump Vendor shall supply all necessary fittings on bearing housing for future oil mist feed and drain. (Addition to paragraph 2.9.2.9 of API-610) Oil fill holes may double as viewing ports if the oiling rings are clearly in sight.

2.8.2.

2.8.3. 2.8.4. 2.8.5. 2.9.

Lubrication 2.9.1. (Addition to paragraph 2.10.1 of API-610) Oil cooling, if required, shall be by air cooling. Cooling water is not available.

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

2.9.2.

(Addition to paragraph 2.10.2 of API-610) All non-pressure lubricated sleeve bearings shall be ring oil lubricated. The ring submergence shall be a minimum of 1/4-inch above the lowest point of the oil rings' internal diameter when the bearing housing oil sump is at its normal level. Oil rings and bearing housings shall be designed so that rings will not become locked or dislocated if the pump is rolled over or held in an unnatural position while being transported. Splash or flood lubrication systems are not acceptable. (Exception to paragraph 2.10.3.1 of API-610) When forced circulation or pressure lubrication is provided, it shall be either the Vendor's standard system or in accordance with Specification MNS-REF-023, General Purpose Pressure Lubrication Systems, whichever is more stringent. The Vendor shall coordinate the lubrication system requirements for pressure-lubricated pump/motor systems.

2.9.3.

2.10.

Materials 2.10.1. 2.10.2. (Addition to paragraph 2.11.1.8 of API-610) Process fluid conditions are shown on the MNS-REF-019. (Addition to paragraph 2.11.2.3.1 of API-610) All major weld repairs shall be 100% radiographed. Major weld repairs include: ? ? those exceeding 10 square inches. ? ? those exceeding 20% of the casting thickness or, ? ? those resulting from hydrostatic test failure. All non-destructive examinations shall be witnessed by COMPANY's inspector. 2.10.3. (Addition to paragraph 2.11.3.7.1 of API-610) Major attachment weld to pressure casings (such as suction and discharge nozzle welds) shall be radiographed. Vendor shall submit drawings showing major attachment weld design, size, materials, and preheat and postheat treatments. Weld procedure qualification records and welder qualifications shall be made available for review by COMPANY's inspector.

2.11.

Drivers 2.11.1. 2.11.2. (addition to paragraph 3.1.4 API-610) Motor drivers 200 HP and above shall be provided in accordance with specification SP- SP-EL-EE-006. Regardless of API 610 requirement, the brake horsepower within 70 120 % of best efficiency capacity on the performance curve shall not exceed the motor nameplate rating. The Vendor shall also quote an alternate motor that will not be overloaded at any point of the performance curve on the maximum diameter impeller. Jack bolts shall be installed on Motors 150 HP and larger. Drive system shall be designed to start and accelerate pump to full-load speed with an open discharge valve. (addition to paragraph 3.1.1 API-610) Gas engine or diesel engine Drivers may be used and shall be a minimum of 110 percent of the maximum horsepower

2.11.3. 2.11.4. 2.11.5. 2.11.6.

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

required for any operating condition. However, the driver system for pumping unit shall be as per specified on the data sheet. 2.11.7. 2.11.8. (addition to paragraph 3.1.10) Gear units shall h ave the minimum horsepower equal to the rated horsepower of the driver Pump driven by variable speed drivers shall be designed to operate continuously at any speed regulated by speed controllers, and to operate briefly, under emergency condition, up to the trip speed.

3.

ACCESSORIES 3.1. Couplings and Guards 3.1.1. (Addition to paragraph 3.2.2 of API-610) Horizontal pumps shall be provided with flexible disk-pack couplings having stainless steel disks. Flexible disk-pack couplings shall have a spacer which provides at le ast 7 inches between the shaft ends. (Addition to paragraph 3.2.5 of API-610) Coupling-to-shaft fits shall be tapered and keyed for applications requiring 250 BHP or more if hub removal is required for seal maintenance regardless of horsepower. Disk-pack couplings shall have a minimum service factor of 1.5. (Addition to paragraph 3.2.7 of API-610) Couplings shall be dynamically balanced and all sections of each coupling will be marked to identify each piece of the respective coupling. (Addition to paragraph 3.2.14 of API-610) A coupling guard shall be fabricated, trial fitted and shipped loose. The guard shall conform to MNS-REF-021. The filler material shall be woven wire with openings no larger than 3/8-inch and wire no smaller than No. 16 (US standard gauge).

3.1.2.

3.1.3.

3.1.4.

3.2.

Baseplates/Skids 3.2.1. 3.2.2. 3.2.3. (Addition to paragraph 3.3.1.3 of API-610) Final pad machining shall occur after all baseplate welding and stress relieving, if any, is completed. (Addition to paragraph 3.3.1.4 of API-610) Eight Stainless steel shim packs, a minimum of 1/4-inch thick, shall be included with each pump. (Addition to paragraph 3.3.1.7 of API-610) If specified as skid-mounted, units shall comply to this paragraph. (Addition to paragraph 3.3.1.14 of API-610) A minimal 2-inch vertical clearance shall be provided under the center of each drive element for insertion of a hydraulic jack. Alignment screws shall be provided both for pumps and driver. Two screws shall be provided at each mounting point ( minimum 1" diameter) 3.2.4. (Addition to paragraph 3.3.1.15 of API-610) Vertical levelling screws (minimum 1" diameter) shall be provided for all skids.

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

3.2.5.

(Addition to paragraph 3.3.1.18 of API-610). Four lifting pad-eyes or lugs shall be provided. If required to preclude rigging fouling, Vendor shall design, fabricate and ship a spreader bar. COMPANY will not return the spreader bar.

3.3.

Instrumentation 3.3.1. All instrumentation shall be designed for use in a Class I, Group D, Division 2 hazardous area (Zone 2). Instrumentation shall be mounted outdoors in the weather and such shall be designed for such purpose. Vendor shall provide all instrumentation necessary for proper operation of the package as described within this specification. This shall include a NEMA 4X control panel and all on skid components. The motor starter shall not be part of this specification. CONTRACTOR shall utilize specified instrumentation manufacturer as stated in this specification, or as specified in ADDENDUM-1 or Purchase Order Data Sheet Control Panel 3.3.4.1 The control panel shall be a free standing NEMA 4X panel with front and back access. In some cases, panel shall be mounted where rear access is not possible and some cases where rear access is desirable. Front and back doors shall be hinged the full length of the enclosure. The panel shall be designed to be 24" wide, 24" deep, and 72" tall. Lifting lugs shall be provide on the top of the enclosure. The purpose of the control panel is to operate and annunciate each individual pump/motor package. Two sets of spare form "C" contacts are to be available for connection to COMPANY's Central Control System for vibration alarm (pump or motor), vibration shutdown (pump or motor), temperature alarm (pump or motor), temperature shutdown (pump or motor), high oil temperature, and low oil level. The enclosure shall contain a 24 window annunciator with 1.5" by 3" windows, all Bently Nevada monitoring and shutdown equipment for each pump, there push-buttons (Lamp test, Acknowledge, Reset) for the annunciator, a "Hand-Off-Auto" selector switch, son-alert horn, necessary terminal strips, protection equipment, etc. Devices such as the annunciator and Bentley Nevada monitoring shall be located behind separate hinged plexi-glass windows. These windows shall have a maximum of two latches to seal out moisture. Latches shall be capable of being operated without tools, such as screw drivers. Power to the panel shall be 110 VAC/60Hz. A converter shall be shall be installed in the panel to provide the necessary 24 VDC for the operation of the annunciator. An amp meter shall be installed on the control panel front be used for indicating the current of each phase of the motor. A four position selector switch shall be installed next to the amp meter to select which phase or "OFF" is being indicated. All CT wiring shall be terminated on appropriated shorting terminal strips.

3.3.2.

3.3.3.

3.3.4.

3.3.4.2

3.3.4.3

3.3.4.4

3.3.4.5

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

3.3.4.6

All overcurrent protection shall utilize Airpax hermetically sealed circuit breakers. These as a minimum shall be utilized on the input and output of the power converter in the panel and the panel incoming 120VAC power. All wires (both internal and external) shall terminate on terminal strips inside the control panel enclosure. This shall include a separate terminal for each ground or shield for each signal. Terminal strips shall have a minimum 25% spare terminals. Each terminal strip shall be permanently labelled. A common ground bus shall be installed at the bottom of each enclosure. All wiring inside the control panel shall be installed in oversized panduit wire thoughs that allow excess room for field wiring. Control Panels shall be designed to allow for top entry and bottom entry cables. COMPANY will install hubs as required on the control panels. Vendor shall provide all instrumentation on the data sheets and listed herewith in. Manufactures of all instrumentation are subject to prior COMPANY approval. Inferior or low quality components will not be acceptable.

3.3.4.7

3.3.4.8 3.3.4.9

3.3.4.10

3.3.5.

On Skid 3.3.5.1 As a minimum, the following instrumentation shall be supplied and installed by Vendor on the pump/motor package skid :
? ? Lube oil temperature indic ation, alarm and shutdown sensors; ? ? Lube oil low level indication, alarm and shutdown sensors.

3.3.5.2 For multistage pumps with hydrodynamic thrust bearing temperature indication, alarm and shutdown sensors, a minimum of three temperature sensors (RTD of thermocouple)shall be embedded in each side in accordance with drawing MNS-REF-024. Vendor shall supply a BentleyNevada 3300, multi-channel, voting logic temperature monitor with firstout indication, continuous display of the highest channel, channel selection, channel fault disable, alarm when one sensor reaches set point, and shutdown when two of three reach set-point. 3.3.5.3 Bearing housing or dual X -Y shaft vibration monitoring system shall utilize Bentley-Nevada accelerometers or non-contact shaft probes. Axial position monitoring system shall be supplied for multistage pumps. Mountings must be rigid and free from local resonance. Vendor shall supply Bentley-Nevada 3300 monitors which will use constant velocity criteria with velocity display, dual channel voting logic, first out indication, continuous display of the highest channel, channel selection, channel fault disable, alarm and shutdown, in accordance with API-678 and API 670.Plug-in, field changeable filters will be used. Vane passing frequencies will normally be filtered. 3.3.6. Instrument Mounting

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

3.3.6.1 All driver and pump instrumentation shall be housed in suitable sized conduit boxes (Similar to Crouse-Hinds type GUJB). The depth of insertion of specific sensors shall be adjustable. Suitable sensor retention/sealing devices shall be mounted in the conduit box; the retention devices will be adjustable with the conduit box cover removed. Vendor shall determine the necessary length between the driver or pump and the conduit box required to house the sensing device. 3.3.6.2 The conduit box shall be connected to a skid mounted NEMA 4X junction box (one only) with conduit. The first 400mm of each conduit run shall be flexible interlocking metal conduit with a liquid tight PVC cover, ANACONDA "SEALTITE" or equal. Connectors for this fle xible conduit shall be liquid tight with integral insulated throats and positive external ground connections. An external ground wire, sized in accordance with NEC Table 250-95, shall be provided. The remaining portion of the conduit terminating at the junction box, shall be 3/4" rigid galvanized conduit. The end of each section shall be cut square and reamed to remove burrs before assembly. 3.3.6.3 All wiring shall be identified at each junction using printed permanent type, black on white, shrinkable plastic type markers. Adhesive backed markers are not acceptable. Only Original Equipment Manufacturer (OEM) extension cables will be used where required, suitable insulation will be applied at each junction of the extension cable(s). 3.3.6.4 (Addition to paragraph 3.4.4.1 of API-610). If specified, and as indicated on the Data Sheets DS-736, accelerometers or non-contact proximity probes shall be furnished and installed. Bentley-Nevada accelerometers shall be installed in accordance with API-678, Accelerometer Based Vibration Monitoring System, and Bentley-Nevada's instructions. Proximity probes shall be installed in accordance with API-670, Noncontacting Vibration and Axial Position Monitoring System, and Bentley Nevada's instructions (see Data Sheets). 3.3.6.5 Sleeve-bearing pumps shall have their vibration measured. If Vendorsupplied, temporarily installed proximity probes are used, vibration acceptance shall be based on the calibrated probes (criteria per paragraph 3.4.4.1 API-610). 3.3.7. Spare parts 3.3.7.1 Vendor shall provide one lot of spare components listed below. These spare parts are needed for initial start-up and commissioning of local monitoring and control panels. The cost for the spare parts shall be included in the Vendor's bid proposal. Number Description 100 2 2 2 Annunciator light bulbs 110 VAC to 24 VDC converters Bentley Nevada Vibration (acceleration) Probes Bentley Nevada Temperature Probes/RTD's of each size

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Above 500 HP Centrifugal Pumps Specification (API) SP-ME-ME-002 Rev. 1

2 2 4 2 3.4. Piping 3.4.1.

and type used Bentley Nevada 3300 Power Supply Bentley Nevada 3300 System Monitor Bentley Nevada 3300 Vibration Monitor Cards Bentley Nevada 3300 Temperature Monitor Cards

(Exception to paragraph 3.5.1.5 of API-610) For handling nonflammable or nontoxic fluids, pipe joints and connections are specified by COMPANY on the Data Sheet. Lube oil shall be considered a flammable fluid. The minimum allowable pipe size is 3/4" 316SS Sch80 NPS. (Additions to paragraph 3.5.5.1 of API-610) Carbon steel lube oil piping shall not be used. Stainless steel (316SS) piping and tubing shall be cleaned with a suitable solvent other than hydrochloric acid. Cleaning shall be performed by Vendor prior to assembly on the pump/driver.

3.4.2.

4.

FABRICATION 4.1. General 4.1.1. Unless otherwise specified and noted by COMPANY, the fabrication of rotating and static equipment shall be at the Vendor shop and shall be in accordance with the international standard. No fabrication may begin until the Vendor has received written approval of detailed fabrication drawings from the COMPANY. Shop detail drawing shall be completed with all dimensions, thickness and detail of construction including dimensional detail of weld joint and nozzles. No fabrication shall be sub-contracted without the prior written approval of the COMPANY. Material shall be as stated on the data sheet. Alternative materials may be used if advantageous with the prior approval of the COMPANY. Proposed substitutions must be clearly defined.

4.1.2. 4.1.3. 4.1.4. 4.1.5.

4.2.

Casting 4.2.1. 4.2.2. The machining, casting and other related work of rotating equipment shall be so designed and conducted to meet the required overall performance. (Addition to paragraph 2.2. of API-610) The casting material of pressurized casing shall be in accordance with ASME Sec. VIII Div.1 standard. However, the pressure casing and flanges shall be designed for the maximum discharge pressure.

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5.

COATING AND PAINTING 5.1. 5.2. 5.3. Unless otherwise specified by COMPANY, The package unit shall be painted in accordance with SP-ME-ME-025 Coating and Painting Specification. All insulated surfaces shall be provided with a prime coat of paint, as a minimum The manufacturers standard finish for elevated temperatures is acceptable only if paints are formulated from recognized heat-resistant ingredients that are adequate for the anticipated temperature.

6.

INSPECTION AND TESTS 6.1. General 6.1.1. Unless otherwise specified, Vendor shall be responsible for all inspection and testing in accordance with PP-QC-GN-003, "Inspection and Test Plan at Shop", PP-QC-GN-004, "Inspection and Test Plan at Field" Vendor shall furnish CONTRACTOR/COMPANY with copies of Vendor's Inspection and Quality Control Plan including all mentioned test records. Vendor shall submit all manufacturing, fabrication, inspection and testing procedures for CONTRACTOR/COMPANY approval at least three (3) weeks in advance of implementing the procedure. Manufacturing and fabrication shall not proceed until Vendors material inspection has been approved by CONTRACTOR/COMPANY. Materials and workmanship shall be CONTRACTOR/COMPANY in the shop. subjected to inspection by

6.1.2. 6.1.3.

6.1.4. 6.1.5.

Vendor shall be responsible for Factory Acceptance Test (FAT). All equipment, materials, consumables, utilities, and facilities for the test shall be furnished by Vendor. Welded piping shall be hydrostatically tested at 1.5 times maximum allowable working pressure (MAWP). Instrumentation system shall be shop pressure tested, functional/operational tested, and calibrated.

6.1.6. 6.1.7. 6.2.

Inspection 6.2.1. (Addition to paragraph 4.2 of API-610) Equipment will normally be inspected at the various plants. A pre-inspection meeting between the COMPANY, Vendor and major subvendors will be held before work starts to review all specifications and inspection requirements. The inspection program as part of the Vendor's QA/QC program will be established at that time. All hold-points will be established (this meeting must be held soon after Order placement so that the hold-points are shown on the schedule). Inspection may include, but not be limited to, the following:

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? ? Visual examination of castings; ? ? Witnessed repairs of castings; ? ? In-process inspection of welding; ? ? Inspection of parts before assembly; ? ? Review of material test reports and certifications; ? ? Review of weld procedure qualification records and welder qualifications; ? ? Review of running clearances documentation; ? ? Review of impeller and rotor balancing documentation; ? ? Observing or witnessing of any tests; ? ? Review of all documentation prior to releasing the complete unit for

shipping;
? ? Inspection for conformance to the Data Sheets; ? ? Visual and dimensional inspection; ? ? Checking of painting and shipping preparation; or ? ? Other inspection which is required by specifications referenced and/or

included in this Specification. 6.2.2. (Addition to paragraph 4.2.2.1 of API-610) Defects shall be judged per ASTM E446, E186, or E280 for radiography and per ASTM E125 for magnetic particle inspection or dye penetrant inspection. Unless otherwise approved by COMPANY, the maximum permissible indications shall be in accordance with MSS-SP-54 for radiography, and MSS-SP-53 for magnetic particle, and MSS-SP-93 for dye penetrant. Ultrasonic inspection procedures and acceptance criteria shall be mutually agreed upon by COMPANY and Vendor.

6.3.

Testing 6.3.1. (Addition to paragraph 4.3.1 API-610) As a minimum, the following witnessed tests shall be performed: Hydrostatic, Residual Unbalance if 2 or more stages, four hours performance, pump efficiency test, NPSH test (per API-610 paragraphs 4.3.4.1) and vibration, and post-performance dismantle if multistage. 6.3.1.1 (Exception to paragraph 4.3.1.2 of API-610) For any pump rated over 400 HP and all multistage pumps, or if requested, Vendor shall submit test agendas for review and comment at least two months prior to testing. The agendas shall include detailed procedures for all running tests, including acceptance criteria for all monitored parameters, a description of the test loop setup and instrumentation. 6.3.1.2 (Exception to paragraph 4.3.1.3 of API-610) Vendor shall notify COMPANY (and COMPANY's inspector) not less than ten working days in advance of a witnessed or observed test. If a test is rescheduled, not less than ten working days notice shall be given in advance of the new test date. In addition to the COMPANY's Inspector, test notification shall be telexed to COMPANY's Inspection Group - Jakarta and

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Procurement Minas OU - Pekanbaru, Procurement Bekasap OU, or Procurement Duri OU. 6.3.2. Hydrostatic Test (Addition to paragraph 4.3.2 of API-610) The gaskets used during hydrostatic tests shall be identical to those supplied with the pump. Leaks pass gasketed areas are unacceptable. 6.3.3. Performance and Vibration Tests 6.3.3.1 (Addition to paragraph 4.3.3.1.1 of API-610) Seals purchased for this Specification shall be used for all tests. There shall be no leakage during stationary pressurization, startup, or running tests. When tilting pad (Kingsbury type) thrust bearings are provided, the temperature of a minimum of two pads on each side (active and inactive) of the bearing shall be recorded at each data point. When hydrodynamic thrust bearings are supplied with pumps of three or more stages, Vendor shall demonstrate that the thrust loading does not exceed 50% of the bearing's continuous rating over any part of the operating range. Vendor shall use load cells or another method approved by COMPANY. Thrust bearing pad temperatures shall not exceed 200F or 75F above the lube oil inlet temperature, whichever is less. 6.3.3.2 (Addition to paragraph 4.3.3.1.2 of API-610) For pumps/motors provided with pressurized lube oil systems, lube oil flow and pressure as well as inlet and drain temperatures shall be recorded at each mechanical test data point. Lube oil temperatures during running tests shall not exceed 180?F or 70?F above the specified ambient temperature, whichever is less. Radial bearing metal temperatures shall not exceed 180?F. For pressurized lube oil systems, the maximum radial bearing temperature rise shall not exceed 50?F at the most adverse operating condition. If the temperature exceeds the above values, the cause shall be corrected and the entire test repeated. Lube oil inlet temperatures shall be varied during the performance mechanical tests. The temperature range shall not be less than that allowed in the Vendor's operating manual for the pump. 6.3.3.3 (Addition to paragraph 4.3.3.2.1 of API-610) The pump suction pressure during performance and vibration tests shall not exceed the rated suction pressure specified on the Data Sheet. The pump shall be run at least two hours after bearing temperatures have stabilized (the first 15 minute interval during which the bearing temperature changes no more than two degrees F). A complete set of mechanical data shall be recorded every 15 minutes and at every performance test point. As a minimum, the test points shall cover 0%, 25%, 50%, 75%, 100%, 110%, 120% of the rated flowrate. 6.3.3.4 (Addition to paragraph 4.3.3.3.1 of API-610) During the performance test, all vibration measurements specified in paragraph 2.8.2.2 or 2.8.2.3 of API-610 shall be made and the results recorded on the test log at the following pump operating points:
? ? Minimum specified operating capacity (20% of rated capacity if not

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specified on the data sheet);

? ? Midway between the minimum operating capacity and rated capacity

(75% of rated capacity if not specified on the data sheet);

? ? rated capacity; and Maximum specified operating capacity (110% of

rated capacity if not specified on the data sheet).

? ? If the pump is purchased with a variable frequency motor-speed

controller, vibration measurements shall be recorded continuously (strip chart or equal) from the minimum continuous flow to the maximum specified operating capacity.
? ? If the pumps are purchased with probes, these shall be used for

vibration tests. If the pumps are purchased with accelerometers, these shall be used for vibration tests unless Vendor-supplied temporary probes are specified. Temporary probe or accelerometer tests may also be specified for pumps purchased with neither probes nor accelerometers. Sleeve-bearing pumps shall have vibration measured on the bearing housings with accelerometers if the speed is 1200 rpm or less, otherwise on the shaft with probes. Rolling element pumps shall have vibration measured with accelerometers.
? ? If Vendor-supplied, temporarily installed proximity probes are used,

vibration acceptance shall be based on the calibrated probes (criteria per paragraph 2.8.4.8 of API-610). Vendor shall record unfiltered vibration and vibration filtered at running speed, twice running speed, and vane passing frequencies. The name, model number, and latest calibration date of the transducers and analyzer used for vibration measurements shall be recorded on the test log. When proximity probes are used, Vendor shall measure and record the slow-roll run out at each probe. 6.3.3.5 (Additions to paragraph 4.3.3.4.3 of API-610) Vendor shall open and check the pumps for evidence of internal rubbing and sleeve bearing damage following performance tests. There shall be no measurable dimensional change or metal transfer in the bearings or close clearance parts. After the cause of any rubbing is corrected, the pump shall be run again and rechecked. Pumps need not be run again if no evidence of rubbing or other defects are found upon disassembly. 6.3.4. NPSH Test (Addition to section 4.3.4.1 of API-610) At no additional cost, a witnessed NPSH test is required for all previously untested impeller patterns. It is also required when the difference between the specified NPSH availa ble and NPSH required is 4 feet or less. Suction valve throttling is not acceptable. 7. PREPARATION FOR SHIPMENT 7.1. Unless otherwise noted in the COMPANYs Request for Proposal and/or Purchase Order, Preparation for shipment shall be in accordance with PP-PC-GG-001, Transportation Packaging of Equipment (General Requirement for Reservation and Protection), PP-PC-

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GG-003 Shipping and Traffic Instruction, PP-PC-GG-004 Packing and Marking Instruction. 7.2. All components (individual pieces, as well as packaged sets) shipped with mounted preassembled piping, tubing, or wiring shall with OSHA requirements and shall carry outside securely affixed large, red, all-weather tags stating the following in bold letters: THIS SYSTEM HAS BEEN REASSEMBLED AND TESTED FOR OPERABILITY AND SAFETY, COMPLIES WITH ALL REQUIREMENTS OF OSHA AND SHALL NOT BE DISTRIBUTED BY UNAUTHORIZED PERSONNEL. Assembly and preparation for shipment shall be in accordance with Vendors standards and as noted herein. Vendor shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers. Each major component shall be properly identified with item and serial numbers. All material shipped separately shall be properly tagged or marked with the item and serial number for which it is intended. Immediately after final testing and prior to shipment, equipment shall be drained, dried and cleaned thoroughly of all grease, loose scale, rust, flux, weld splatter and rubble, both internally and externally. Adequate protection shall be provided against mechanical damage and atmospheric corrosion in transit, and for mutually acceptable period of outdoor storage at job site before installation. Preparation for shipment and packing will be subject to inspection and rejection by COMPANYs inspectors. All costs occasioned by such rejection shall be to the account of the CONTRACTOR. Equipment shall be packed, securely anchored, and skid mounted when required. All items, which can be damaged by water, shall be securely wrapped in waterproof paper or plastic before placed in wooden crates. Bracing, support, and rigging connections shall be provided to prevent damage during transit, lifting, or unloading. Flanged openings shall be protected with metal cover plate to prevent damage during shipment. Covers shall be a minimum of thick and shall be installed with full size rubber-gasketted metal or wood closure using minimum of 4 full diameter bolts. Large diameter flanges will require enough full diameter bolts to set the cover all around. The cover and flange shall be taped for waterproof protection. Open end of pipe shall be capped for protection. The cap shall be removable. Female threaded connection shall be plugged with solid metal pipe plugs, and male threaded connections shall be protected with full metal pipe caps. Separate, loose and spare parts shall be completely boxed. Piece of equipment's and spare parts shall be identified by item number and service and marked with COMPANYs order number, tag number, and weight, both inside and outside of each individual package or container. Exposed finished and machined surfaces, including bolting, shall be given a coating of rust

7.3.

7.4.

7.5.

7.6.

7.7.

7.8.

7.9. 7.10. 7.11. 7.12.

7.13. 7.14. 7.15.

7.16.

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inhibiting compound. Internal metal surfaces shall be sprayed or coated with a suitable rust preventive prior for shipment. Opening shall be suitably tagged to indicate the rust preventive applied. 7.17. 7.18. Mechanical seal assemblies (if any) shall be fully protected from rusting and entry of moisture and dirt. One complete set of the installation, operation, and maintenance instructions shall be packed in the boxes or crate with equipment. A recommended spare part list for 2 years operation shall be included also. No equipment shall be released for shipment from Vendors shop until inspection release has been issued from CONTRACTORs inspector. Vendor shall provide COMPANY the instruction that necessary to preserve the integrity of the storage preparation, after the equipment arrives at the job site and before startup.

7.19. 7.20.

8.

INSTALLATION , START UP AND COMMISSIONING 8.1. 8.2. Vendor shall present his representatives to assist start up and commissioning upon request by COMPANY. Vendor shall submit complete parts lists for all equipment and accessories supplied. The lists shall include Manufacturer's unique part numbers, materials of construction, and delivery time. Well in advance of shipping, Vendor shall prepare detailed installation instructions, precommissioning checklists, and job site test agendas for COMPANY approval. These stepby-step instructions, checklists and test agendas shall be comprehensive and describe all steps necessary for: 1) COMPANY to install the complete unit to the foundation, 2) COMPANY and Vendor commissioning engineer to verify completion of all precommissioning procedures, and 3) COMPANY and Vendor commissioning engineer to verify that all hydraulic, mechanical, vibration, and electrical performance criteria are met. The preparation of these documents shall be included in the Lump Sum Amount. Vendor is responsible for any deficiencies in hydraulic, mechanical, vibration, or electrical performance at the job site. If specified, COMPANY will prepare a Supplemental Agreement to the Purchase Order for the services of Vendor's commissioning engineer. The basis for this Agreement will be Vendor's proposal received with his Base Proposal. All commissioning engineers contracted under a Supplemental Agreement shall be competent, experienced (5 years minimum), factory trained, and certified. The commissioning engineer shall come equipped with all special tools and information required to expeditiously perform his work per the COMPANY -approved precommissioning checklist and job site test agenda. Specia l tools may include

8.3.

8.4.

8.5.

9.

VENDORS GUARANTEE 9.1. Mechanical

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9.1.1.

All equipment and component parts shall be warranted by the Vendor against defective materials, design, and workmanship for 1 year after being placed in service (but not more than 18 months after date of shipment) If any mal-performance or defects occur during the guarantee and warranty period, the Vendor shall make all necessary alterations, repairs, and replacement free of charge, free on COMPANY warehouse. Field labor charges, if any, shall be subject to negotiation between the Vendor and the COMPANY.

9.1.2.

9.2.

Performance Unless exception is recorded by the Vendor in his proposal, the equipment shall be guaranteed for satisfactory performance at all operating conditions specified on the data sheet.

10.

INSTRUCTION TO VENDOR 10.1. 10.2. Vendors proposal shall be in strict accordance with this Specification, the Pump Data Sheet and the Requisition. If Vendor wishes to take exceptions or propose alternates to this Specification, the Pump Data Sheet or the Requisition, he shall describe the deviations he proposes and shall indicate the adjustment to his proposed price applicable to each deviation should COMPANY elect to accept individual deviations. Any special tools and gauges required for maintenance work shall be supplied with each unit or group of identical units, together with complete instructions for their use. The quoted efficiency of the pump at its operating point shall be based upon the quoted wearing ring clearance. If driver is a motor supplied by COMPANY, COMPANY may state the NEMA standard frame size for the motor on the order data sheet instead of providing a certified motor dimension drawing. When this is done, the certified pump dimension drawing shall be prepared by Vendor on the basis of the NEMA dimensions. Pump Vendor shall also list on the data sheet the suction specific speed including the calculations for the first stage impeller. Calculation to be used is for RPM, GPM, and feet of NPSHR at best-efficiency point for the maximum impeller. For double suction impellers, the GPM at the best-efficiency point shall be divided by 2. Pump that have suction specific speed greater than 11,000 are not acceptable without approval by COMPANY for a particular pump application. Vendor shall provide Operating Manual of this specification as specified on Vendor data requirements list.

10.3. 10.4. 10.5.

10.6.

10.7. 10.8.

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