WORK METHOD MANUAL

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

230 kbd only. : Vibration Monitoring Sheet .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).2 5.: 0 ONSHORE CONSTRUCTION Page 2 of 17 REKMAL TABLE OF CONTENTS SECTION DESCRIPTION PAGE 1 2 3 4 5 5.3 5.1 5.4 5.WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO. APPENDICES 3 APPENDICES 4 : Operation Log Sheet.

II. Doc. III. Carigali Standard Procedure. PURPOSE This document generally covers the Mechanical Running Test Procedure for Pumps with electric motor drivers for MCOT Rejuvenation Project Phase 2. 4. PSP-MCOTR-18B. Guideline for Testing & Precommissioning Procedure. 3. No. Detailed Testing and Precommissioning Plan Procedure. from 230 kBD Plan. Checksheet procedure 1. MCD-1. Test procedure for each pump will have checklist describing procedure for running the specified pump. No. Doc.: 0 ONSHORE CONSTRUCTION Page 3 of 17 REKMAL APPENDICES 5 : MCC-29.WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO. DEFINITIONS PCSB : Petronas Carigali Sdn Bhd . 2. REFERENCE I. Testing and Precommissioning Plan Procedure. CSP-T-20. and MCD-2. API 610 9 th PSP-MCOTR-18A. edition. Electric Motor-Driven Centrifugal and Testing Record Step by step for mechanical run test APPENDICES 6 : Pump. IV. SCOPE This procedure shall be applied to all electric-driven motor pumps utilized in MCOT Rejuvenation Phase 2 Project.

Fire Extinguisher ii. Inspector Rotating . Electric Motor Driven Centrifugal Pump. iv. iii.2. such as utility water or the process product as the pumping liquid. 5. Vibration analysis. Safety barricade surrounding area pump to be tested 5. Operation Log sheet v. Checksheet and Testing Record. MCC – 04.2. ii. Pump Alignment Sheet iv.5 Man Power i.: 0 ONSHORE CONSTRUCTION Rekmal : Page 4 of 17 REKMAL Rekayasa Industri Malaysia Sdn Bhd 5.3 HSE Requirement i. Coupling Alignment Record Sheet iii.1 Documents i. PROCEDURES 5.2 PRE-REQUISITE CHECK The prerequisite check shall be made on the following items before the mechanical running test is performed : 5.2.2. P & ID 5. MCC – 29.2 Equipment Statutory All equipment as stated in P&ID 5. Temperature Infrared Ray (TIR) Tachometer F key or F tool 5. The test will be conducted with the proper fluid source. ii.WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO.4 Tools i.1 ITEMS TO BE TESTED Pump listed in the Appendices-1 shall be given a mechanical running test during precommissioning stage.2.

For vertical barrel pump. v.2. iv. Ensure that the pump mechanical running test lines (test Loop) has been checked as per mark-up P&ID. surrounding prior the mechanical running test is performed.WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO. iv. ix. xi. . vi.6 Check list activity i. Ensure suction strainer are installed All spring support lock on the pipe system line are removed The unit must have a safety barricade vii. iii. Ensure the fire extinguisher is presented near the unit x. ensure liquid has been filled into the barrel with the vent line in open condition. Make sure mechanical seal pump is manually being water flushed before the pump start running. Make sure coupling has been installed properly Coupling fastened guard is installed and securely ii.: 0 ONSHORE CONSTRUCTION ii. Page 5 of 17 REKMAL Operator Electrical and Instrument Supervisor Mechanical 5. Make sure that vessel or Sump has been filled with the liquid at normal level. iii. viii. Final pump alignment must be completed Motor no-load run (solo-run) test has been completed.

xiii. Each items listed on the step-by-step procedure to be confirmed or mutually agreed by REKMAL and PMT .WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO. 5. xv. xiv. Person in charge for the mechanical running from all discipline related are ready on their position. These procedures will be provided as a checklist prior to run the unit.3 PUMP RUNNING PROCEDURE Pump will have a step-by-step procedure for running. the motor to be run for a moment to check for correct shaft rotation of the pump unit. Page 6 of 17 REKMAL Just before the running test for the units driven by electric motor. 5. For pump without the recycle lines can be tested depend on working avaibility of the inventory / process liquid.: 0 ONSHORE CONSTRUCTION xii. this will be done after the oil temperature on the bearing housing are stabilized.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. . refer to Appendices 6. for data recording and any response required. Measuring tools and accessories are required to be set properly Operation log sheet are ready to be filled in.

2. Note : 1.2 inch/s) RMS. unfiltered vibration : 5.0 mm/s (0. • Vertical Suspended pump which follow the API 610 9th Edition. 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.3 . Max. All the vibration check and recording will be done as per API 610 Ninth edition section 5.9.0 mm/s ( 0.: 0 ONSHORE CONSTRUCTION Page 7 of 17 REKMAL During the running test. unfiltered vibration : 3.4.1 VIBRATION Unless otherwise specified by vendor. Vibration limits at flow rate other than the rated flow should be discussed with MCOT if required and mutually agreed upon.12 in/s) RMS. 3. the following requirements shall be met. 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. Max.WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO. 5.

4. oil outlet temperature below 70 0C (160 0F) For ring oiled or spash system.2 BEARING TEMPERATURE (Recheck Page 8 of 17 REKMAL to Vendor recommendation) All pumps.3 Reliability Running mechanical test run.4.: 0 ONSHORE CONSTRUCTION 5. 5. refer to check sheet MCC-29.WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO.2. 5. motors shall operate within the following bearing temperature limits (as per API-610 para.10. unless otherwise specified by manufacturer • For pressurised system. especially for pump with minimum flow facilities. oil sump temperature below 820C (180 0F) • 5. . These document will be part of Test Report.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. pump shall continuously run for 24 hours without any interruption.

WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION 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 : .: 0 ONSHORE CONSTRUCTION Page 9 of 17 REKMAL 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.

: 0 ONSHORE CONSTRUCTION Page 10 of 17 REKMAL 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. flow Without min. flow Without min. flow Without min. flow Without min. flow Without min. flow Note : . 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Equipment no. flow Without min. flow Without min.WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO. 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. 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.

APPENDICES 2 MARK-UP PID FOR PUMP MECHANICAL RUNNING (TEST LOOP) FOR 230 KBD ONLY .WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO.: 0 ONSHORE CONSTRUCTION Page 11 of 17 REKMAL Pump system without minimum flow facility will be tested as required and agreed by all parties.

WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO.: 0 ONSHORE CONSTRUCTION Page 12 of 17 REKMAL APPENDICES 3 OPERATION LOG SHEET .

: 0 ONSHORE CONSTRUCTION Page 13 of 17 REKMAL APPENDICES 4 VIBRATION MONITORING SHEET .WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO.

WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO.: 0 ONSHORE CONSTRUCTION Page 14 of 17 REKMAL APPENDICES 5 ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP CHECKSHEET AND TESTING RECORD .

: 0 ONSHORE CONSTRUCTION Page 15 of 17 REKMAL APPENDICES 6 Step by step Start up Procedure .WORK METHOD MANUAL CONSORTIUM PROCEDURE NO: WMM-MCOTR-110 REVISION NO.

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