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DOCUMENT NO.

PT Caltex Pacific Indonesia

REV.

SP-ME-ME-003
DATE : October 9, 2001 SHEET :

1
1
OF

TRIPATRA SPECIFICATION

20

PREPARED BY CHECKED BY APPROVED BY

Nurhasan Nurhasan Shawn

NHS NHS SPD

BELOW 500 HP CENTRIFUGAL PUMPS SPECIFICATION (API)

PT. CALTEX PACIFIC INDONESIA

REV

DATE

PAGES

DESCRIPTION

PREPD

CHKD

APPD

COMPANY

0 1

10/09/01 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 1 15/5/02

PT. CALTEX PACIFIC INDONESIA

Below 500 HP Centrifugal Pumps Specification SP-ME-ME-003 Rev. 1

TABLE OF CONTENT
1. GENERAL .......................................................................................................................... 4 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7. 1.8. 2. Scope........................................................................................................................ 4 Terminology.............................................................................................................. 4 References................................................................................................................. 4 Conflicting Requirements ........................................................................................... 5 Definitions ................................................................................................................ 5 Others References...................................................................................................... 5 Vendor Responsibilities.............................................................................................. 6 COMPANY Responsibilities ....................................................................................... 6

BASIC DESIGN .................................................................................................................. 6 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 2.10. 2.11. 2.12. General..................................................................................................................... 6 Bolting...................................................................................................................... 7 Pressure Casings....................................................................................................... 7 Nozzles and Miscellaneous Connections...................................................................... 7 Rotating Elements...................................................................................................... 7 Wear Rings ............................................................................................................... 8 Mechanical Shaft Seal................................................................................................ 8 Vibration and Balance............................................................................................... 9 Bearings and Bearing Housing................................................................................... 9 Lubrication ............................................................................................................. 10 Materials ................................................................................................................ 10 Drivers ................................................................................................................... 10

3.

ACCESSORIES................................................................................................................. 11 3.1. 3.2. 3.3. 3.4. Couplings and Guards............................................................................................. 11 Base Plate/Skids...................................................................................................... 11 Instrumentation....................................................................................................... 12 Piping..................................................................................................................... 12

4.

FABRICATION................................................................................................................. 13 4.1. General................................................................................................................... 13

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Below 500 HP Centrifugal Pumps Specification SP-ME-ME-003 Rev. 1

4.2. 5. 6.

Casting................................................................................................................... 13

COATING AND PAINTING............................................................................................. 13 INSPECTION AND TESTS............................................................................................... 13 6.1. 6.2. 6.3. General................................................................................................................... 13 Inspection ............................................................................................................... 14 Testing.................................................................................................................... 15

7. 8. 9.

PREPARATION FOR SHIPMENT................................................................................... 17 INSTALLATION , START UP AND COMMISSIONING................................................ 18 VENDORS GUARANTEE............................................................................................... 19 9.1. 9.2. Mechanical............................................................................................................. 19 Performance ........................................................................................................... 19

10.

INSTRUCTION TO VENDOR.......................................................................................... 19

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1:

Project Specific Clarifications & Requirements

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Below 500 HP Centrifugal Pumps Specification SP-ME-ME-003 Rev. 1

1.

GENERAL 1.1. Scope 1.1.1. This specification together with the latest edition of API Standard 610 covers requirements for horizontal and vertical pumps, including in-line pumps, in continuous duty petroleum industry process services. It does not cover light-duty pumps for non-critical services such as light bracket-mounted pumps or horizontal integral motor pumps for water service nor pumps of a highly specialized nature such as chemical-handling pumps. This specification supplements the data sheets which contain the operating conditions of each pump. Compliance by the Vendor with this specification does not relieve Vendor of the responsibility of furnishing pumps and accessories of proper design, mechanically suited to meet operating guarantees at specified service condition on the applicable data sheet. Neither does it relieve the Vendor of the responsibility of furnishing equipment assembled and prepared for shipment in professional manner.

1.1.2. 1.1.3.

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 purpose: The terminology shall have the meanings as above ? ? For Direct Procurement by COMPANY purpose: Vendor shall also be responsible as CONTRACTOR

1.3.

References 1.3.1. Related Specification


? ? PP-PC-GG-002 ? ? PP-PC-GG-003

Shipping and Traffic Instruction Packing and Marking Instruction

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? ? SP-EL-EE-005 ? ? SP-EL-EE-006 ? ? SP-IN-II-002 ? ? SP-ME-ME-025 ? ? PP-QC-GG-003 ? ? PP-QC-GG-006

Induction Motor Below 200 HP Induction Motor 200 HP and above Instrument with Package or Mechanical Unit Coating and Painting Specification Inspection and Test at Shop Welding Procedure

1.3.2.

Code and Standard As applicable, the following industry specifications, latest edition as appended, are incorporated into this specification (not attached):
? ? API-610 ? ? API-670 ? ? API-678 ? ? API-614

Centrifugal Pumps for General Refinery Services Non-contacting Vibration and Axial Position Monitoring Systems Accelerometer-Based Vibration Monitoring Systems Lubrication, Shaft-sealing, and Control Oil Systems for Special Purpose Applications

1.4.

Conflicting Requirements 1.4.1. 1.4.2. Where local codes or regulations are more stringent, the requirements of the local codes or regulations shall govern. Should conflict exist between this specification and other documents, the following order of precedence shall govern :
? ? Purchase Order ? ? Data Sheets or item specific written requirements ? ? This specification ? ? Other referenced specifications ? ? Requisition ? ? 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 this specification, and paragraph 2.1.1 of API 610.

1.6.

Others References (addition to paragraph 1.5.1 of API-610) specifications and drawings listed in paragraph 7 are a part of this specification. If there are conflicts, discrepancies, errors, or omissions between the various documents, Vendor shall make no assumptions. All such matters shall be referred to COMPANY for COMPANYs decision. Generally, more stringent provisions may apply.

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1.7.

Vendor Responsibilities The Vendor is responsible for supplying complete units which perform to the 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 suppliers meet their obligations as stated by Vendor. The pump Vendor shall assume unit responsibility. Unit responsibility refers to the responsibility for coordinating the technical aspect of the equipment and all auxiliary systems included in the scope of the purchase order.

1.8.

COMPANY Responsibilities COMPANY responsibilities include: 1.8.1. 1.8.2. 1.8.3. 1.8.4. 1.8.5. 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.

2.

BASIC DESIGN 2.1. General 2.1.1. (addition to paragraph 2.1.9. 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 2.1.10 of API-610) The semi-open or fully open impeller can be used for handling of fibrous fluid. The diameter of impellers of pumps with constant speed drivers shall be not greater than the following: Type and Size of Pump Single-stage under 4-inch discharge Single-stage 4-inch discharge and over Multi-stage % of Max. Dia. Allowed 90 95 95

2.1.2. 2.1.3.

An impeller of larger diameter is acceptable if reserve head and capacity equal to that which would have been obtainable from a pump with a 90 or 95 percent of maximum diameter impeller is available by means other than increasing impeller diameter. Such case is:

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Below 500 HP Centrifugal Pumps Specification SP-ME-ME-003 Rev. 1

? ? Vertical pumps to which stages can be added. Vertical pump barrels shall

provide the future stages.


? ? Pumps with variable -speed drive which can be speeded up (not spares for

motor-driven pumps).
? ? Pumps for which another impeller pattern is available to provide the required

reserve. 2.1.4. Pumps shall have stable head / capacity curves which continuously rise to shutoff for all applications. The head rise for all quoted pumps shall be at least between 10% - 20% of the head at rated capacity. Pumps shall have a preferred operating region of 70-120 percent of best efficiency capacity of the furnished impeller. Rated capacity shall be within of 80-110 percent of best efficiency capacity of the furnished impeller. Vendor shall quote expected sound level in dBA at three (3) feet from the equipment. This quote shall be based that the equipment without the use of enclosures. The sound level shall not exceed 85 dBA. All vertical pumps shall be limited to 1750 RPM.

2.1.5.

2.1.6.

2.1.7. 2.2. Bolting

Vertical multi-stage pumps shall have bolted bowls. Screwed bowls are not acceptable. 2.3. Pressure Casings 2.3.1. (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 enter to the rotating element. The placement of splitter may be on the casing or impeller element as per specified on the data sheet.

2.3.2.

2.4.

Nozzles and Miscellaneous Connections 2.4.1. All pumps shall be provided with vent connections unless pump is self-venting due to arrangement of nozzles. Tapped connections shall be provided for completely draining pump casing of horizontal pumps. A tapped drain connection in the pump bracket (3/4-inch minimum, 1-inch preferred) shall be provided for removal of stuffing box packing drips. Alternate drain connections are subject to approval of PURCHASER.

2.4.2.

2.5.

Rotating Elements 2.5.1. All impellers shall be keyed to their shafts, including impellers in vertical pumps. Impellers on pumps with overhung shafts shall be secured to the shaft by a lock nut or cap screw. Either securing device shall be threaded to tighten by liquid drag on the impeller during normal rotation and a positive mechanical locking method (corrosion resistant set screw, tongue-type washer, etc.) is required. Cap

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screws shall be of a high strength material with fillets and a reduced diameter shank to prevent stress concentrations. 2.5.2. In in-line single stage pumps , either integral or coupled shafts are acceptable, but shaft deflection requirements must be met without use of product lubricated bushings. Inter-stage bushings shall be split for easy removal in multi-stage horizontally split pumps.

2.5.3. 2.6.

Wear Rings 2.6.1. One and two stage pumps with closed impellers shall be fitted with replaceable case and impeller wearing rings on both sides of the impeller unless deleting the back wearing rings will reduce net axial thrust on pump with high suction pressure. Materials of construction for multistage pump close-clearance parts shall resist galling by providing hard-facing over corrosion resistance.

2.6.2. 2.7.

Mechanical Shaft Seal 2.7.1. 2.7.2. Materials for mechanical seals, including the sleeve under the seal shall be in accordance with latest edition of API 610 and the data sheets. Vent and drain connections (1/2 inch preferred, 3/8-inch minimum) shall be provided between the bushing and the seal faces, except that such connections are not required on pumps handling non-corrosive stocks with vapor pressure above atmospheric such as propane and butane. Pumps shall be designed to permit installation of vent or drain piping from these connections. Re-circulation piping, when provided, shall be -inch OD. 18-8 stainless steel tubing, 0.095-inch minimum wall thickness, fittings installed as per specified on the data sheet. The restricting orifice shall be in the gland plate connection. For LPG or highly toxic service, or service over 4500 F an orifice restricting flow to the atmosphere in case of tubing failure shall be provided at the discharge or suction nozzle connection. This orifice shall be in addition to the orifice at the gland plate connection. The cooling stream shall not impinge on seal parts in such a manner as to cause erosive wear. Renewable type throat bushings are required in all pumps. Throat bushings locked in place only by being pressed in from the low pressure side of the stuffing box is not acceptable. When the pumped liquid contains H2S and/or CO2, the secondary seal material with high-corrosion material and/or high-thermal resistant shall be used such as perfluoroelastomer (kalrez) or polysulfied (thiokol). However, the material selection will be specified later on data sheet as per COMPANYs approval. Below 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.

2.7.3.

2.7.4.

2.7.5.

2.7.6. 2.7.7.

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2.7.8. 2.7.9.

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 sta inless steel tube fittings. All parts of the flushing system shall be at least of quality equal to the pump casing materials. (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.

2.7.10.

2.7.11.

2.8.

Vibration and Balance 2.8.1. The Vendor shall demonstrate that the pump can operate at the quoted minimum continuous stable flow without exceeding the vibration limits given in paragraph 2.8.3.7 of API 610. For pumps over 100 horsepower, vibration switches shall be furnished for pumps and motors (total of 2 switches required for each pump / motor package). Vertical pumps to have one vibration switch on the electric motor only. The Vibration switches manufacturers will be selected as per COMPANYs approval Vibration switches shall be mounted on an adequate bracket. All rotors with more than two impellers shall be multiplane balance (rotating element is checked for balance after impeller is added to the shaft). Final rotor balance or multistage pump shall be documented as per Appendix J of API standard 610 Eight Edition, Aug 1995, Procedure of Residual Unbalance Verification. All impellers and rotor balancing shall be documented and available for COMPANY review.

2.8.2.

2.8.3.

2.9.

Bearings and Bearing Housing 2.9.1. 2.9.2. 2.9.3. 2.9.4. Unless otherwise specified, bearing housing shall be arranged as per paragraph 2.9.2 API- 610. Cooling coils, including fittings, shall be Admiralty. (addition to paragraph 2.9.2.2 of API-610) Trico otomatic oilers shall be provided The radial bearing shall be hydrodynamic sleeve type and the thrust bearing shall be hydrodynamic tilt-pad thrust assembly when one of the following conditions exist:
? ? When dN factor are 300,000 or more.[A dN factor is the product of bearing

size (bore) in millimeters and the rated speed in revolutions per minute].
? ? When standard anti-friction bearings fail to meet an L10 rating life ( see

AFBMA Standard 9) of either 25,000 hours with continuos operation at rated conditions or 16,000 hours at m aximum axial and radial load and rated speed.

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? ? When the product of pump rated horse power (kilowatts) and rated speed in

revolutions per minute is 2.7 million (2.0 million) or greater. 2.10. Lubrication 2.10.1. 2.10.2. (addition to paragraph 2.10.1 of API-610) oil cooling shall be by air cooling for high speed pump. (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 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 dis-locked if the pump is rolled over or held in an unnatural position while being transported.

2.11.

Materials 2.11.1. When on the Purchaser Pump Data Sheet materials are specified only with the material class, Vendor shall identify the materials in the proposal with their applicable ASTM, AISI, ASME, or SAE numbers, including the material grade. Compatibility with ASTM standard is required. When casting repairs are authorized by the material specifications, repair welding shall be done with weld metal of the same nominal chemical composition as the parent metal casting. Cast iron shall not be repaired by welding. Welders and welding procedures shall be qualified in accordance with Section IX of the ASME Code. When handle fluid with H2S content and/or CO2 content, the material of secondary seal that have high corrosion resistant and high temperature resistant such as low-austenitic steel or high austenitic steel shall be used. However, the material selection will be specified later on data sheet and/or as per COMPANYs approval.

2.11.2.

2.11.3.

2.12.

Drivers 2.12.1. (addition to paragraph 3.1.4 API-610) Motor drives below 200 HP shall be provided in accordance with SP-EL-EE-005,Induction Motor for Below 200 HP. 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

2.12.2.

2.12.3. 2.12.4. 2.12.5. 2.12.6.

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required for any operating condition. However, the driver system for pumping unit shall be as per specified on the data sheet. 2.12.7. 2.12.8. (addition to paragraph 3.1.10) Gear units shall have 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 stainless disks and a spacer to give at least 7 inches between shaft ends. Medium load classification is acceptable for centrifugal pumps. The Vendor list are according to COMPANYs prior approva l in writing. Pumps driven by motors with sleeve bearings shall be provided with limited-endfloat couplings in accordance with NEMA Specification. Gear couplings require the addition of stops to limit axial movement). This allows maximum end float per the following table: Motor HP 125 200 250 450 250 <500 3.1.3. Syn. Speed, rpm 3600 1800 & less 3600 Min. Motor Rotor End-Play, in 1/4 1/4 1/2 Max. Coupling End-Float, in 3/32 3/32 3/16

3.1.2.

When gear-type limited-end-float couplings are provided, pump manufacturers installation instructions shall cover end-play settings. A special tag shall be attached to the coupling identifying it as limit-end-float and giving end-play setting instructions. (addition to paragraph 3.2.5 of API-610) Coupling to shaft 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. Coupling guards shall cover the rotating parts to within -inch of the stationary housings. Coupling guards shall not deflect over 1/8 of an inch, contact moving components, or result in a permanent deformation when subjected to a 200 pound static load applied in any direction.

3.1.4.

3.1.5. 3.1.6.

3.2.

Base Plate/Skids 3.2.1. (addition to paragraph 3.3.13 of API-610) Pedestals supporting pumps shall have water jackets for cooling if flow temperature exceeds 5000 F. Vendor shall quote their standard base plate as base bid. As an alternate, Vendor shall quote heavy

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duty oil field type base p late including a drawing of skid. Heavy duty skid should be adequate for shipping pump and motor mounted on skid. 3.2.2. (addition to paragraph 3.3.18 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. (addition to paragraph 3.3.2) Where pumps handle flammable or toxic fluids, baseplates shall have drain-rims or drain-pans which are sloped for the complete drainage. Vendor shall also quote foundation design calculation and drawings (the soil bearing capacity is 1500 lb / ft2). Horizontal alignment screws are required for drivers weighing above 60 pounds. (addition to paragraph 3.3.1.15 of API-610) Vertical levelling screws shall be provided for all base plates when the driver weight exceeds 60 pounds.

3.2.3.

3.2.4. 3.2.5. 3.2.6. 3.3.

Instrumentation 3.3.1. The selection of condition monitoring and system protection specification shall be as per specified SP-IN-II-002Instrument with Package or Mechanical Unit,and based on sparing philosophy, critical level of pump, pump size. All instrument shall be designed as per data sheet. Instrument shall be mounted outdoors in weather and such shall be designed for such purpose. (addition to paragraph 3.4.3.1 API-610) If specified and as indicated on the data sheet, accelerometers or non-contact proximity probes shall be furnished and installed. The manufacturer brand will be specified later on the COMPANY. The accelerometers shall be installed in accordance with API-678, accelerometer based vibration monitoring system. Proximity probes shall be installed in accordance with API-670, Non-contacting vibration and axial position monitoring system.

3.3.2. 3.3.3.

3.4.

Piping 3.4.1. (exception to paragraph 3.5.1.4 API-610) for handling nontoxic or nonflammable 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 316SS SCH80 NPS. (addition to paragraph 3.5.1.3) The piping systems shall be designed and arranged for easy disassembly and maintenance. (addition to paragraph 3.5.1.11) Piping sizes and shall be 3/8 inch (10 mm) minimum, except for mechanical seal and lantern ring piping. Connection size shall be 1/2 inch (15 mm) minimum. (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 the Vendor prior to assembly on the pump/driver.

3.4.2. 3.4.3.

3.4.4.

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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 fabric ation 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 of 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.

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-GG-003, "Inspection and Test Plan at Shop", PP-QC-GG-004, "Inspection and Test Plan at Field" Vendor shall furnish CONTRACTOR/COMPANY with copies of Vendor's Inspection and Quality Control Plan.

6.1.2.

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6.1.3.

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

6.1.4. 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:
? ? 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.

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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 Procurement Minas SBU - Pekanbaru. 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

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inlet and drain temperatures shall be recorded at each mechanic al 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

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

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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 available 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-PCGG-003 Shipping and Traffic Instruction, PP-PC-GG-004 Packing and Marking Instruction. 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. 7.3. 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

7.2.

7.4.

7.5.

7.6.

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installation. 7.7. 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 comple tely 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 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 applie d. 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.

7.8. 7.9. 7.10. 7.11.

7.12. 7.13. 7.14.

7.15.

7.16. 7.17.

7.18. 7.19.

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.

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8.3.

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. Special tools may include

8.4.

8.5.

9.

VENDORS GUARANTEE 9.1. Mechanical 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 i n 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

10.3.

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unit or group of identical units, together with complete instructions for their use. 10.4. 10.5. 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 applic ation. Vendor shall provide Operating Manual of this specification as specified on Vendor data requirements list.

10.6.

10.7. 10.8.

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