Onshore Terminal For KG DWN 98/2

Development Project

DOC. NO.
Pre-Commissioning & Commissioning REV.
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PRE –COMMISSIOING & COMMISSIOING PROCEDURE

FOR

FIRST GAS - Lean MEG Pumps

0 12-02-2020 ISSUED FOR APPROVAL SK DC DC

REV. DATE DESCRIPTION PRPD CHKD APPD
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Revision History

Revision Date of
Reason for change
No. issue
0 12-02-2020 ISSUED FOR APPROVAL
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CONTENTS

1. PROJECT DESCRIPTION
1.1 INTRODUCTION.
1.2 PROJECT COMMISSIONING SCOPE.
1.3 PURPOSE OF THIS DOCUMENT
2. HEALTH SAFETY & ENVIRONMENT
3. COMMISSIONING SYSTEM
3.1 PRE- COMMISSIONING.
3.2 PRE-REQUISITE FOR PRE-COMMISSIONING
3.3 ENERGISATION PROCEDURE
3.4 COMMISSIONING
3.5 PRE-REQUISITE FOR COMMISSIONING
4. COMMISSIONING PROCEDURE
4.1 COMMISSIONING OF PROCESS
4.2 COMMISSIONING OF PIPING
4.3 COMMISSIONING OF INSTRUMENTATION
4.4 COMMISSIONING OF ELECTRICAL SYSTEM
5. OPERATING PROCEDURE
5.1 METHOD STATEMENT
5.2 OPERATING PROCEDURE
6. SYSTEM HANDOVER
6.1 SYSTEM/SUBSYSTEM CLASSIFICATION
6.2 SITE ACCEPTANCE TEST
6.3 PERFORMANCE GUARANTEE RUN
6.4 START UP & HYDROCARBON INTRODUCTION
7. ANNEXURE #01: LEAN MEG INJ PUMP -4 HRS. MRT TEST FORMAT
8. ANNEXURE #02: SYSTEM-SUBSYSTEM CLASSIFICATION FOR LEAN MEG INJ PUMP
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1. PROJECT DESCRIPTION
1.1. INTRODUCTION
First Gas from the KG-DWN-98/2 Cluster 2B gas fields U-3 and U-1 (U Field wells) will be tied into the
subsea production system infrastructure of the Vashishta and S1 field development with the objective of
achieving early monetization of KG-DWN-98/2 field. Gas from the U field will be processed via subsea
tieback to the S1 &Vashishta Onshore Terminal. Rich MEG processing and lean MEG injection for the
U field will be handled by the S1 & Vashishta Onshore Terminal.80wt% lean MEG for U field production
will be provided by the Vashishta MEG Storage Tank (ON-TK-1901), with new lean MEG injection
pumps up to June 2020.
Lean MEG at 90wt% concentration will be produced from the OMF facility for hydrate inhibition of the
raw well stream fluids and will be transferred directly to Manifolds GM01 and GM-02 via a 6” subsea
pipeline, prior to the production wells via umbilical’s, where it is injected downstream of the production
choke valve.
As part of U Field production, 2 x 50% HP separators, 1 x 100% GDU, Chemical Injection (Scale &
corrosion inhibitor system), Lean MEG and Methanol injection pumps, power generation, fuel gas and
flare (HP) system are going to be installed
1.2. PROJECT COMMISSIONING SCOPE
 Responsible for testing and commissioning the facilities, Field Test Trials, Guarantee Test Run and
demonstrate the operability and handing over of Units as required in the Tender Package
 Shall carry out all testing and certification activities in conjunction with approved procedures, up to
the date of the Final Acceptance
1.3. PURPOSE OF THIS DOCUMENT
The purpose of this document is to set out the requirements and methodology for the Pre-
commissioning & commissioning activities with the project specification, manufacturer’s
recommendation, applicable codes and standard. The procedure is prepared elaborately for the
purpose of clarity and understanding for a comprehensive and safe pre-commissioning &
Commissioning activities. The procedure gives system wise categorization and sub-systems
classification
2. HEALTH, SAFETY & ENVIRONMENT
One of the objectives while carrying out the pre commissioning & commissioning is the project’s commitment
to safety and environment. All precaution therefore must be taken to ensure the safety of personal, property
and local environment.
 Safety procedure must be in place prior to commencement of any testing. Safety personal must be
made aware of the testing program.
 Notices and barrier should be placed where possible indicating the testing area.
 Safety personal should be posted to keep the area clear of any unauthorized person with pre. Comm. &
comm. work.
 All spillages are to be reported immediately to the company. Dispose of waste material shall be in
approved manner and compliance with local authority regulation. To achieve the safety record it is
essential that all the personal involved in the pre-com & commissioning Activities are properly trained
and qualified.
  Hand held/Portable Gas Detectors shall be available all the time during Pre- Commissioning &
Commissioning activities.

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 Permit to work system shall be adhered to at all time.
 Tool box talk activity (TBT) will be conducted before the activities start and shift change to ensure all
the personnel involved in the activity are aware the safety requirement for the task in hand.
 Mobile phone is not allowed in red zone area.
 Vehicle fitted with spark arrester shall be permitted at the red zone area. Vehicles speed limits will be
adhered to at all time.
 Smoking shall not permitted at red zone area.
 Only correct tools and equipment shall be used.
3. COMMISSIONING SYSTEM
On achievement of Mechanical Completion, responsibility for the facility will transfer from those
responsible for construction to those responsible for pre-commissioning and commissioning.
3.1 PRE-COMMISSIONING
Pre-commissioning activities are defined as the activities to be performed after erection / installation
of an equipment / system to make it “Ready For Commissioning”. This includes but not limited to the
activities like charging of lube oil, calibration of all PSVs and measuring instruments there after loop
checking, complete checking of the safety system, operability test of equipment and system as a
whole plus recommended checks on electrical system
3.2 PRE-REQUISITES FOR PRE-COMMISSIONING
The completion of the following activities has to be confirmed before starting the Pre-commissioning /
commissioning activities. This is essentially a verification of signed document as a proof of completion.
 All Erection/Installation work done as per Project specifications.
 All Tie-in connections identified and made as per design documents.
 Mechanical Completion Walk down to be carried out prior start of commissioning
 All required Earthing Systems are fully tested and commissioned. Different types of earth connections
to the panels and ground continuity are in line with the project specifications.
 Commissioning of MCC, UPS, Earthing system, HVAC, utility power supply, Lighting and Firefighting
system (portable fire extinguishers, sprinklers etc.).
 Completion of “A” punch list aroused from the construction.
 Availability of Lock-out-tag-out procedure, commissioning spares and Security control in place for
CCR
3.3 ENERGISATION PROCEDURE
LIVENING UP Notice to be issued to client/PMC and all concerned prior energization of Panel. Cold
SAT (Site Acceptance Test) to be performed prior energization followed by Hot SAT.
The Activities includes visual inspection & verification of all Hardware / Breaker/ Fuse ratings with
approved Bill of Materials (BOM), Power & Earth integrity checks in accordance to Single Line
Diagram (SLD), Instrument loop checks, and Panel function tests, Energization of electrical
equipment, Bump test and running motors without loads.
Energize Utility power before powering up the UPS power to Control Panel. Switch on the breakers in
the power distribution panel and observe the status of Equipments for healthiness. If any abnormality
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observed, Switch off the Power and rectify the same. Communication between different nodes and
Redundancy levels of hardware are to be checked after. Complete the functional checks and record the
same after energizing the panel as per project requirement. Refer vendor SAT procedure and check
sheets for complete testing of the panel
The bump test to be carried out for Rotatory equipments. The purpose of the test to verify the direction
of rotation in field side and Starting current drawn by the equipment parallel in MCC. Measured values
are to be recorded and witnessed by the client.
3.4 COMMISSIOING PROCEDURE
Commissioning activities is carried out after the pre- commissioning completion. These activities to
dynamically verify functionality of equipment and to ensure that systems, or facilities forming part of a
system, are in accordance with specified requirements to bring that system into operation
It includes activities such as verification of Ready for commissioning (RFC) certificate, power integrity
checks, hardware and software healthiness check and finally site acceptance.
3.5 PRE-REQUISITES FOR COMMISSIONING
Pre-requisites for commissioning includes the following as minimum:
 Pre-start up Safety Audit carried out and relevant recommendations closed out.
 All Firefighting and safety support systems commissioned and their operability ensured.
 Pre-commissioning and System check completed for individual system & sub-systems and documented.
 Punch list cleared and Ready for Commissioning status acknowledged by COMPANY
 Process drains system checked for free flow of water to open drain system.
 Electrical Equipment (system) pre-commissioning report acknowledged by COMPANY.
 Cause and effect checked as per C&E chart and correct operation confirmed.
 Functional Test for System & Sub-system completed.
 Safety barriers and warning signboards erected. No hot work shall be permitted within 100 m radius
from the hydrocarbon system to be commissioned.
 Relevant authorities notified and in attendance as required.
 Communication system between all relevant locations checked and confirmed.
 All Commissioning personnel well informed of their roles and responsibilities.
 Commissioning personnel and Safety officers have taken up their respective positions
 Process flow path open in accordance with approved procedure.
 Vehicle entry and movement restricted in the commissioning area.
 Commissioning spares availability is ensured.
 Ready for commissioning request submitted for COMPANY approval.
4. COMMISSIONING OF PROCESS SYSTEMS
Commissioning will be sequenced in such a way that temporary power, Lighting and Firefighting system
including all support and utility systems has to be commissioned prior start of Process packages.
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Site Preparation:
 Obtain permit to work from the COMPANY prior to Testing as per the Safety Rules & Regulations.
 Conduct visual survey and identify the existing switchgear panel where LV feeders is installed and
Local control station as well as pump.
 Barricade the area; Fix warning sign boards, showing keep away, Men at work. place Warning Signs to
prevent entry by Unauthorized Personnel
 Before starting the testing of motors, the area will be checked and make sure that there are no
underground services existing at the proposed construction area.
 Ensure the availability of latest documents, SLD's “As Built” Mark-Ups/Latest revision
 Confirm that the area is clean and free of Fire, Tripping and Slipping Hazards. Surroundings are
accessible without any obstruction
 Confirm that the Earthing System Testing is completed and Neutral/ Instrument Earthing (ITR)s are
Signed Off as per Earthing Philosophy
 Confirm the Communication Test carried out between Power Generator source and Site Substation and
architecture Diagram are checked for Electrical System
4.1 COMMISSIONING OF PIPING SYSTEMS
Air Blowing of Pipelines to be done after lines are hydro tested and Test Certificates have been signed off.
After blowing, Start the compressor and slowly divert the flow of air from the compressor into the hose fitted
to blowing arrangements line and perform system function test. When drying out line get specified limit, stop
the dry air blowing.
Prior to introduction of hydrocarbon in a system, all the piping and equipment are to be leak tested and
inerted. Leak Testing will be conducted by using Nitrogen and Helium mixture. Same Nitrogen will be used
for inerting the systems after the leak test
For leak test, allow the line to pressurize up to 1.5 times gauge pressure and kept it on hold. Depressurized
the line if there is no significant pressure drop after ½ hours. Remove all the temporary arrangements.
Check all the flanges joints in the line using shop solution and attend the leak if found. Hold the pressure
about 1/2 hours.
Nitrogen purging shall be carried out after the Leak test after ensuring the isolation of the area under test,
introduce nitrogen in the system Pressurized the system in steps. Released the nitrogen air mixture from the
designated vent connection. Using oxygen level meter measure O 2 contain at the high vent point. Repeat
the Step if O2 content is to found to be more than 2% v/v. Maintain positive pressure and isolate the system
if O2 content is less than 2% v/v.
4.2 COMMISSIONING OF INSTRUMENTATION SYSTEM
Field instruments are powered up and loop tested from field to control room and back to field for
closed loops. All instruments shall be calibrated to confirm their accuracy prior to their initial use and
every six (6) months thereafter and record of calibration shall be maintained, but if any doubt on the
performance it will be calibrated or replaced suitably.
 Graphics, communication networks and interface with other PLC System will be checked.
 All instruments loop response to be verify as per cause and effect chart.The alarms shall be
verified and noted. And all alarm shall be reviewed in graphics pages.
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 All PID loops functional test to be done. Loop checking shall be completed prior start of function
check. The functional test to be carried out in front of TPI/ COMPANY
 The Logic and interlocks check which was done in FAT shall be verified at SAT also during
functional test. MOD BUS mapping shall be verified with PLC.
 The functional check to be carried out with respect to C&E. Causes are to be checked and its effects
to be verified parallel as mentioned in cause and effect chart.
Dynamic functional test are to be carried out for the system logics, ESD valves, and Control valves prior to
handover of the systems for start-up
Pre-requisite:
 Confirm feeders to the pump motors are kept in test position.
 Trip signals from Level-1A/B shutdowns are not active
 During simulation, inhibit signal to any device or equipment which will affect the normal operation.
(Refer: Cause and Effect)
 Confirm all the results on DCS HMI
 After successful completion of simulation, Confirm to normalize the actions performed and reset the
effects to normal conditions. Maintain records of functional tests
The findings will be recorded in a specified format for all the tests and checks.
Required Tools for Loop Test/Calibration
1. Handheld 375/475 Communicator with Calibration Certificate
2. 4 – 20mA Simulator for Non – HART type Transmitter
3. Digital Calibrator, Fluke 702 or Equivalent
4. Portable Pressure Calibrator
5. Multi-meter, Standard Tools & Radio
4.3 COMMISSIONING OF ELECTRICAL SYSTEM
4.3.1 MOTORS
Pre-requisite:
Verify the Power & Control cables coming from LT / HT MCC Panel feeders to motors are properly
terminated at their end with Phase sequence inside motor’s terminal box. The Motor / LCS Name
Plate details, all cable termination shall be verified with the latest revision drawings.
BUMP test to be performed before going for No load Run test.
No Load Run Test
After all pre-requisites the Power through MCC feeder shall be given to motor The initial current
value which will be drawn by motor shall be checked by clamp meter and recorded in a sheet. Verify
the drawing current is as per requirement or not.
Once the motor continues its full running speed its current drawing requirement will be reduced and
after some time it shall be checked and verified whether the motor is drawing it shall be 30-40% of
full load current.
Full Load Run Test
The motor will draw the high amount of current that might go 300% of full load current. Measure the
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current with tongue tester and note it down. Once the motor reach to its full run speed, then the
current drawn by motor will be gradually reduced and will reach to full load current rating. Check the
current value once the motor run in its full speed with full load and note it down the measured value.
The applicable tests to be perform for motors are
 Motor’s insulation resistance test
 Bearing temperature Check
 Motor vibration Check
4.3.2 SWITCHGEAR/ MCC PANEL TEST
It includes panel enclosure, bus bar, CT & breaker / contactor. The following precautions should be taken
care, before starting the test:
Pre-Requisites:
 Ensure it is free from surface dust and moisture and isolated from other connected system, which
may feedback to other components or circuits not under test.
 Verify the ground and test equipment being connected to system ground.
 Barricade the test area and prevent un-authorize entry in test area during test.
 CT’s secondary terminals shall be shorted. VT’s & Surge arresters shall be isolated from the equipment
under test
 Circuit breakers/contactors should be inserted and closed.
 Bus bars should be fully mounted tightened and shields between phases &between phases and
earth should be in place. Moreover, bus bar covers should be in place.
 All Earthing switches related to equipment under test should be open
 Bus bar conductivity test shall be performed.
 Insulation resistance test should be performed before and after commencing the test.
 Instructions of test equipment being used should be followed.
 After each test subject under test should be discharged to ground. The test
connection shall be done properly.
Required test voltage shall be raised slowly and maintained for one minute between one phase and
other phases connected to ground and then reduced slowly to zero, testing shall be repeated for other
phases as mentioned above. During each test leakage current shall be recorded. After the above test,
another test shall be repeated after opening all circuit breakers / contactors and applying test voltage
across opening distance between poles with three poles shorted on both sides and grounded on one
side only.
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5. OPERATING PROCEDURE
5.1 METHOD STATEMENT - LEAN MEG PUMP
1. Check and ensure all fixing bolts, nuts of pump, gear box, motor and accessories are properly
tightened. Make air tight all joints of suction & discharge connection.
2. Make sure that electrical equipment are properly earthed, Earthing shall be done with adequate
size of earthing strip
3. Check lubrication oil level of reciprocating pump, gear box, force feed lubrication.
4. Check filter / strainer are in clean condition. If liquid which is pumped carrying some abrasive
particles, impurities, it may cause scratches or scoring marks on plunger surfaces. This may
cause of plunger seal failure.
5. Aligning the coupling by means of a ruler and a pair of outside callipers. Repeat the same check
@900; 1000; 2700; 2600 angles. Tolerances for aligning the coupling to be checked.
6. Measure gap ‘P ’at 4 places 90° apart Using Filler Gauge. The difference in maximum &
minimum gap will be the Total Indicated Reading (TIR), which will be the angular misalignment
present
7. Check free movement of pump ports by rotating coupling manually.
8. Plunger pumps are not self-priming, therefore a positive suction head should always be
provided.
9. Suction line should be as straight as possible, minimizing changes in size, minimum joints and
positioned in such a way to allow air pockets and bubbles to escape. Suction line must be
connected to the pump. The pump must never run dry. Set the pressure line in dump mode (to
release trap air) in order to let the air in the pump to get out easily thus facilitating the pump
priming
10. A suitable relief valve must be installed in discharge line.It is necessary to examine the suction
and discharge valves periodically for any excessive wear or cutting by abrasive particles in
liquid has not impaired their efficiency. Any worn or damaged parts must be replaced
11. Check the level of the lubricating oil. By help of dip stick provided. Fill the oil from topside. Run
lubrication pump for 15 minutes prior to starting the main pump. Make sure of the correct grade
of oil is filled up to desired level
12. Pump shall always be started with by-pass valve in open condition and discharge valve in close
condition Thus, the pump will start on non-pressurizes condition. After few second, while liquid
is passing smoothly through bypass line, open discharge valve and close by pass valve to
generate pressure in system.
13. When starting the pump up for the first time or after every wiring re-connection check for proper
direction of rotation. Check that the rotating speed does not exceed the rated value during
operation.
14. Check and make sure that there will not be any abnormal noise from pump, gear box and motor
and pipe line
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5.2 PUMP OPERATING PROCEDURE
5.2.1 Start/Restart Mode
Before Starting the Lean MEG Injection Pump (ON-P-1907 A/B), Operator on Site Shall follow the
Procedures given below.
1. Oil Level of Pump Power End Should Be up to the required marked Level on the Level
Indicator.
2. Check for Oil Level in the Mechanical Lubricator (Item No. 42 in Drg. No. MIS-0265 Rev C).
3. Ensure the Recycle Line Pressure Control Valve PV1976A/B Direct Acting via PIC1976A/B
is 100% Open.
4. Ensure that the Gate Valve is closed of Suction Strainer Drain to avoid any Flow Loss.
5. Open all the Suction, Discharge, & Recycle line DBB’s 100% Including DBB’s on Pressure
Gauges PI1973A/B & PI1974A/B and DBB’s on Pressure transmitter PZT1975A/B &
PIT1976A/B.
6. Inlet DBB & Outlet Ball Valve of Pressure Safety Valve PSV1977A/B shall be Locked Open
100%.
7. Lock Close the Inlet DBB & Outlet Valve of Pressure Safety Valve PSV1978A/B.
8. Now Turn the Switch ON & Push the START Button Located on the Local Control Station
Mounted on the Pump Skid.
Important Note: Always Check the Pump Power End Oil Quality in Level Indicator/Dip Stick after
every 2000 Hrs. / if the Oil Color Changes from Golden Brown to Milky White. Also Check the Oil
Level in Mechanical Lubricator after every 100 Hrs. or if the Volume goes Below the Level Indicator,
fill the Oil.
5.2.2 Stop / Failure Mode
Before Stopping the Lean MEG Injection Pump (ON-P-1907 A/B), Operator on Site Shall follow the
Procedures given below.
1. Depressurize the Discharge Line by 100% Opening up the Recycle Line Pressure Control
Valve PV1976A/B Direct Acting via PIC1976A/B.
2. Push the Stop Button & Turn the Switch OFF, located on the Local Control Station Mounted
on the Pump Skid.
3. In case of Input signal failure, the Pressure Control Valve Controller will be put in Manual
mode and Freeze its output at the last value. Valve opening & closing to be done manually.
4. Check the Oil Level of Pump (ON-P-1907 A/B) Crankcase After the Crankcase Temp.
comes down to Ambient temperature, If the Oil Level is Showing Upto/Below the Minimum
Marked level on level indicator then Refill the same with Appropriate Oil Type/Volume.
(Refer Document KG98/2-ONT-UVA-ME-L011-DO-L04)
5. Check for Oil Level in the Mechanical Lubricator (Item No. 42 in Drg. No. MIS-0265 Rev C)
if showing Low level on Level Indicator Then Refill the same with Appropriate Oil
Type/Volume. (Refer Document KG98/2-ONT-UVA-ME-L011-DO-L04)
6. SYSTEMS HANDOVER (FINAL ACCEPTANCE)
Each handover and acceptance must be supported with the relevant documentation and be agreed
by both parties. Handover Steps illustrates handover points, scope, prerequisites, documentation
and Handover/acceptance parties
This process is based on mechanical completion, pre-commissioning and commissioning being
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executed on a subsystem or system basis. System – subsystem divide the entire facilities into the
small groups & further helps in for commissioning the entire facilities sequentially. This approach
lends itself to the systematic and logical flow of activities from mechanical completion through to
pre-
Commissioning, commissioning and operations, and will result in an overlap of these different
tasks. The benefits of a ‘subsystem’ approach can be seen in HANDOVER
6.1 SYSTEM – SUB SYSTEM DESCRIPTION
A system is a composite assembly of equipment, instruments, electrical supplies etc., which can be
defined as having a singular purpose. It is a section of the assets for which a clear function can be
identified, and to a significant extent can be commissioned and brought into operation either in
isolation or with primary support e.g. power from adjacent systems.
A subsystem can be defined as part of a system that can be commissioned in its own right before
being combined with other subsystems of the same system. Additionally, to facilitate or achieve
commissioning milestones, subsystems / systems may be aligned with subsystems from a different
system, or with other systems, to provide a commissioned entity.
A rational breakdown and ‘ring fencing’ of systems and subsystems to define the minimum required
to achieve major milestones will facilitate construction (mechanical completion) work scope
definition and aid planning. This will also result in efficient and logical milestones that support the
delivery of the project in accordance with the execution strategy.
6.2 SITE ACCEPTANCE TEST (SAT) AT SITE
Packaged equipment and control systems are normally tested (SAT) onsite prior to start-up, where
actual process and utility fluids are available as there can be no guarantee that equipment is not
disturbed during transit and generally not all testing is possible in the factory, or at intermediate
integration site(s).
Site acceptance tests are incorporated into the system commissioning dossiers. In certain cases
this may require the presence of the vendor for installation and function checks and training of
operations and maintenance staff.
Preparation for SAT will be coordinated by a nominated specialist. During the engineering and
construction phases, proposed vendor checks and tests will be reviewed by asset owner and
commissioning discipline specialists to determine the acceptability of the proposed checks,
dynamic testing procedures and the associated documentation
There must be checks and procedures applied to ensure that everything will work first time when
integrated tests are carried out at the site.
6.3 PERFORMANCE GUARANTEE RUN TEST
Process Start-Up refers to the introduction of process fluids and taking the facility to its designed
operating condition in a controlled manner. In general 72 hours shall be taken as the performance
guarantee test run check (PGTR) for the PUMP on various Operation Modes.
6.4 STARTUP AND HYDROCARBON INTRODUCTION
The operations team will be responsible for start-up and will lead this under the direction of the
Operations Manager with the Commissioning Team in a supporting role. Completion of Start-Up means
that the facilities have been proven to function, with process fluids, over a pre-agreed project’s intent. It
also requires that all outstanding or remedial work associated with provision and use of the facilities is
complete. In exceptional cases where remedial works are still outstanding, the work scope, timing and
resourcing of these have already been agreed. Start-Up is the confirmation that the Project has
adequately completed its scope.
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Prior to introduction of hydrocarbon, a pre Start-up audit shall be carried out. Company shall conduct an
audit confirm the facilities and activities of Contractor comply with the requirements of the Contract and
that they are safe and ready for Commissioning.
The objective of the pre-start up audit is to demonstrate the facilities, systems etc. operational readiness.
The audit shall verify key items such as:
 Facilities are constructed as per Design
 Operations philosophy is complied with;
 Asset Integrity is verified and can be demonstrated;
 Necessary Vendor support is identified and scheduled;
 Operations staff are sufficiently trained and competent;
 Commissioning ‘imperatives’ are in place and complied with;
 Project assurance in place and HSE-Method Statement is in place
 Design Integrity has been maintained since AFC issue;
 Checks performed during Commissioning were adequate to demonstrate integrity.
 Calibration of PSVs and all measuring instruments. Confirm that the pre commissioning dossier which
contains all the calibration reports were accepted and signed.
 Confirm that loop checking of all the field instruments were completed as per “Loop Checking Procedure
 Complete checking of the safety system
 Checks on electrical system and other vendor packages.
 Checking of all the valves and fittings for their intended operations
 The delivery, storage and cataloguing of all spares. Items for which a defect Notice are issued to be
rectified and all defect Notices shall have been closed out.
 The Completion Documents along with all Design Documents to As-Built
 The hydro testing of the pipe line, pig barrel and associated piping as described elsewhere in the system
 All required Installations for Temporary Power Supply fully Tested and Commissioned
 System Readiness Test complete for control system and Building FGS.
 All Relevant Electrical Systems are required to Start Commissioning Test and Commissioning of Site
Equipment
 Confirm the Electrical System or Sub-Systems are in Service or available to place in to Service. If the
System is partially complete, then the part that is completed must support the Commissioning activity.
 Confirm that all the instruments were calibrated either in workshop or at vendor woks.
 Confirm that all the pre commissioning activities were completed and the A&B ITRs were filled up,
signed and uploaded to Computer system.
 Confirm that Ready for Commissioning certificate is issued. Coordinate with Company to witness the
commissioning activities.
The preparation of the commissioning plan and submission to Company for review.

MRT TEST REPORT FORMAT

Document Title
Onshore Terminal for KG DWN 98/2 Development Project
Document No.
Rev. No.
MECHANICAL RUN TEST REPORT
Date
TAG NO. KW/HP VOLTAGE CURRENT FREQ. EQUIPMENT/SERVICE
TIME PUMP MOTOR TEMPERATURE IN DEG C @ AMBIENT CONDITIONS (APPROX. 30 DEG C) SOUND AT 1 METER DISTANCE
PRESSURE FLOW STUFFING GEAR
DURATION RPM CURRENT IN AMPERE (35) BEARING CRANKCASE GEARBOX OIL MOTOR MOTOR(DE) PUMP(NDE)
(Kg/cm2) (M3/H) BOX BOX
30 MIN. 282 1.75 185 R-PH Y-PH B-PH 40 40 50 40 50 40 <85 DB <85 DB <85 DB
00:30
01:00
01:30
02:00
02:30
03:00
03:30
04:00
VIBRATION AT RATED PRESSURE
CHAMBER CRANKCASE GEARBOX MOTOR BASE FRAME
AXIAL VERTICAL HORIZONTAL AXIAL VERTICAL HORIZONTAL AXIAL VERTICAL HORIZONTAL AXIAL VERTICAL HORIZONTAL AXIAL VERTICAL HORIZONTAL
<3 MM/S <3 MM/S <3 MM/S <3 MM/S <3 MM/S <3 MM/S <3 MM/S <3 MM/S <3 MM/S <5MM/S <5MM/S <5MM/S <3 MM/S <3 MM/S <3 MM/S
00:30
01:00
01:30
02:00
02:30
03:00
03:30
04:00
REMARKS/COMMENTS:

SIGNATURE: VENDOR SIGNATURE: SIGNATURE: TPI/

(GOMA) CONTRACTOR ( TPL) CLIENT (ONGC)
 SYSTEM –SUBSYSTEM CLASSIFICATION
FOR FIRST GAS –LEAN MEG INJECTION PUMP

SL NO SYSTEM NAME SUB SYSTEM DESCRIPTION SUB- SUBSYSTEM TEST PACK (AS MARKED IN P&ID)

1. PROCESS A. MEG Tank to Lean a) Piping 1. 3’-ON-ML-19151-AS (From 3” isolated valve)

(SUCTION) MEG Pump
2. 3”-ON-ML-19184-AS to TP 1994A (pump ON-Z-1907 A)

3. 3”-ON-ML-19169-AS to TP 1994C (pump ON-Z-1907B)

d) Instrumentation 1. Field instruments

2. Control Room (DCS) instruments

e) Mechanical 1. Lean MEG pumps (2 nos),

2. Valves and fittings

3. Pulsation dampeners

4. Pressure safety valves

f) Electrical 1. connections to MCC/substation

2. Motor

3. LCP

PROCESS G. Lean MEG pump a) Piping 1. 2”-ON-ML-19168-G22 (discharge of pump no ON-Z-1907A)

(DISCHARGE) discharge to TUTU
2. 2”-ON-ML-19165-G22 (Discharge of Pump No. ON-Z-1907B)

3. 2”-ON-ML-19152-G22 (Along with the bypass line)

d) Instrumentation 1. Field Instruments

2. Control room instruments connections

f) Electrical 1. Connections to LCP

2. Connections to substation

g) Mechanical 1. Valves and fittings

2. Pressure relief valve settings

3. Pulsation dampeners

2. Process (SAFETY) PSV relief line from pump a) Piping 1. 3”-ON-ML-19165-AS (Psv relief line of Pump No ON-Z-1907B
to existing MEG storage
tank ( ON- TK-1901)
2. 3”-ON-ML-19155-AS (Common PSV relief line to existing MEG
storage tank ON-TK-1901)

c) Mechanical 1. Valves and fittings

2. PSV settings

3. Instrument Air From TP 2402 to Lean MEG a) Piping 1. 2”-ON-IA-24211-AD1

Injection pumps
2. 1”-ON-IA-24243- AD1 (To pump ON-Z-1907A)

3. 1”-ON-IA-24247- AD1 ( To pump ON-Z-1907B)

d) Mechanical Valves and fittings

e) Instrumentation Local instruments mounted in the line