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REKMAL
CONSORTIUM
WORK METHOD MANUALPROCEDURE NO:
ONSHORE CONSTRUCTION
WMM-MCOTR-110
REVISION NO.: 0
MECHANICAL PUMP TEST RUN PROCEDURE
FOR
PETRONAS CARIGALI SDN BHD
KUALA LUMPUR
CONSORTIUM REKAYASA INDUSTRI MALAYSIA AND SIMFONI
TEMASEKPCSB
REV
NO.DATE PREPARED BY REVIEWED BY APPROVED BY REVIEWED BY APPROVED BY
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
0 27 . 04 . 10 Iwan 27.04.20 Sholeh 29.04.10 Re!
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Page 2 of 17
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1 PURPOSE 3
2 SCOPE 3
3 REFERENCE 3
4 DEFINITIONS 3
5 PROCEDURES 3
5.1 ITEMS TO BE TESTED 35.2 PRE-REUISITE C!EC" 45.3 PUMP RUNNING PROCEDURE 5
5.4 ACCEPTANCE CRITERIA #5.5 TEST SC!EME AND C!EC" LIST 7
APPENDICES
APPENDICES 1 $ L%&' of '(e P)*+& ,(%( e/)%e
*e(a0%a )00%0g 'e&'APPENDICES 2 $ Ma-)+ PID fo P)*+ Me(a0%a
R)00%0g Te&' Loo+6
23 89 o0:.
APPENDICES 3 $ O+ea'%o0 Log S(ee'.
APPENDICES 4 $ ;%8a'%o0 Mo0%'o%0g S(ee'
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APPENDICES 5$ MCC-2<6 Ee'% Mo'o-D%=e0 Ce0'%f)ga
P)*+6 C(e&(ee' a09 Te&'%0g Reo9
APPENDICES #$ S'e+ 8: &'e+ fo *e(a0%a )0 'e&'
+oe9)e
1. PURPOSE
This document generally covers the Mechanical Running Test
Procedure for Pumps with electric motor drivers for MCOT
Rejuvenation Project Phase 2.
Test procedure for each pump will have checlist descri!ing
procedure for running the specified pump.
2. SCOPE
This procedure shall !e applied to all electric"driven motor
pumps utili#ed in MCOT Rejuvenation Phase 2 Project$ from 2%&
'( Plan$ MC("1$ and MC("2.
3. REFERENCE
I. Testing and Precommissioning Plan Procedure$ (oc. )o.
P*P"MCOTR"1+,$
II. (etailed Testing and Precommissioning Plan Procedure$
(oc. )o. P*P"MCOTR"1+'$
III. ,P- 1& / th edition.
IV. Carigali *tandard Procedure$ C*P"T"2&$ 0uideline for
Testing Precommissioning Procedure.
4. DEFINITIONS
PC*' Petronas Carigali *dn 'hd
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Remal Reayasa -ndustri Malaysia *dn 'hd
5. PROCEDURES
5.1 ITEMS TO BE TESTED
Pump listed in the ,ppendices"1 shall !e given a mechanical
running test during precommissioning stage.
The test will !e conducted with the proper fluid source$ such as
utility water or the process product as the pumping li3uid.
5.2 PRE-REUISITE C!EC"
The prere3uisite chec shall !e made on the following items
!efore the mechanical running test is performed
4.2.1 (ocumentsi. MCC 5 2/$ 6lectric Motor (riven Centrifugal
Pump$ Checsheet and Testing Record.
ii. MCC 5 &7$ Coupling ,lignment Record *heetiii. Pump ,lignment *heetiv. Operation 8og sheetv. P -(
4.2.2 63uipment *tatutory,ll e3uipment as stated in P-(
4.2.% 9*6 Re3uirementi. :ire 6;tinguisherii. *afety !arricade surrounding area pump to !e
tested
4.2.7 Toolsi. <i!ration analysis.ii. Temperature -nfrared Ray =T-R>iii. Tachometeriv. : ey or : tool
4.2.4 Man Poweri. -nspector Rotating
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ii. Operator
iii. 6lectrical and -nstrument *upervisoriv. Mechanical
4.2. Chec list activity
i. :inal pump alignment must !e completed
ii. Motor no"load run =solo"run> test has !een
completed.
iii. Mae sure coupling has !een installed properly
iv. Coupling guard is installed and securelyfastened
v. 6nsure suction strainer are installed
vi. ,ll spring support loc on the pipe system line
are removed
vii. The unit must have a safety !arricade
surrounding prior the mechanical running test
is performed.
viii. 6nsure that the pump mechanical running test
lines =test 8oop> has !een checed as per
mar"up P-(.
i;. 6nsure the fire e;tinguisher is presented near
the unit
x. Mae sure that vessel or *ump has !een filled
with the li3uid at normal level.
;i. Mae sure mechanical seal pump is manually
!eing water flushed !efore the pump start
running. :or vertical !arrel pump$ ensure li3uid
has !een filled into the !arrel with the vent line
in open condition.
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xii. ?ust !efore the running test for the units driven
!y electric motor$ the motor to !e run for a
moment to chec for correct shaft rotation of
the pump unit.
xiii. Measuring tools and accessories are re3uired
to !e set properly
xiv. Operation log sheet are ready to !e filled in.
xv. Person in charge for the mechanical running
from all discipline related are ready on theirposition$ for data recording and any response
re3uired.
5.3 PUMP RUNNING PROCEDURE
Pump will have a step"!y"step procedure for running. These
procedures will !e provided as a checlist prior to run the unit.
6ach items listed on the step"!y"step procedure to !e confirmed
or mutually agreed !y R6@M,8 and PMT $ refer to ,ppendices .
5.4 ACCEPTANCE CRITERIA
Mechanical running test shall !e conducted as general for 27
=twenty four> hours running continuously and log operating data
every two hour intervals$ this will !e done after the oil
temperature on the !earing housing are sta!ili#ed. :or pump
without the recycle lines can !e tested depend on woring
avai!ility of the inventory A process li3uid.
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(uring the running test$ the following re3uirements shall !e met.
5.4.1;IBRATION
Bnless otherwise specified !y vendor. Bnfiltered vi!ration
levels measured on the !earing housings shall not e;ceed
the value given !elow
• :or centrifugal pump which follow the ,P- 1& /th
6dition. Ma;. unfiltered vi!ration %.& mmAs =&.12
inAs> RM*.
• <ertical *uspended pump which follow the ,P- 1&
/th 6dition. Ma;. unfiltered vi!ration 4.& mmAs = &.2
inchAs> RM*.
Note :
1. Vibration readings will be taken on the upper
bearing housing of the motor for vertical pumps with rigid
couplings and on the top pump bearing housing for vertical
pumps with flexible couplings.
2. Vibration limits at flow rate other than the rated
flow should be discussed with MCOT if reuired and mutuall!
agreed upon.
3. "ll the vibration check and recording will be done
as per "#$ %&' (inth edition section ).*.+
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5.4.2BEARING TEMPERATURE (Recheck to Vendor
recommendation)
,ll pumps$ motors shall operate within the following !earing
temperature limits =as per "#$,%&' para. ).&'.2- unless otherwise
specified b! manufacturer
• :or pressurised system$ oil outlet temperature !elow
&&
C =1&&
:>
• :or ring oiled or spash system$ oil sump temperature
!elow +2&C =1+& &:>
5.4.3Re%a8%%':
Running mechanical test run$ pump shall continuously run for 27hours without any interruption$ especially for pump withminimum flow facilities.
5.5 TEST SC!EME AND C!EC" S!EET
Test scheme =!y mared up P-(> and chec sheet to !e
prepared and su!mitted =attached> when issue application for
the testing of respectively pump. These document will !e part of
Test Report$ refer to chec sheet MCC"2/.
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APPENDICES 1
LIST OF PUMPS ?!IC! REUIRE MEC!ANICAL RUNNING
TEST
No. E"#$%&en' no. Na&eRe&a()
1 P*42+0P(o#,e Wa'e( T(an-e(
P#&% W$'h &$n$&#& /low
2 P*42+P(o#,e Wa'e( T(an-e(
P#&%W$'h &$n$&#& /low
P*4270P(o#,e Wa'e( T(an-e(
P#&%W$'h &$n$&#& /low
4 P*4240 AIG/ V*4220 Re,$(,#la'$on
P#&%W$'h &$n$&#& /low
P*4240 BIG/ V*4220 Re,$(,#la'$on
P#&%W$'h &$n$&#& /low
+ P*420 AIG/ V*420 Re,$(,#la'$on
P#&%
W$'h &$n$&#& /low
7 P*420 BIG/ V*420 Re,$(,#la'$on
P#&%W$'h &$n$&#& /low
P*1+20 A Slo% O$l T(an-e( P#&% W$'h &$n$&#& /low
9 P*1+20 B Slo% O$l T(an-e( P#&% W$'h &$n$&#& /low
10 P*1410 S3PS Boo-'e( P#&% W$'h &$n$&#& /low
11 P*1420 S3PS Boo-'e( P#&% W$'h &$n$&#& /low
12 P*140 S3PS Boo-'e( P#&% W$'h &$n$&#& /low
1 P*1000 /a-' 3oo% P#&% S)$ W$'h &$n$&#& /low
14 P*2000 e' M$5 P#&% S)$ W$'h &$n$&#& /low
1 P*1200 6(#e P#&% W$'h &$n$&#& /low
1+ P*+900 O$l! Wa'e( P#&% W$'h &$n$&#& /low
17 P*+910 O$l! Wa'e( P#&% W$'h &$n$&#& /low1 P*+940 O$l! Wa'e( P#&% W$'h &$n$&#& /low
19 P*427 P(o#,e Wa'e( Re,$(,#la'$on W$'h &$n$&#& /low
20 P*420 P(o#,e Wa'e( Re,$(,#la'$on W$'h &$n$&#& /low
21 P*410 San Wa-h T(an-e( W$'h &$n$&#& /low
22 P*420 San Wa-h T(an-e( W$'h &$n$&#& /low
No'e $
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Pump system with minimum flow facility can !e tested for 27 hours
and agreed !y all parties
APPENDICES 1 o0'%0)e9LIST OF PUMPS ?!IC! REUIRE MEC!ANICAL RUNNING
TEST
No. E"#$%&en' no. Na&eRe&a()
2 P*40e' P#&% o San Wa-he(
S!-'e& Non ele,'($,*($en &o'o(
24 P*1+10 A Slo% O$l S#&% P#&% W$'ho#' &$n. low
2 P*1+10 B Slo% O$l S#&% P#&% W$'ho#' &$n. low
2+ P*+ AEl#en' D$-,ha(8e S#&%
P#&%
W$'ho#' &$n. low
27 P*+ BEl#en' D$-,ha(8e S#&%
P#&%W$'ho#' &$n. low
2 P*+ 6El#en' D$-,ha(8e S#&%
P#&%W$'ho#' &$n. low
29 P*+20 A TPI*2 S#&% P#&% W$'ho#' &$n. low
0 P*+20 B TPI*2 S#&% P#&% W$'ho#' &$n. low
1 P*+20 6 TPI*2 S#&% P#&% W$'ho#' &$n. low
2 P*+40 A TPI*2 Wa'e( P#&% W$'ho#' &$n. low
P*+40 B TPI*2 Wa'e( P#&% W$'ho#' &$n. low
4 P*+40 6 TPI*2 Wa'e( P#&% W$'ho#' &$n. low
P*+9 A S'o(& Wa'e( S#&% P#&% W$'ho#' &$n. low
+ P*+9 B S'o(& Wa'e( S#&% P#&% W$'ho#' &$n. low
7 P*+20 A Rel$e 3$"#$ P#&% W$'ho#' &$n. low
P*+20 B Rel$e 3$"#$ P#&% W$'ho#' &$n. low
9 P*74 A 6lo-e D(a$n S#&% P#&% W$'ho#' &$n. low
40 P*74 B 6lo-e D(a$n S#&% P#&% W$'ho#' &$n. low
41 P*7496lo-e D(a$n S#&% Ra$n
Wa'e( P#&%W$'ho#' &$n. low
No'e $
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Pump system without minimum flow facility will !e tested as re3uired
and agreed !y all parties.
APPENDICES 2
MAR"-UP PID FOR PUMP MEC!ANICAL RUNNING TEST LOOP
FOR 23 "BD ONL@
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APPENDICES 3
OPERATION LOG S!EET
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APPENDICES 4
;IBRATION MONITORING S!EET
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APPENDICES 5
ELECTRIC MOTOR DRI;EN CENTRIFUGAL PUMP
C!EC"S!EET AND TESTING RECORD
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APPENDICES #
S'e+ 8: &'e+ S'a' )+ Poe9)e