DOCUMENT NO.

PT Caltex Pacific Indonesia

REV.

SP-ME-ME-007
DATE :

1
1
OF

OCT 9, 2001
Nurhasan Nurhasan Shawn

SHEET :

18

SPECIFICATION

PREPARED BY CHECKED BY APPROVED BY

NHS NHS SPD

CENTRIFUGAL FIRE PUMPS

PT. CALTEX PACIFIC INDONESIA

REV

DATE

PAGES

DESCRIPTION

PREPD

CHKD

APPD

0 1

10/9/01 15/5/02

ALL ALL

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

NHS Team

NHS Team

SPD Team

TABLE OF CONTENT 1. GENERAL .......................................................................................................................... 3 1.1. 1.2. 1.3. 1.4. 2. Scope........................................................................................................................ 3 Terminology.............................................................................................................. 3 References................................................................................................................. 3 Conflicting Requirement............................................................................................ 4

BASIC DESIGN .................................................................................................................. 4 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. General..................................................................................................................... 4 Nozzles and Miscellaneous Connection ....................................................................... 6 Rotating elements...................................................................................................... 6 Wear Rings ............................................................................................................... 6 Running Clearances................................................................................................... 6 Mechanical Shaft Seals.............................................................................................. 7 Vibration and Balance............................................................................................... 7 Bearings and Lubrication........................................................................................... 8 Materials .................................................................................................................. 8

3.

ACCESSORIES................................................................................................................... 9 3.1. 3.2. 3.3. 3.4. 3.5. Right Angle Gear....................................................................................................... 9 Couplings and Guards............................................................................................... 9 Baseplates/skids ........................................................................................................ 9 Piping..................................................................................................................... 10 Instrumentation....................................................................................................... 11

4. 5. 6.

FABRICATION................................................................................................................. 11 COATING AND PAINTING............................................................................................. 12 INSPECTION AND TESTS............................................................................................... 12 6.1. 6.2. 6.3. 6.4. 6.5. Inspection ............................................................................................................... 12 Tests - General........................................................................................................ 13 Hydrostatic Test ...................................................................................................... 13 Performance and Vibration Tests.............................................................................. 13 NPSH Test .............................................................................................................. 15

7.

PREPARATION FOR SHIPMENT................................................................................... 15

PT. CALTEX PACIFIC INDONESIA

Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

8. 9. 10.

INSTALLATION AND COMMISSIONING..................................................................... 16 ANNUAL TEST................................................................................................................. 16 GUARANTEE................................................................................................................... 16 10.1. 10.2. Mechanical............................................................................................................. 17 Performance ........................................................................................................... 17

11.

VENDOR DATA ............................................................................................................... 17

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1: Project Specific Clarifications & Requirements

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Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

1.

GENERAL 1.1. Scope This Specification covers the minimum performance requirements for heavy duty diesel engine-driven, single or multistage, horizontal or vertical, centrifugal fire water pump(s) for PT Caltex Pacific Indonesia in Riau Province, Sumatra, Indonesia. Generally, this Specification is applicable to pumps which meet any of these conditions : 1) require reliability, 2) are greater than 150 BHP, 3) operate at greater than 3600 RPM, 4) operate at greater than 250 F, 5) are required to pump with low NPSHA, 6) pump flammable stocks, or optimal 7) pump hazardous or corrosive stocks. 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 Refers to PT Caltex Pacific Indonesia as the ultimate 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 the company selected by COMPANY or CONTRACTOR which is responsible for the Purchase Agreement or Purchase Order of the goods/services specified in this specif ication. Note: ? ? For EPC (Engineering, Procurement and Construction) project purposes: The terminology shall have the meaning as above. ? ? For Direct Procurement by COMPANY purposes: Vendor shall also be responsible as CONTRACTOR. 1.3. References 1.3.1. Related Specification : ? ? PP-PC-GG-003
? ? PP-PC-GG-004 ? ? PP-QC-GG-006, ? ? SP-ME-ME-025, ? ? PP-QC-GG-003, ? ? PP-QC-GG-004,

Shipping and Traffic Instruction Packing and Marking Instruction Welding Procedure. Coating and Painting Specification. Inspection and Test Plan at Shop. Inspection and Test Plan at Field.

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Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

? ? SP-ME-ME-008

Diesel Engine for Centrifugal Fire Pumps

1.3.2.

Codes and Standards :

? ? 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. Valves, Flanges and Fittings, and Other Piping Components. Magnetic Particle Examination Methods.

? ? MSS-SP-53 Quality Standards for Steel Castings and for Forging and for

? ? MSS-SP-54 Quality Standards for Steel Castings and for Valves, Flanges and

Fittings, and Other Examination Method.

Piping

Components

Radiographic

? ? MSS-SP-93 Quality Standards for Steel Castings and for Valves, Flanges and

Fittings, and Other Piping Components Radiographic Examination Method - Liquid Penetrant Examination Method.
? ? NFPA-20

Standard for the Installation of Centrifugal fire Pumps.

1.4.

Conflicting Requirement 1.4.1. In case of conflict between this Specification and its associated Specifications and the above Codes and Standards, the Vendor shall bring the matter to the COMPANYs attention for resolution and approval in writing. However, the most stringent requirement shall be applied. Should conflicts exist between this specification and other documents, the following order of precedence shall govern:
? ? Purchase Order. ? ? Data sheets. ? ? This Specification ? ? Other COMPANY Specifications ? ? Other Referenced Publications ? ? Approved for Construction Drawings ? ? Vendors Code

1.4.2.

2.

BASIC DESIGN 2.1. General

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Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

2.1.1. 2.1.2. 2.1.3.

Horizontal pump shall be of split case or end suction design. The horizontal centrifugal pump in horizontal or vertical position shall not be used where a static suction lift is involved. Pumps shall furnish not less than 150% of rated capacity at not less than 65% of total rated head. The shutoff head shall not exceed 120% of rated head for split case pumps, nor 140% for end suction pumps. The deep well pump shall be vertical shaft turbine type pump with rotating impellers suspended from the pump head by a column pipe which also serves as a support for the shaft and bearing. When the static water level exceeds 50 ft (15 m) below ground, oil lubricated type pumps shall be used. (Exception to paragraph 2.1.1 of API-610) Impeller diameters shall not exceed 95% of the maximum diameter. (Addition to paragraphs 2.1.3 and 2.6.1 of API 610) Repelling vane construction is not acceptable. (Addition to paragraph 2.1.4 of API-610) Pumps that have a suction-specific speed (NSS) greater than 11,000 are not acceptable. (Addition to paragraph 2.1.7 of API-610) Parallel operation design is required. Curves shall continuously rise to 110% to 120% of the rated head at shut off. (Addition to paragraph 6.1 (13) of API-610) Suction specific speeds shall be calculated at the best-efficiency flow (as defined by paragraph 2.1 of API-610) for the maximum impeller diameter as defined in paragraph 2.1.1 of this Specification. (Addition to paragraph 2.1.9 of API-610) COMPANY desires pumps which will not produce noise which may cause hearing impairment, speech interference, or a public nuisance. Pump Sound Pressure Levels (SPL) at any location 3 feet from the pump and its connecting piping shall not exceed the following values: Octave Band Center Frequency (Hz) 31 63 125 250 500 1000 2000 4000 Maximum SPL dBA(ref 0.0002 microbar) 100 96 92 90 90 90 90 90

2.1.4.

2.1.5. 2.1.6. 2.1.7. 2.1.8. 2.1.9. 2.1.10.

2.1.11.

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Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

8000 2.1.12.

90

Vendor shall provide evidence of compliance with noise limits for all pumps and motors. This requirement may be satisfied by submitting certified noise test data obtained at Vendor's plant or noise test data obtained on a unit of identical design and construction running under rated load conditions in an existing plant. (Addition to paragraph 2.1.10 of API-610) High energy p ump dynamic heads shall be limited to 850 feet per stage. (Addition to paragraph 2.1.11 of API-610) the rated speed for vertical (not inline) pumps shall be limited to 1800 rpm. (Exception to paragraph 2.1.12 of API-610) No cooling water is available. (Addition to paragraph of API-610) The pump and driver will be installed inland, out-of-doors in Sumatra, Indonesia. Site Conditions are shown on the Data sheets. (Exception to paragraph 2-13 of NFPA 20). No permanently installed meters or hose valves are required for pump on-site performance testing.

2.1.13. 2.1.14. 2.1.15. 2.1.16.

2.1.17. 2.2.

Nozzles and Miscellaneous Connection 2.2.1. (Addition to paragraph 2.3.3 of API-610) Tapped connections (NPS 3/4 minimum) shall be provided to insure complete draining of horizontal pump casings and case-to bearing bracket. Casing vents (NPS 3/4 minimum) are required unless the pump has a self-venting nozzle design. (Exception to paragraph 2.3.6 (1) of API-610) Flat-faced flanges are not acceptable on casings other than cast iron. Flat-Faced cast iron case flanges shall be supplied with mating flat-faced carbon steel (ASTM A105) pipe flanges of equal or greater operating and hydrostatic test pressure ratings.

2.2.2.

2.3.

Rotating elements (Addition to paragraph 2.5.4 of API-610) Impellers for multistage pumps shall be individually secured against axial movement in either direction along the shaft. Interference fits alone are not considered adequate axial mechanical restraint.

2.4.

Wear Rings (Addition to paragraph 2.6.4 of API-610) Renewable front and back case wearing rings or wear plates are required for all pumps unless axial thrust balancing dictates otherwise. Pumping vanes shall not be used to establish axial balance. Multistage pump inter-stage bushings may be used instead of backside case wearing rings.

2.5.

Running Clearances 2.5.1. (Addition to paragraph 2.6.4 of API-610) All actual assembled running clearances shall be measured,. and documented and be available for COMPANY review prior to performance testing.

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Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

2.5.2.

(Addition to paragraph 2.6.4.1 of API-610) When the deflection of multistage pump components unavoidably equals or exceeds the running clearances, materials of construction for these close clearance parts shall resist galling. The galling resistance shall be at least equivalent to materials such as cast iron and bronze. Materials of less galling resistance are not permitted. Hard-facing over corrosion resistant base metal is one acceptable method of providing adequate galling resistance. Final material selections shall be subject to COMPANY review.

2.6.

Mechanical Shaft Seals 2.6.1. (Addition to paragraph 2.7.1.2 of API-610) Hydraulically balanced seals shall provide 12 months of zero leakage minimum. VENDOR is responsible for assuring a reliable seal design. Acceptable manufacturers are: 1) BW/IP, 2) Durametallic, and 3) John Crane. (Addition to p aragraph 2.7.1.10 of API-610) A tapped connection in the seal gland plate or seal chamber for recirculation of flushing fluid shall be provided. For vertical pumps, the seal chamber shall be provided with a vent at the highest point. Pumps with inboard and outboard bearings shall have cartridge mechanical seals. The pressure at the seal face shall be above 25 psig to preclude the entry of air.

2.6.2.

2.7.

Vibration and Balance 2.7.1. (Addition to paragraphs 2.8.1.3, 2.8.1.9, and 2.8.1.10 of API-610) For systems with a wet, lateral critical speed below the maximum continuous running speed (excluding vertical turbine pumps), or if specified, critical speed amplification factors shall be measured during coast down, critical speeds shall be test-stand confirmed, and lateral critical speed vibration analyses are required. (Addition to paragraph 2.8.2.1 of API-610) All rotors with more than two impellers shall be sequentially, multi-plane, dynamically balanced during assembly. balance correction shall only be applied to elements mounted after the previous correction. Rotors with single -keyed couplings shall be balanced with half keys in place. The maximum allowable unbalanced force at any journal at maximum continuous speed shall not exceed 10% of the static loading of that journal. All impeller and rotor balancing shall be documented. Documentation shall be submitted to the COMPANY. (Addition to paragraphs 2.8.2.2 and 2.8.2.3 of API-610) Filtered vibration measurements shall also be made and the results recorded for frequencies of twice running speed and at any dominant sub-synchronous frequencies (defined as greater than 10% of the running frequency amplitude). (Addition to paragraphs 2.8.2.5 of API-610) During the factory performance test, Vendor shall demonstrate that the pump can operate from the quoted minimum

2.7.2.

2.7.3. 2.7.4. 2.7.5.

2.7.6.

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continuous stable flow to 150% of rated flow without exceeding the specified vibration limits of API-610 paragraphs 2.8.2.2 or 2.8.2.3. 2.8. Bearings and Lubrication 2.8.1. 2.8.2. (Addition to paragraph 2.9.1.1 of API-610) Reworked or reconditioned bearings are not acceptable. (Addition to paragraph 2.9.10 of API-610) Replaceable thrust collars shall be provided when axial position or thrust pad temperature monitoring systems are not installed. (Addition to paragraph 2.9.11 of API-610) Constant level oilers shall be fourounce or larger inverted glass bottle Trico Opto-matic. (Addition to paragraph 2.9.1.15 of API-610) Oil fill holes may double as viewing ports if the oiling rings are clearly in sight. (Exception to paragraph 2.9.1.18 of API-610) Oil cooling, if required, shall be by air cooling. Cooling water is not available. (Exception to paragraph 2.10.2 of API-610) When forced circulation or pressure lubrication is provided, it shall be in accordance with Specification EMS-K-3563, General Purpose Pressure Lubrication Systems. The Vendor shall coordinate the lubrication system requirements for pressure-lubricated pump/motor systems. (Addition to paragraph 2.10.5 of API-610) All non-pressure lubricated sleeve bearings shall be ring oil lubric ated. The ring submergence shall be a minimum of 1/4-inch above the lowest point of the oil ring internal diameter when the bearing housing oil sump is at its normal level. Oil rings and bearing housings shall be designed so that rings will not become locked or dislocated if the pump is rolled over or held in an unnatural position while being transported. Splash or flood lubrication systems are not acceptable.

2.8.3. 2.8.4. 2.8.5. 2.8.6.

2.8.7.

2.8.8.

2.8.9. 2.9. Materials 2.9.1. 2.9.2.

(Addition to paragraph 2.11.1.8 of API-610) Process fluid conditions are shown on the data Sheet. (Addition to paragraph 2.11.3.1 of API-610) If Welded, suction and discharge nozzle welds shall be inspected, as specified on the data sheets. Weld procedures shall be submitted for COMPANY review. Vendor shall submit drawings showing major attachment weld design, size, materials, preheat and postweld heat treatment. (Addition to paragraph 2.11.4.3 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 MSSSP-93 for dye penetrant. Ultrasonic inspection procedures and acceptance criteria shall be mutually agreed upon by COMPANY and Vendor.

2.9.3. 2.9.4.

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Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

3.

ACCESSORIES 3.1. Right Angle Gear 3.1.1. Vertical shaft pumps shall be provided with right angle gear. A spiral bevel geared, high efficiency, single reduction, totally enclosed gear unit with vertical hollow shaft shall be provided. The gear shall have service factor of 2.0 if splash lubricated, or 1.5 if furnished with a positive pressure lubrication system. The gear unit shall be equipped with a marine package and shall be air cooled with a normal design ambient temperature for the thermal rating of the gear. The gear shall also include an auxiliary 90/10 Cu-Ni cooling coil for additional cooling when temperature are above the design ambient. The gear ratio shall be suitable for the rated speed of the pump and driver, and the gear head shall be design to transmit maximum horsepower required by the pump at any point throughout the pump characteristic curve from shut off to max. capacity. The gear head shall have thrust bearing of sufficient capacity and ample safety factor to carry the entire weight of the rotating parts of the pump plus the hydraulic thrust of the pump impellers. The upthrust rating shall be at least 30% of the downthrust rating.

3.1.2. 3.1.3.

3.1.4.

3.1.5.

3.2.

Couplings and Guards 3.2.1. (Addition to paragraph 3.2.2 of API-610) Horizontal pumps shall be provided with flexible disk-pack couplings (Thomas or Metastream only) having stainless steel disks. Flexible disks-pack couplings shall have spacers which provide at least 7 inches between the shaft ends. (Addition to paragraph 3.2.4 of API-610) Both halves of couplings shall be bored and key-seated. Each coupling half shall be provided with its key. (addition to paragraph 3.2.5 of API-610) Coupling-to-shaft fits shall be tapered for applications requiring 250 BHP or more or if hub removal is required for seal maintenance regardless of horsepower. Disk-pack couplings shall have a minimum service factor of 1.5 (Addition to paragraph 3.2.7 of API-610) Couplings shall be dynamically balanced if the design speed is over 3600 RPM o r if recommended by the coupling sub-vendor. A coupling guard shall be fabricated, trial fitted and shipped loose. The guard shall conform to GC-K-99519. The filler material shall be woven wire with openings no larger than 3/8-inch and wire no smaller than no. 16 (US standard gauge).

3.2.2. 3.2.3.

3.2.4.

3.2.5.

3.3.

Baseplates/skids

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Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

3.3.1.

Skid components shall not interfere with the installation or removals of lifting gear (e.g slings, shackels, etc). Sling shall not contact skid components during lifting. A drip pan shall be installed under the engine, constructed of not less than 3/8 plate properly supported and slopped to a six-inch channel drain through installed across the center of the skid and drained on each side. Accessible skid surface shall be covered with grouting. For offshore application all bolting on the skid shall be 316 stainless steel. Anti seize compound shall be used on all stainless steel threaded mating surface to prevent seizing regardless of the force applied. The compound shall be impervious to sea water wash out and will not drip or run or lose lubricity under severe weather conditions. The skid shall be constructed to provide easy removal of the engine oil pan without removing the engine from the skid. Oil drain shall be accessible for draining without draining into the skid drain pan. (Addition to paragraph 3.3.1.3 of API-610) Final pad machining shall occur after all base-plate welding and stress relieving, if any, is completed. All machinery pads on the base-plate shall be machined to allow the installation of 1/8-inch shims under the mounting locations on the motor. Stainless steel shim packs a minimum of 1/4-inch thick shall be included. (Addition to paragraph 3.3.1.7 of API-610) If specified as skid-mounted, units shall comply to this paragraph and paragraph 2.4.3 of API-610). (Addition to paragraph 3.3.1.8 of API-610) The base-plate and pedestal support assembly shall be the heavy duty grouted-type. 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 3.3.1.11 of API-610) Vertical leveling screws shall be provided for all base-plates/skids. (Addition to paragraph 3.3.1.12 of API-610) A minimal 2-inch vertical clearance shall be provided under the center of each drive element for insertion of a hydraulic jack. Alignment screws shall be provided.

3.3.2.

3.3.3.

3.3.4.

3.3.5. 3.3.6.

3.3.7. 3.3.8.

3.3.9. 3.3.10.

3.4.

Piping 3.4.1. 3.4.2. Piping shall be designed, fabricated and tested in accordance with ANSI B 31.3 The cooling water supply piping shall be from the discharged of the pump, taken off prior to the pump discharged valve. Threaded rigid piping shall be used for this connection. The pipe connection shall include an indicating manual shut off valve, an approved flushing type strainer, pressure regulator, automatic electric solenoid valve listed for fire protection services, and a second indicating manual shut off valve. A by-pass line with manual valves and flush type strainers shall be installed around the manual shut off valve, strainer, pressure regulator, and solenoid valve.

3.4.3.

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Centrifugal Fire Pumps SP-ME-ME-007 Rev. 1

3.4.4.

(Exception to paragraph 3.4.1.11 of API-610) For handling nonflammable or nontoxic fluids, pipe joints and connections may be Vendor 's standard or as specified by COMPANY on the Data Sheet. Lube oil shall be considered a flammable fluid. The minimum allowable pipe size is SCH80 NPS 3/4. (Additions to paragraph 3.4.3.4 of API-610) Carbon steel lube oil piping shall not be used. Stainless steel piping and tubing shall be cleaned with a suitable solvent other than hydrochloric acid. Cleaning shall be performed by the Vendor prior to assembly of the pump/driver.

3.4.5.

3.5.

Instrumentation When specified and as indicated on the Data Sheets DS-736, Vendor shall supply (manufacturers are subject to COMPANY approval) and install instrumentation : 3.5.1. 3.5.2. 3.5.3. Lube oil temperature indication, alarm and shutdown sensors; Lube oil low level indication, alarm and shutdown sensors; For multistage pumps with hydrodynamic thrust bearing: thrust bearing temperature indication, alarm and shutdown sensors. A minimum of three temperature sensors (RTD or thermocouple ) shall be embedded in each side in accordance with Drawing GB-G-1098. As indicated of the data Sheets, Vendor or COMPANY shall supply a multichannel, voting logic temperature monitor with first-out indication, continuous display of the highest channel, channel selection, channel fault disable, alarm when one sensor reaches set point and shutdown when two of three reach set point. Bearing housing or dual X -Y shaft vibration monitoring system us ing BentlyNevada accelerometers or non-contact shaft probes. Axial position monitoring system shall also be supplied for multistage pumps with differential pressures more than 1000 psi or if recommended by Vendor. Mounting must be rigid and free from local resonance. As indicated of the Data Sheets, Vendor or COMPANY shall supply monitors which will use constant velocity criteria with velocity display, dual channel voting logic, first out indication, continuous display of the highest channel, channel selection, channel fault disable, alarm and shutdown in accordance with and API-678 and API-670. Plug in, field changeable filters will be used. Vane passing frequencies will normally be filtered.

3.5.4.

4.

FABRICATION 4.1. 4.2. 4.3. 4.4. 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. No fabrication shall be sub-contracted without the prior written approval of the COMPANY. Material shall be as stated on data sheet. Alternative materials may be used if advantageous with the prior approval of the COMPANY. Proposed substitutions must be clearly defined.

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5.

COATING AND PAINTING Unless otherwise specified, Coating and Painting shall be in accordance with SP-ME-ME-025 Coating and Painting Specification.

6.

INSPECTION AND TESTS 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" 6.1. Inspection The intent of inspection is to provide quality control during all activities rather than only final acceptance criteria. The Vendor is responsible for QA/QC within his own plant as well as assuring and coordinating that all sub-vendors and suppliers comply with their QA/QC requirements as specified, generally recognized or implied. 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 (Addition to paragraph 4.2 API-610) Equipment will normally be inspected at the various plants. A pre-inspection meeting between the COMPANY, Vendor and major sub-vendors 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 casting; ? ? Witnessed repairs of casting; ? ? In-process inspection of welding; ? ? Inspection of parts before assembly; ? ? Review of material test reports and certification; ? ? 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

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? ? Other inspection which is required by specifications referenced and/or included in this

Specification. 6.2. Tests - General 6.2.1. As a minimum, the following tests shall be performed: hydrostatic, residual unbalance if 3 or more stages, two hours performance and vibration, postperformance dismantle if multistage. (Addition to paragraph 4.3.1 of API-610) For any pump rated over 400 HP and all multistage pumps, or if requested, Vendor shall submit test agendas at least two months prior to testing. The agendas shall include a description of the test loop setup, instrumentation, and a specific step-by-step description of the test program. If any, pressurized lube oil systems used during running tests shall meet the cleanliness requirements of API-614, Section 4.3. (Addition to paragraph 4.3.1.3 of API-610) Required tests are shown on the Data Sheets. Whether the tests are witnessed are also shown on the Data Sheets.

6.2.2.

6.2.3. 6.2.4. 6.3.

Hydrostatic Test (Addition to paragraph 4.3.2.3 of API-610) The gaskets used during hydrostatic tests shall be identical to those supplied with the pump. Leaks past gasketed areas are unacceptable.

6.4.

Performance and Vibration Tests 6.4.1. (Addition to paragraph 4.3.3.1 of API-610) The pump section pressure during performance and vibration tests shall not exceed the rated suction pressure specified on the Data Sheet. As a minimum, Vendor shall record all mechanical and performance test data at the following five points: shutoff, minimum continuous stable flow, half-way between minimum continuous and rated flow, rated flow and 150 % of rated flow. The pump shall be run at least two hours after all bearing temperatures have stabilized (the first 15 minutes interval during which the bearing temperature changes no more than 2F). A complete set of mechanical data shall be recorded every 15 minutes and at every performance test point. (Addition to paragraph 4.3.3.2 of API-610) If a performance test should be specifically waived by COMPANY, the pump head, power and NPSHR shall fall within the specified limits of paragraph 4.3.3.6 of API-610). (Addition to paragraph 4.3.3.5 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. (Addition to paragraph of API-610) For pumps/motors provided with pressurized lube oil systems, lube oil flow and pressure as well as inlet and drain temperatures shall be recorded at each mechanical test data point.

6.4.2.

6.4.3.

6.4.4. 6.4.5.

6.4.6.

6.4.7.

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6.4.8.

Lube oil inlet temperatures shall be varied during the performance mechanical tests. The temperature range shall not be less than that allowed in the Vendors Operating manual for the pump. 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. Lube oil temperatures during running tests shall not exceed 180F or 70F above the specified ambient temperature, whichever is less. Radial bearing metal temperatures shall not exceed 180F. For pressurized lube oil systems, the maximum radial bearing temperature rise shall not exceed 50F at the most adverse operating condition. If the temperature exceeds the above values, the cause shall be corrected and the entire test repeated. (Addition to paragraph 4.3.3.7 of API -610) When hydrodynamic thrust bearings are supplied with pumps of three or more stages, the 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 loads 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. (Addition to paragraph 4.3.3.8 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

6.4.9.

6.4.10. 6.4.11.

6.4.12.

6.4.13.

on the Data Sheet);

? ? Midway between the minimum operating and rated capacity (75% of rated

capacity if not specified on the Data Sheet);

? ? Rated capacity; and ? ? Maximum specified operating capacity (150% 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. 6.4.14. If the pumps are purchased with probes, these shall be used for vibration test. If the pumps are purchased with accelerometers, these shall be used for vibration test 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 housing with accelerometers if the speed is 1200 rpm or le ss, otherwise on the shaft with probes. Rolling element pumps shall have vibration measured with accelerometers. If Vendor -supplied, temporarily installed proximity probes are

6.4.15.

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used, vibration acceptance shall be based on the calibrated probes (criteria per paragraph 2.8.2.3 of API-610). 6.4.16. 6.4.17. Vendor shall record unfiltered vibration and vibration filtered at running speed, twice running speed, and vane passing frequencies. The name, model number, and latest calibration date of the transducers and analyzer used for vibration measurements shall be recorded on the test log. When proximity probes are used, Vendor shall measure and record the slow-roll run-out at each probe. (Addition to paragraph 4.3.3.10 of API-610) if specified, 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.

6.4.18.

6.5.

NPSH Test (Addition to paragraph 4.3.4 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-003, Transportation and Traffic Instructions, PP-PC-GG-004 Packing and Marking Instruction. At the completion of the equipment testing, Vendor shall prepare the equipment for shipment and storage according to manufacturers recommendation procedures. Vendor shall provide engine oil and coolant and gear housing oil for initial fields fill. All untapped openings shall be provided with 3/16 inch thick metal or 0.5 inch wood closures bolted in place with no less then four bolts with full rubber gaskets. All tapped openings disconnected for shipping purpose shall be plugged with solid, long-shank steel plugs wrapped with teflon tape. All connections, including those for instruments, instrument leads, and the like shall be identified with a securely attached 316 stainless steel metal tag indicating the type of connection, the instrument, or the line description of the connecting piping. 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 of the unit for which it is intended. Small, easily damaged parts shall be removed, tagged and adequately protected from damage during shipment by storing in wooden crates. The wooden crates shall contain a packing list on the outside. All item which can be damaged by water, shall be securely wrapped in waterproof paper or plastic before being placed in wooden crates.

7.2. 7.3. 7.4.

7.5.

7.6.

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7.7.

(Exception to paragraph 4.4.1.1 of API-610) The exterior surface of the equipment and associated instruments and piping shall be coated in accordance with the Coating System Specification SP-ME-ME-026. (Addition to paragraph 4.4.1.5 of API-610) After test and inspection, all internal parts including bearings, shafts and all machined surfaces shall be flushed and coated with a commercial purpose-made Rust Preventative to protect equipment during shipment and outdoor storage for six months. Vendor shall provide written storage procedures. (Addition to paragraph 4.4.1.6 of API-610) Flanged openings shall be covered with bolted, rubber gasketed metal closures.

7.8.

7.9.

8.

INSTALLATION AND COMMISSIONING 8.1. 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. Field acceptance test shall be conducted as defined in paragraph 11-2 of NFPA20. Vendor shall be responsible for conducting the tests and shall submit a test agenda at least two months prior to testing. 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 optical alignment tools, multi-channel direct readout vibration monitors, multi-channel direct readout temperature monitors, ammeters, etc.

8.2.

8.3.

8.4.

9.

ANNUAL TEST Annual test shall be conducted as defined in paragraph 11-3 of NFPA20. Any signif icant reduction in the operating characteristics of the fire pump assembly shall be reported and repairs made immediately.

10.

GUARANTEE

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10.1.

Mechanical 10.1.1. All equipment and component parts shall be warranted by the Vendor against defective materials, design, and workmanship for 1 year after being placed in service (but not more than 18 months after date of shipment) If any mal-performance or defects occur during the guarantee and warranty period, the Vendor shall make all necessary alterations, repairs, and replacement free of charge, free on COMPANY warehouse. Field labor charges, if any, shall be subject to negotiation between the Vendor and the COMPANY.

10.1.2.

10.2.

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.

11.

VENDOR DATA (Addition to paragraph 6.2. of API-610) 11.1. 11.2. Vendor shall submit (Air Mail or courier) certified dimensional and detail drawings, other documents to COMPANY and the Vendor's Data Requirement List. Vendor shall submit an Activity Bar Chart Schedule. As a minimum the schedule shall include activities and intervals for:
? ? Design of the pump, driver, foundation, instrumentation, controller etc.; ? ? COMPANY drawing review or approval as applicable; ? ? Procurement of components; ? ? Fabrication of components; ? ? Inspection and testing including hold points as established in the pre-inspection

meeting for individual components; and

? ? Transportation

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