Mechanical centrifugal pump test run procedure (SAT)

INDEX

1. Purpose
2. Scope
3. Reference and documents required
4. Tools required
5. Man power
6. Items to be tested
7. Pump running procedure
8. Acceptance criteria
9. Reliability
10. Test scheme and check list
11. Appendices
a. Pumps which require mechanical running relevant certificates
b. Mark up P&ID for pump mechanical running (test loop)
c. Operation log sheet
d. Vibration monitoring sheet

1. Purpose
Mechanical running test procedure (SAT) for centrifugal pumps with electric motor drivers
installed in TDU.
2. Scope

This procedure will be applied to all electric driven motor pumps utilized in TDU project.

3. Reference and documents required
i. Electric motor driven centrifugal pump, check sheet and testing record.
ii. Centrifugal Pump and electric motor data sheet, vendor supplied test certificates, pump
performance curves and performance certificates.
iii. FAT A type checklist
iv. P&ID
v. Operation log sheet

4. Tools required
i. Vibration analysis
ii. Temperature Infra red ray (TIR)
iii. Tachometer
iv. F key or F tool

5. Manpower
i. Inspector for rotating equipments
ii. Operator
iii. Electrical and instrument supervisor

6. Items to be tested
Pumps listed below shall be given a mechanical test during SAT / pre-commissioning stage.
The test will be conducted with proper fluid source, such as utility/ RO water as pumping liquid.
List of pumps which required mechanical running test
Sr. NO. Equipment Tag Equipment Name Remark
1 P-980101B SWRO High Pressure Pump
2 P-980201B SWRO High Pressure Pump
3 P-980301B SWRO High Pressure Pump
4 P-980401B SWRO High Pressure Pump
5 P-980103B BWRO High Pressure Pump
6 P-980203B BWRO High Pressure Pump
7 P-980303B BWRO High Pressure Pump
8 P-980403B BWRO High Pressure Pump
9 P-980103D CIP Pump
10 P-980101K MDG Feed Pump
11 P-980201K MDG Feed Pump
12 P-980301K MDG Feed Pump
13 P-980401K RO Flushing Pump
14 P-980402K Utility Water Delivery Pump
15 P-980403K Utility Water Delivery Pump
16 P-980101F Sea Water Pump
17 P-980102F Sea Water Pump
18 P-980103F Sea Water Pump
19 P-980104F Sea Water Pump
20 P-980101J Backwash Pump
21 P-980102J Backwash Pump

7. Pump running procedure
7.1 Checklist activity
1. Final pump alignment must be completed.
2. Motor no-load run (solo-run) test has been completed.
3. Make sure coupling has been installed properly.
4. Coupling guard is installed and securely fastened.
5. Ensure suction strainer is installed (if applicable).
6. All spring support lock on the pipe system line is removed.
7. The unit must have a safety barricade surrounding prior the mechanical running test is
performed.
8. Ensure that pump mechanical running test lines (test loop) has been checked as per mark-up
P&ID.
9. Ensure suction tank or vessel has been filled with the liquid at normal level.
10. Make sure mechanical seal pump is manually being water flushed before the pump start running.
For vertical barrel pump, ensure liquid has been filled into barrel with the vent line in open
condition.
Check the oil quantity and contamination of bearing lubricating oil.
11. Just before running test for the units driven by electric motor, the motor to be run for a moment
to check for correct shaft rotation of the pump unit.
12. Measuring tools and accessories are required to be set properly.
13. Operation log sheet are ready to be filled in.
14. Person in charge for the mechanical running from all discipline related are ready on their
position, for data recording and any response required
7.2 Pump start up procedure:
Before pump start-up you must perform these tasks:-
1. Fully open the suction valve.
2. Check pump priming is adequate at pump suction (for vertical pump, remove the priming plug
from the pump head and slowly fill the pump with liquid. Replace the priming plug and tighten
securely).
3. Fully close or partially open the discharge valve, depending on system conditions.
4. Check the correct direction of rotation of the pump on the motor.
5. Start the pump and check the direction of rotation.
6. Verify the pump by means of the vent valve in pump head and same time, slowly open the
discharge valve until the pump reaches the desired flow (close the vent valve at this time) i.e.
differential pressure drops to operating pressure.
7. Make sure that the motor reaches the rated revolution after starting and also its pressure rises,
and then, open the discharge valve gradually
8. Check the pressure gauge to ensure that the pump quickly reaches the correct discharge
pressure.
9. If the pump fail to reach the correct pressure, perform these steps:
a. Stop the driver
b. Prime the pump again.
c. Restart the pump.
10. Monitor the pump while it is operating.
a. Check the pump for bearing temperature, vibration, and noise.
b. If the pumps exceed normal levels, then shut down the pump immediately and correct
the problem.
11. Repeat steps 7 and 8 until the pump runs properly.






8. Acceptance criteria
Mechanical running test shall be conducted as general for 24 hours running continuously and
log operating data every two hour intervals, this will be done after oil temperature on the
bearing housing are stabilized. For pump without the recycle lines can be tested depend on
working availability of the inventory / process liquid. During the test following requirements
shall be met.
a) Vibration
Unless otherwise specified by pump supplier, unfiltered vibration levels measured on the
bearing housings shall not exceed the acceptable values mentioned in approved pump data
sheets
Note:
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.
Vibration limits at flow rate other than rated flow shall be discussed with TPF if required and
mutually agreed upon.

9. Reliability
Running mechanical test run, pump shall continuously run for 24 hours without any interruption,
especially for pump with minimum flow facilities.
Test scheme and check sheet
Test scheme (by marked up P&ID) and check sheet to be prepared and submitted when issue
application for the testing of respectively pump.
Note:
A. Pump system with minimum flow facility can be tested for 24 hours and agreed by all
parties
B. Pump system without minimum flow facility can be tested for 24 hours and agreed by all
parties
C. For troubleshooting during startup and commissioning, please refer the pump manual
provided.