BSP ENGINEERING MAINTENANCE JOB ROUTINE

B.S.P. ENGINEERING MAINTENANCE JOB ROUTINE

HORIZONTAL CENTRIFUGAL PUMP MJR: M.CP.090(PS).E

APPROVED BY: OPM/11 XOP/2 REVISION 1 OF 01/09

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SCHEDULED PREVENTIVE MAINTENANCE (6 MONTHLY)

SPARE PARTS REQUIRED QTY P/NO. SAP No:

Mechanical Seal (if fitted) as required
Packing (if fitted) as required

OILS AND GREASES REQUIRED QTY P/NO. SAP No:

Tellus 46 200L 8728041381 1000064791
Barbatia Grease 4 17kg 8721304051 1000256035
Alvania EP Grease 2 grease HD BRG 180kg 8721261181 1000086733

SPECIAL TOOLS REQUIRED QTY P/NO. SAP No:

Hand-held vibration pen model SKF CMVP50/mm/s rms

SAFETY:
- FULL PPE MUST BE WORN AT ALL TIME
- APPROPRIATE PERMIT TO WORK TO BE RAISE WHEN REQUIRE

WARNING:
- ISOLATE MECHANICALLY & ELECTRICALLY WHEN REQUIRE
- PUT ISOLATION CERTIFICATE WHERE APPLICABLE
- ADHERED HSE BSP WASTE HANDLING PROCEDURE HSE MODULE 51

IF IN DOUBT, ASK THE SUPERVISOR.

YOU SHALL NOT START, AND YOU ARE REQUIRED TO STOP, ANY ACTIVITY IF YOU BELIEVE IT
CANNOT BE DONE SAFELY, OR IT FAILS TO MEET OUR ENVIRONMENTAL AND HEALTH
STANDARDS. THIS IS YOUR DUTY.
________________________________________________________________________________________________

This MJR section contains Assurance Tasks associated with Performance Standard for PC003 Rotating Equipment.

The Assurance Tasks shall be carried out and the Assurance Measures Results recorded onto the attached Performance
Standard Shop Paper.

The results need to be recorded in SAP via transaction QE51N.

Assurance Tasks:
1. Visual Integrity Inspection (Produced Hydrocarbons)
Leakage from Equipment Package, Pipes & Valves, shaft seals or casings
There shall be no detectable produced hydrocarbon leaks from the rotating equipment.
A leak is defined as:
GAS: 20% LEL measured at 4 (100mm) "downwind"
LIQUID: 4 drips per minute, or 1 litre in 24 hrs.
Assurance Measure: No unacceptable leaks

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 BSP ENGINEERING MAINTENANCE JOB ROUTINE

2. Seal Protection System Function Test (If Fitted)

The seal protection system(s) shall alarm and operate (i.e. trip the unit) at the correct set-point.
Assurance Measure: Seal protection alarms and operates

Note: Function test to be executed by Instrument team

Results recording to be done by Mechanical team
________________________________________________________________________________

PROCEDURE:

Before Shutdown:

1. Visual/noise observation.

1.1 Check all joints and mechanical seal for leakage.

1.2 Check for undue noise.

NOTES: Record any abnormality in the check-sheet for correction or replacement on shutdown.
2. Process observation.

2.1 Check that suction and discharge pressures are normal.

2.2 Record (P1) and discharge (P2) pressures.

3. Vibration measurements.

3.1 Measure vibration from the driver to the driven. Record vibration readings in the checksheet.

3.2 Place vibration pen/meter on or nearest bearing housing and perpendicular to the surface (90 Deg. (+/- 10 Deg.)

3.3 When possible, vibration should be measured in 3 directions.

- The vertical direction (V
- The horizontal direction (H)
- The axial direction (A)

3.4 Check condition of all flexible hoses for wear and cracks.

4. Points of measurement.
Point ID Level Unit
Motor amp Amp
Suction pressure (P1) kPa
Discharge pressure(P2) kPa
Location Vertical Horizontal Axial
Motor NDE (point 1) NDE bearing mm/s
Motor DE (point 2) DE bearing mm/s
Pump DE (point 3) DE bearing mm/s
Pump NDE (point 4) NDE bearing mm/s
Legend: NDE:Non-drive end.
DE:Drive-end.
Notes:Point 4 is to be placed on the pump non-drive end bearing housing.

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 BSP ENGINEERING MAINTENANCE JOB ROUTINE

5 Review vibration level.

5.1 Tolerances based on ISO2372.

Motor power rating: Up to 15 kW.
- Good/Satisfactory: 0 to 1.8 mm/sec RMS
- Still acceptable: 1.8 to 4.5 mm/sec RMS (Alarm level)
- Unacceptable: Above 4.5 mm/sec RMS (Warning level)
Motor power rating: 15 to 300 kW.
- Good/Satisfactory: 0 to 2.8 mm/sec RMS
- Still acceptable: 2.8 to 7.1 mm/sec RMS (Alarm level)
- Unacceptable: Above 7.1 mm/sec RMS (Warning level)
Motor power rating >300KW (Large machines with rigid and heavy foundations where natural frequency
exceeds machine speeds).
- Good/Satisfactory : 0 to 4.5 mm/sec RMS
- Still acceptable : 4.5 to 11.2 mm/s RMS (Alarm level)
- Unacceptable : Above 11.2 mm/s RMS (Warning level).

5.2 Vibration diagnostic broad guidelines - hand-held probe.

- Excessive vertical vibration: Mechanical looseness
- Excessive horizontal and vertical vibration: Imbalance
- Excessive axial vibration: Misalignment
5.3 If vibration level is found excessive (Warning level), shutdown the running pump and start-up/put the stand-by
pump on-line. Carry out the outlined works as stated below.

5.3.1 Alignment.

- Carry out alignment check. Re-align if necessary.

- Record figures of before & after alignment in the checksheet

NOTE:1)Alignment to be zero +/- 0.014mm at all points Face & Bore.
2)For CPRP11 oil transfer Pump - Alignment to be +/- 0.1016mm (.004") angular and +/- 0.1524mm
(0.006") concentric alignment respectively.

5.3.2 Coupling.

- Check condition of drive coupling and bolts. Replace if necessary.

5.3.3 Hold down bolts.

- Check tightness of holding down bolts. If one or more bolts are loose, confirm motor to pump alignment. Re-
torque hold down bolts.

5.3.4 Motor check (if only motor vibration is excessive)

- Uncouple and run the motor.

- Measure motor vibration. If vibration is found excessive, check/replace the motor.

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 BSP ENGINEERING MAINTENANCE JOB ROUTINE

5.3.5 Pump check.

Measure shaft lift and end play clearances (0.13mm/0.005 ins. max). If clearances are found excessive, strip
pump/remove and install exchange unit, as applicable. If removed, send back to workshop. Investigate and
rectify as necessary.

NOTE:
- If major replacement or repairing work is necessary, raise a "Corrective" SAP Work Order showing manpower and
materials required.
- Close Work Permit.
- Enter Equipment History details and change the JOB STATUS to "TECO CNF" in SAP.

5.4 Proceed the following tasks if vibration level is within Good/Satisfactory/Still acceptable condition.

5.4.1 Grease (if applicable)

- If grease nipples are fitted, lubricate pump bearings with Alvania EP Grease 2.

5.4.2 Start-up standby pump.

- Start-up/put standby pump on line. Shutdown running pump.

After shutdown:

6 Mechanical seal cyclone line (if fitted)

6.1 Remove mechanical seal quench/cyclone line. Clean as necessary to ensure free flow of liquid for mechanical
seal cooling/flushing.

7 Lube oil (if oil lubricated)

7.1 Drain oil from pump bearing housing. Clean lubricator bowl and refill with Tellus oil 46.

NOTE: Disposal of lube oil contaminated waste and waste oil shall be refer to HSE BSP WASTE HANDLING
PROCEDURE .HSE MODULE 51.

8 Packing glands (if fitted)

8.1 Replace shaft packing glands. Assemble packing glands with joints 90 degree apart.

8.2 Hand tighten packing glands nut. When the pump is running, ensure that there must be a small leakage.

8.3 If grease nipple is fitted, lubricate the shaft gland packing box with one shot of Barbatia Grease 4.

9 Guards

9.1 Check condition and security of guards.

10 Carry out maintenance painting and preservation work on the unit and its auxiliary equipment

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 BSP ENGINEERING MAINTENANCE JOB ROUTINE

11 Close Work Permit.

12 Enter Equipment History details and change the JOB STATUS to "TECO" in SAP.

13 Record vibration and process readings in SAP equipment history.

- - - - - - - - END - - - - - - - -

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 BSP ENGINEERING MAINTENANCE JOB ROUTINE

HORIZONTAL CENTRIFUGAL PUMP M.CP.090(PS).E

SCHEDULED 6 MONTHLY PREVENTIVE MAINTENANCE

CHECKSHEET
(Record and return the completed check sheets to Respective Support Engineer for analysis).

WORK ORDER NO:

LOCATION. MANUFACTURER SERIAL NO:

EQUIPMENT TYPE/MODEL: DATE LAST OVERHAUL:
HOURS SINCE LAST / OVERHAUL: START SINCE LAST OVERHAUL:
INSPECTION START DATE: FINISH DATE:

No Work-To-Be-Done Value Remarks

1. Visual/noise observation. DONE:YES / NO
1.1 Check all joints and mechanical seal for leakage.
DONE:YES / NO
Check for undue noise.
1.2 NOTES:Record any abnormality for correction or replacement
DONE:YES / NO
on shutdown.

2 Process observation.

2.1 Check that suction and discharge pressures are normal.

DONE:YES / NO

2.2 Record suction (P1) and discharge (P2) pressures. P1 =

DONE:YES / NO
P2 =
Vibration Check
3 REMARKS: Points of measurement.

Point ID Level Unit

Motor amp Amp
Suction pressure (P1) kPa
Discharge pressure(P2) kPa
Location Vertical Horizontal Axial
Motor NDE (point 1) NDE bearing mm/s
Motor DE (point 2) DE bearing mm/s
Pump DE (point 3) DE bearing mm/s
Pump NDE (point 4) NDE bearing mm/s
Legend: NDE:Non-drive end.
DE:Drive-end.
Notes:Point 4 is to be placed on the pump non-drive end bearing housing.

3.1 Review vibration level.

If vibration level is excessive (Warning level), shutdown the running pump and start-up/put stand-by pump on-
line. Carry out the outlined works as stated below.
3.2 Alignment.
- Carry out alignment check. Realign if necessary. (Use laser alignment tools if available).

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 BSP ENGINEERING MAINTENANCE JOB ROUTINE

Before alignment

Face Bore

After alignment

Face Bore

NOTE:Alignment to be zero +/- 0.014mm at all points Face & Bore.

Coupling.
3.3 - Check condition of drive coupling and bolts. Replace if DONE:YES / NO
necessary.
Hold down bolts.
3.4 - Check tightness of holding bolts. If one or more bolts are loose, DONE:YES / NO
confirm motor to pump realignment. Re-torque hold down bolts.
3.5 Motor check. (if only motor vibration is excessive). DONE:YES / NO
3.6 Uncouple and run the motor. DONE:YES / NO
Measure motor vibration. If vibration is found excessive,
3.7 DONE:YES / NO
check/replace the motor.
Pump check.
- Measure bearing life end play clearances (0.13mm/0.005
3.8 ins.max). If clearances are found excessive, strip pump/remove DONE:YES / NO
and install exchange unit, as applicable. If removed, send back
to workshop. Investigate and rectify as necessary.
Record pump bearing lift and end play clearances.
3.9 Lift = DONE:YES / NO
End-play =

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 BSP ENGINEERING MAINTENANCE JOB ROUTINE

NOTE:
If major replacement or repairing work is necessary, raise a "Corrective" SAP Work Order showing manpower
and materials required.
Close Work Permit.
Enter Equipment History details and change the JOB STATUS to "TECO" in SAP.
4 Proceed the following tasks if vibration level is within
DONE:YES / NO
Good/Satisfactory/Still acceptable condition.
5 Start-up/put standby pump on line. Shutdown running pump.
DONE:YES / NO
Grease (if applicable)
6 - If grease nipples are fitted, lubricate pump bearings with
DONE:YES / NO
Alvania EP Grease 2.

Mechanical seal cyclone line (if fitted).

Remove mechanical seal quench/cyclone line. Clean as
7 necessary to ensure free flow of liquid for mechanical seal DONE:YES / NO
cooling/flushing.

Lube oil (if oil lubricated).

8 - Drain oil from pump bearing housing. Clean lubricator bowl
DONE:YES / NO
and refill with Tellus 46 oil to required level.

Packing glands (if fitted).

9 Replace shaft packing glands. DONE:YES / NO

9.1 Assemble packing glands with joints 90 degree apart.

DONE:YES / NO
Hand tighten packing glands nut. When the pump is running,
9.2 ensure that there must be a small leakage. DONE:YES / NO

If grease nipple is fitted,

10 - lubricate the shaft gland packing box with one shot of Barbatia
DONE:YES / NO
Grease 4.

Guards
11 Check condition and security of guards. DONE:YES / NO

Carry out maintenance painting and preservation work on the

12 unit and its
DONE:YES / NO
auxiliary equipment.

Records any component/parts need to be replaced on next visit

Component/Parts Part Number Defect/damaged

Checked by: Date Ref.Ind/Company:

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