OAKWELL ENGINEERING INTERNATIONAL PTE LTD

No. 8 ALJUNIED AVE. 3, OAKWELL BUILDING

SINGAPORE 389933
TEL: (65) 6741-9000 FAX: (65) 6741-6613
WEBSITE: www.oakwell.com.sg

BIEN DONG 1 PROJECT

PROJECT NUMBER: 4211281

FAT PROCEDURE (MT1-SK-4910)

DOCUMENT TITLE

TOTAL NO. OF PAGES

17 pages

VENDOR'S ORDER NO.

WHP-PMPS

VENDOR'S OWN DOCUMENT NO.

REV

758911-PVD-Q-MT1-4910-PRO-0007

TRANSMITTAL NO.

DATE
31/08/2011

163

SUBMITTED FOR:

REVIEW / APPROVAL

INFO

FINAL

REVIEW DOES NOT CONSTITUTE ACCEPTANCE OF

DESIGN DETAILS, CALCULATIONS, TEST METHODS
OR MATERIALS DEVELOPED OR SELECTED BY
VENDOR, NOR DOES IT RELIEVE VENDOR FROM
FULL COMPLIANCE WITH CONTRACTUAL OR OTHER
OBLIGATIONS.

VENDOR NAME:

PVD Tech / Oakewll Engineering Intrl Pte ltd

PACKAGE DESCRIPTION:

CHEMICAL INJECTION SKID

A.

ACCEPTED

TAG NO:
B.

ACCEPTED, PROCEED WITH

WORK AND INCORPORATE
COMMENTS AND RE-SUBMIT.

MODEL TYPE:

MT1-SK-4910

WAX/PPD/DEMULSIFIER

VENDOR DOCUMENT NUMBER (IF APPLICABLE):

C.

NOT ACCEPTED. REVISE AND RESUBMIT.

D.

FOR INFORMATION ONLY.

758911-PVD-Q-MT1-4910-PRO-0007
VDRL DOC CODE:

Q22
NAME:

SIGNATURE:

DATE:

PTSC PO No.
18352010/PTSCMC/MHH

Minor comments: Syed Azhar (Mechanical Engineer) 14 Sept 11

PURCHASER DOCUMENT NUMBER

PKG NO.

TYPE

MT1-10-108

Q22

SEQUENCE

001

REV

MT1-10-108-Q22-001

1
WHP-MT1

758911-PVD-Q-MT1-4910-PRO-0007

FACTORY ACCEPTANCE TEST PROCEDURE

MT1-SK-4910
CHEMICAL INJECTION SKID

31/8/11
29/4/11

FOR APPROVAL

CCK
CCK

RAVI

RAVI

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

Work Instruction Title:

Document No.:
758911-PVD-Q-MT1-4910-PRO-0007

REV. No.:

Page:

2 OF 7

Approved By:

Approved Date:

Effective Date:

PROJECT MANAGER

AUGUST 31, 2011

AUGUST 31, 2011

FACTORY ACCEPTANCE TEST

PROCEDURE

1.0

Scope
This procedure covers the requirements and conditions for factory acceptance testing
(FAT) of theChemical
Methanol Injection Package (MT1-SK-4910) for BIEN DONG 1 Project
that are supplied by PVDTECH/Oakwell Engineering International Pte Ltd.

2.0

3.0

Responsibilities
2.1

The factory acceptance testing shall be under the supervision of the Project
Manager or his assigned personnel.

2.2

The Project Department shall be responsible for co-coordinating the functional

test and shall inform the Client Authorized Representative (C.A.R.) to witness
the test.

2.3

The Project Manager and his assigned personnel and his foreman/supervisor
shall be responsible for preparing the test packages and providing all necessary
technical assistance.

Purposes
3.1

The objective for the test is to ensure that the performance of the pumps,
valves and instruments on the completed package can meet the requirement as
specified in Clients specification and to check any deviations.

3.2

Reference Drawings and Documents:

S/No

Description

Document No.

1.
2.
3.
4.
5.
6.
7.
8.
9.

PROJECT SPECIFICATION
P&ID
GA Drawing
ITP
TANK STRESS CALCULATION
TANK DATA SHEET
MANUAL VALVE DATA SHEET
STRAINER DATA SHEET
PUMP & MOTOR DATA SHEET
GENERAL ARRANGEMENT DRAWINGS
- PUMPS AND MOTORS

BD-00-M-S-0345
758911-PVD-P-MT1-4910-PID-0001
758911-PVD-S-MT1-4910-DWG-0001
758911-PVD-Q-MT1-XXX-ITP-0001
758911-PVD-M-MT1-4910-CAL-0001
758911-PVD-M-MT1-4910-DSH-0001
758911-PVD-M-MT1-4910-DSH-0002
758911-PVD-M-MT1-4910-DSH-0003
758911-PVD-M-MT1-4910-DSH-0004

10.

758911-PVD-M-MT1-4910-DWG-0001

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

Work Instruction Title:

Document No.:
758911-PVD-Q-MT1-4910-PRO-0007

REV. No.:

Page:

3 OF 7

Approved By:

Approved Date:

Effective Date:

PROJECT MANAGER

AUGUST 31, 2011

AUGUST 31, 2011

FACTORY ACCEPTANCE TEST

PROCEDURE

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

4.0

STORAGE TANK GA & DETAIL FOR

WAX-PPD-DEMULSIFIER
SKID PIPING GA DRAWINGS
TE-IN SCHEUDLE Piping
INSTRUMENT INDEX
CABLE SCHEUDLE
CABLE BLOCK DIAGRAM
INSTRUMENT CABLE/ CABLE TRAY
LAYOUTS
INSTRUMENT HOOK-UP DIAGRAMS
ALARM / TRIP SET POINT LIST
LEVEL GAUGE / LEVELTRANSMITTER
DATA SHEET
PRESSURE SAFETY VALVE DATA
SHEET
PRESSURE TRANSMITTER DATA
SHEET
PRESSURE GAUGE DATA SHEET
PULSATION DAMPENER DATA SHEET
DIFFERENTIAL LEVEL TRANSMITTER
DATA SHEET
CALIBRATION POT DATA SHEET
PRESSURE CONTROL VALVE DATA
SHEET (Back Pressure Regulator)
SHUT DOWN VALVE DATA SHEET
MONOMETER DATA SHEET
DOUBLE BLOCK AND BLEED DATA
SHEET
SINGLE BLOCK AND BLEED DATA
SHEET
ROTAMETER DATA SHEET
JUNCTION BOX - SPECIFICATION AND
DRAWINGS
SKID ELECTRICAL TERMINATON
DRAWINGS

758911-PVD-M-MT1-4910-DWG-0001
758911-PVD-L-MT1-4910-DWG-0001
758911-PVD-L-MT1-4910-SCH-0001
758911-PVD-I-MT1-4910-GL-0001
758911-PVD-I-MT1-4910-SCH-0002
758911-PVD-I-MT1-4910-DWG-0001
758911-PVD-I-MT1-4910-DWG-0002
758911-PVD-I-MT1-4910-DWG-0003
758911-PVD-I-MT1-4910-GL-0002
758911-PVD-I-MT1-4910-DSH-0001
758911-PVD-I-MT1-4910-DSH-0002
758911-PVD-I-MT1-4910-DSH-0003
758911-PVD-I-MT1-4910-DSH-0004
758911-PVD-I-MT1-4910-DSH-0005
758911-PVD-I-MT1-4910-DSH-0006
758911-PVD-I-MT1-4910-DSH-0007
758911-PVD-I-MT1-4910-DSH-0008
758911-PVD-I-MT1-4910-DSH-0009
758911-PVD-I-MT1-4910-DSH-0010
758911-PVD-I-MT1-4910-DSH-0011
758911-PVD-I-MT1-4910-DSH-0012
758911-PVD-I-MT1-4910-DSH-0013
758911-PVD-E-MT1-4910-GD-0001
758911-PVD-E-MT1-4910-DWG-0001

Preparation and Start-Up Check

4.1

Preparation
B

4.1.1

Pump Power Supply

Check and ensure that a temporary 415V /50Hz / 3 phase power supply
source is provided to each Chemical Injection pump together with

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

Work Instruction Title:

Document No.:
758911-PVD-Q-MT1-4910-PRO-0007

REV. No.:

Page:

4 OF 7

Approved By:

Approved Date:

Effective Date:

PROJECT MANAGER

AUGUST 31, 2011

AUGUST 31, 2011

FACTORY ACCEPTANCE TEST

PROCEDURE

temporary start/stop push buttons.

4.2

4.1.2

Hose and Valve

A quick opening/closing valve shall be attached to the hose that
provides potable water to the Chemical storage tanks through the fill
point nozzle. Valve shall be easily accessible for operation.

4.1.3

Valves and Miscellaneous

All valves, fittings, tubing and pipes used in the test shall have a
maximum pressure rating suitable for the maximum supply pressure.
All drain valves / vent valves along the pipes and tubing shall be all in
a closed position. The drain valves shall be opened when necessary
for draining off liquid or water after testing and vent valves opened
when needed to bleed off air pocket captured within the lines, and then
close back after bleeding off air. Isolation valves to calibration pots
shall be opened for calibration of pump flow rate during testing, and
when desire flow rate achieved the isolation valves shall be turned to
close position. Other valves shall be in an open position.

Start-up check
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7

4.3

Check that the pumps are securely fastened to the skid.

Check the technical data of the pumps.
Check each pipe system is done in accordance with the approved P&ID
Check all instruments are installed as in proper position and are fitted
correctly as in accordance with the approved drawing.
Check pressure setting on the nameplate of all PSVs. Ensure that is in
accordance with the approved P&ID. (refer to Para. 6.2)
Check all instruments are pre-calibrated. (Calibration report /
certificate to be demonstrated).
Ensure the Lubricating oil level in the pump is in correct level.

Fill-up check for pump suction lines (applicable for each pump)
4.3.1

Open water-filled Skid Tank discharge/Outlet valves and let the water
flood the suction lines by gravity.

4.3.2

Check that there is no leakage on all threaded, flanged and welded

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

Work Instruction Title:

Document No.:
758911-PVD-Q-MT1-4910-PRO-0007

REV. No.:

Page:

5 OF 7

Approved By:

Approved Date:

Effective Date:

PROJECT MANAGER

AUGUST 31, 2011

AUGUST 31, 2011

FACTORY ACCEPTANCE TEST

PROCEDURE

connections on all suction lines.

4.3.3

Ensure all liquids on suction lines are properly drained, to ensure no air
lock in the suction system.

4.3.4

Check and ensure all joints (welded & threaded) and instruments along
the suction lines are without leakage after filling of liquid.

4.3.5

Charging pressure of Dampener Gas Filling (Nitrogen only): 80% of

operating pressure.

.
5.0

Procedure
5.1

System Start-up
The sequence of testing shall be carried out as follows:
5.1.1

Set-up system as per approved P&ID.

5.1.2

Install a temporary pressure-creating device (backpressure valve) at the

discharge tie-in point. Marked up P&ID for test circuit to be provided.

5.1.3

Open the pump suction and discharge valves.

5.1.4

Set the pump capacity adjustment knob to 100%.

5.1.5

Turn on the power supply for the pumps one at a time. Measure the
starting current, Noise level, Vibration level.

5.1.6

Pump should be running. Watch out for noise, vibration and any
abnormalities. Check for any leakage along the piping / tubing, pump
internal and external.

5.1.7

Gradually increase the line pressure by closing all pressure-creating

devices slowly till the required rated operating pressure is achieved.

5.1.8

Pressure indicated in pressure gauge would represent the rated

operating pressure required for the pump. The pump capacity shall be
adjusted to the maximum pump capacity at the rated pressure.

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

Work Instruction Title:

Document No.:
758911-PVD-Q-MT1-4910-PRO-0007

REV. No.:

Page:

6 OF 7

Approved By:

Approved Date:

Effective Date:

PROJECT MANAGER

AUGUST 31, 2011

AUGUST 31, 2011

FACTORY ACCEPTANCE TEST

PROCEDURE

5.1.9

6.0

Run the pump for 10 minutes or until the flow at the outlet has
stabilized.

Test Requirement
6.1

Pumps
The pump in the package shall run to obtain the operating requirement as
follows:
Skid Tag No. MT1-SK-4910
S/No Pump Tag No.
1
MT1-P-4910A
2
MT1-P-4910B
3
MT1-P-4920A
4
MT1-P-4920B
5
MT1-P-4940A
6
MT1-P-4940B
LPH liter per hour

6.2

Operating Requirements
60 LPH @ 163.6 barg
60 LPH @ 163.6 barg
4 LPH @ 135.5 barg
4 LPH @135.5 barg
60 LPH @ 163.6 barg
60 LPH @ 163.6 barg

Pressure Safety Valves (PSV)

6.2.1

S/No
1
2
3
4
5
6
6.2.2

The following PSVs shall not be tested during FAT. However, it shall
be verified against factorys calibration certificates that should be made
available. The individual pressure settings are as follows:

PSV Tag No
PSV- 4910A
PSV- 4910B
PSV 4920A
PSV 4920B
PSV 4940A
PSV 4940B

Skid Tag No.MT1-SK-4910

Set Pressure(Barg)
190
190
160
160
190
190

The above-mentioned PSVs must be installed in place before operating

the respective pumps to safeguard the pumps and ancillary equipments
and pipelines.

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

Work Instruction Title:

Document No.:
758911-PVD-Q-MT1-4910-PRO-0007

REV. No.:

Page:

7 OF 7

Approved By:

Approved Date:

Effective Date:

PROJECT MANAGER

AUGUST 31, 2011

AUGUST 31, 2011

FACTORY ACCEPTANCE TEST

PROCEDURE

6.3

Level Transmitters
The high and/or low alarm set-points of the above instruments shall be
checked and confirmed against factory calibration certificates.

6.4

Pressure Transmitters
The pressure transmitter shall be tested as follows:
a) While the system is running, note the reading on the Pressure Gauges and
then check against the display readings of corresponding PIA. The readings
are then verified against the manufacturers calibration certificate.
b) PIA High/Low Alarm set point shall be checked.
c) IRCD rack , instruments ( Flow meters) will only be tested with actual
fluid.. cannot be tested with water.

7.0

IRCD rack Testing

a)
b)
c)

8.0

IRCD rack piping connections are to be checked the interconnection piping are
tightened as per layout drawing.
IRCD rack, all the Shut Down Valves are to be tested the actuator opening
fully close and open positions, by injecting of air supply from the manifold.
All the Flow meters are only be tested with hart communicator to measure the
flow rate reading

Test Report

8.1 All test records shall be prepared by Oakwell and initiated by

PVDTech/Oakwells Representative and Client or C.A.R. and shall be kept
and filed by PVDTech/Oakwells Engineering department.
8.2
8.3

Test records are to be submitted as part of vendor documentation.

The factory acceptance test (FAT) Record Form shall be attached with this
procedure.

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

-------------------------------------------------------------------------------------------Factory Acceptance Test (FAT) Report
Client
Consultants
Purchaser Order
Project
Equipment
Report No.

1.0

Reference
1.1
1.2
1.3

2.0

FAT Procedure
Piping & Instrument Diagram
General Arrangement

Process Parameters
2.1
2.2
2.3
2.4
2.5

3.0

:
:
:
:
: CHEMICAL INJECTION PACKAGE
:

Discharge Pressure
Design Pressure
Capacity/Flowrate
Design Temperature
Operating Temperature

:
:
:
:
: Ambient

Testing Conditions
S.N

Parameters

Testing Medium

Testing Temperature(Amb)

Test Duration

Detail/Actual Value
Potable Water
C
30 mins

Remarks

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

-------------------------------------------------------------------------------------------4.0

Pre-testing Inspection Checklist

S/N
1

Description
Overall appearance and condition

All piping, fitting and connections

All valves and its orientation

All instruments condition

Check for pump lubricant oil for proper

level, if any

Check electrical junction box, wiring

and terminations

Check equipment nameplates and

instrument tags

Status

Remarks

Note: Tick the status column when item has been inspected.
Please fill in the remarks column if any. If space is insufficient, please use
attached remarks form.

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

-------------------------------------------------------------------------------------------5.0

Pump Test Record

PUMP/MOTOR TEST RECORD SHEET
MT1-P-4910 A
MT1-P-4910 B

Skid Tag No.

Test Medium
Pump Model
Pump Tag No.
Operating Flow, m3/hr
Operating Pressure, Bar
Megger Test On Motor R-E
B-E
Y-E
Motor Running Current
Motor Rotation

PUMP/MOTOR TEST RECORD SHEET

MT1-P-4920 A
MT1-P-4920 B

Skid Tag No.

Test Medium
Pump Model
Pump Tag No.
Operating Flow, m3/hr
Operating Pressure, Bar
Megger Test On Motor R-E
B-E
Y-E
Motor Running Current
Motor Rotation

PUMP/MOTOR TEST RECORD SHEET

Skid Tag No.
MT1-P-4940 A
MT1-P-4940 B
Test Medium
Pump Model
Pump Tag No.
Operating Flow, m3/hr
Operating Pressure, Bar
Megger Test On Motor R-E
B-E
Y-E
Motor Running Current
Motor Rotation

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

-------------------------------------------------------------------------------------------DIMENSIONAL CHECK (SKID/TANK)
Skid Dimension
Length(mm):

Width(mm):

Height(mm):

Tank Dimension
Length(mm):

Width(mm):

Height(mm):

5.1

INSTRUMENT CHECK SHEETS

Level Gauge Integrated with Level Transmitter Function Inspection

No.
1

Description

Checked

Remarks

Tag No.: LG/LT-4910

Level Indication of Level Gauge

Tag No.: LG/LT-4920

Level Indication of Level Gauge

Tag No.: LG/LT-4940

Level Indication of Level Gauge

Difference Level Transmitter Function Inspection

No.
1

Description
Tag No.: LZT-4910
4-20 mA
Level Indication of Level Gauge
Tag No.: LZT-4920
4-20 mA
Level Indication of Level Gauge
Tag No.: LZT-4940
4-20 mA
Level Indication of Level Gauge

Checked

Remarks

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

--------------------------------------------------------------------------------------------

Back Pressure Valve Function Inspection

No.
1

Description
Tag No.:PCV-4910 A

Tag No.:PCV-4910 B

Tag No.:PCV-4920 A

Tag No.:PCV-4920 B

Tag No.:PCV-4940 A

Tag No.:PCV-4940 B

Checked

Remarks

Checked

Remarks

Pressure Transmitter Function Inspection

No.
1

Description
Tag No.: PT-4910 A
High Level Alarm
Low Level Alarm
Tag No.: PT-4910 B
High Level Alarm
Low Level Alarm
Tag No.: PT-4920 A
High Level Alarm
Low Level Alarm
Tag No.: PT-4920 B
High Level Alarm
Low Level Alarm
Tag No.: PT-4940 A
High Level Alarm
Low Level Alarm

Tag No.: PT-4940 B

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-------------------------------------------------------------------------------------------High Level Alarm
Low Level Alarm
7
8
9
10
11
12

Tag No.: PIT-4911 A

Low Level Alarm
Tag No.: PIT-4911 B
Low Level Alarm
Tag No.: PIT-4921 A
Low Level Alarm
Tag No.: PIT-4921 B
Low Level Alarm
Tag No.: PIT-4941 A
Low Level Alarm
Tag No.: PIT-4941 B
Low Level Alarm

Calibration Gauge Function Inspection

No.
1
2
3

Description
Tag No.: MT1-4910

Checked

Remarks

Checked

Remarks

Tag No.: MT1-4920

Tag No.: MT1-4940

Shut Down Valve Function Inspection

No.
1
2

Description
Tag No.: SXV-4910A
Tag No.: SXV-4910B

Tag No.: SXV-4910G

Tag No.: SXV-4910H

Tag No.: SXV-4910J

Tag No.: SXV-4910K

Tag No.: SXV-4940A

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

-------------------------------------------------------------------------------------------8

Tag No.: SXV-4940B

Tag No.: SXV-4940G

10

Tag No.: SXV-4940H

11

Tag No.: SXV-4940J

12

Tag No.: SXV-4910K

Flow Meter Function Inspection

No.
1
2

Description
Tag No.: FIT-4910A
Tag No.: FIT -4910B

Tag No.: FIT -4910G

Tag No.: FIT -4910H

Tag No.: FIT -4910J

Tag No.: FIT -4910K

7
8

Tag No.: FIT -4940A

Tag No.: FIT -4940B

Tag No.: FIT -4940G

10

Tag No.: FIT -4940H

11

Tag No.: FIT -4940J

12

Tag No.: FIT -4910K

Checked

Remarks

Checked

Remarks

Checked

Remarks

Level Indicator Function Inspection

No.
1
2
3

Description
Tag No.: LI-4912
Tag No.: LI-4922
Tag No.: LI-4942

Pressure Gauge Function Inspection

No.
1

Description
Tag No.: PG-4910A

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--------------------------------------------------------------------------------------------

5.0

Tag No.: PG-4910B

Tag No.: PG-4920A

Tag No.: PG-4920B

Tag No.: PG-4940A

Tag No.: PG-4940B

NOISE LEVEL CHECK SHEET

S/N
1

CHECK POINT
A

RESULT (dBA) < 85 dBA

Note: The check point should be 1 meter away from the skid.

REMARKS

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

-------------------------------------------------------------------------------------------Pump Test Record
Tag No.
Setting (% Stroke)
100
75
50
25
10
10
25
50
75
100

Pressure
(Barg)

Flowrate
(MPH)

OAKWELL ENGINEERING INTERNATIONAL PTE LTD

--------------------------------------------------------------------------------------------

REMARKS:
S/No.

Descriptions of Deficiency/discrepancy

Action By

Date
Rectified

Status