PRE-COMMISSIONING ITP-PC-M-PUMP

PUMP
INSPECTION & TEST REPORT

A) INTRODUCTION

The following procedure is intended to ensure that the quality of constructed product and its associated
activities are completed by competent persons and:
1. Comply with current and applicable specified requirements (including Corporation specifications /
contract terms and conditions, national / international standards, manufacturer’s
recommendations and industry best practices.
2. Are conducted in a safe and professional manner.
3. Provide an audit trail for verification of Quality Assurance and Quality Control compliance.

This procedure is for all PUMP Competent personnel shall complete all inspection / construction
activities and record all activities on Water Corporation Document ITP-PC-M_PUMP for each asset
constructed.

NOTE:
 Please ensure that all ITP documents are completed by a competent person and that all Water
Corporation SAFETY and operational requirements are to be complied with at all times in
relation with Water Corporation and AS/NZS Standards where applicable.

B) COMPLETED DOCUMENTS

Completed documents are to be scanned and saved as a .pdf file in the relevant AQUA folder utilising
the following naming convention:

LOCATION - DISCIPLINE - ASSET – ASSET TYPE – VENDOR NAME – DOCUMENT TYPE – P&ID
TAG – REVISION NUMBER

E.g. RavenswoodPS_M_Valve_Butterfly_Tyco_PC_1000BV3422_1

The commissioning manager shall coordinate incorporation of completed ITPs in conjunction with the
CAMEL.

Feedback on improvements to ITPs should be directed to MESB Mechanical for incorporation into future
versions.

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AQUADoc No: 10089641 Document Custodian: Team Leader – Mechanical
Version Date: 03.02.2016 Next Review Date: 03.02.2019
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INSPECTION & TEST REPORT

* All Pre-Commissioning documents shall contain the following sections (1 – 2) which capture generic
asset information

1. REFERENCE INFORMATION
INSPECTION DATA ASSET DATA
PROJECT NAME: MANUFACTURER:

LOCATION: MF SERIAL NO:

INSPECTION DATE: WC FLER / TAG NO:

INSPECTOR NAME: TYPE / MODEL NO / SIZE:

PROJECT / CONTRACT NO: DESIGN CRITERIA:

ATTENDEES:

2. INSPECTION PREPARATION
OSH compliance requirements.
Obtain QA / QC documentation (review outstanding items).
Relevant Water Corporation standards.
Relevant Australian Standards.
Supporting contract documentation / approved drawings.
Provision of required test equipment (portable vibration monitor and temperature sensor).
Provision of required test reports and certificates
Provision of completed construction verification

3. INSPECTION PRELIMINARIES YES NO N/A COMMENTS/DETAILS

“Punchlist” reviewed and free of significant
1 defects preventing asset pre-
commissioning?
Hazard identification and risk assessment for
2
asset pre-commissioning complete?
Electrical construction and pre-
3
commissioning ITPs complete?
Mechanical and electrical site specific pre-
4
requisite ITPs complete?

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AQUADoc No: 10089641 Document Custodian: Team Leader – Mechanical
Version Date: 03.02.2016 Next Review Date: 03.02.2019
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INSPECTION & TEST REPORT

*Contents of Section 4 (Inspection) and Section 5 (Test) are Asset Specific and shall reflect relevant SPS /
Australian Standard(s) where practicable. Entries shall also be worded to reflect the procedures involved in
a step-by-step manner; i.e. “Conduct visual inspection and ensure pre-start photographs are taken”,
“Extract bearing housing covers to expose bearings and full shaft length”.

4. INSPECTION YES NO N/A COMMENTS/DETAILS

ROTATION
Pump and motor shafts rotate freely by
1 hand without rub, noise or obvious out of
balance?
ANCILLARY AND TEMPORARY EQUIPMENT
All ancillary systems available and on-line?
2 (eg. external seal water, lube oil, cooling
water, room ventilation systems)
Temporary instruments (if required)
3 installed? (eg. vibration transducers, flow
meters, pressure gauges)
CONTROL AND PROTECTION SYSTEMS
All electrical / instrument control and
protection systems available and on-line?
4
(eg. pump and motor protection, process
control systems)
All mechanical / hydraulic control and
protection devices available and on-line?
5 (eg. min. flow recirculation lines, surge
vessels, relief valves, bursting discs,
automatic control valves)
HYDRAULICS
6 Pump suction fully primed?
Pump casing full of liquid and all air
7
removed?
8 All pump suction valves open?
Open flow path available for pumped liquid
9
once the discharge valve is opened?
Seal water system primed and isolation
10
valves open?
Instrument impulse lines primed and
11
vented?
All connections along flow path hydraulically
12
tight (no leaks)?
System static head conditions suitable for
pump operation?
13

ACCESS
Area around pumpset clean, free of debris
14 and barricaded off from other works (if
required)?
15 Emergency stop pushbutton accessible?

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AQUADoc No: 10089641 Document Custodian: Team Leader – Mechanical
Version Date: 03.02.2016 Next Review Date: 03.02.2019
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PUMP
INSPECTION & TEST REPORT

5. TEST YES NO N/A COMMENTS/DETAILS

PRESSURE TEST
With the isolation suction and discharge
valves closed pressure test to the maximum
1 line pressure.
Check for leaks at pump nozzles, seals and
tappings
PERFORMANCE DATA
“Bump” start the pump motor to ensure
2
direction of rotation of motor is correct
Ambient temperature, bearing temperatures
Record pre-start measurements per
3 and static heads recorded prior to pump
Appendix B.
start-up?
Pumpset performance parameters recorded Record operating measurements per
4
during pumpset operation? Appendix B.
PERFORMANCE ASSESSMENT
5 Bearing temperatures acceptable?
6 Bearing vibration levels acceptable?
Pitch and level of noise emanating from
7
pump, motor and bearings acceptable?
Pump and pipework connections
8
hydraulically tight (no leaks)?
For pumps equipped with mechanical seals:
9 - Seals are hydraulically tight (no leaks)?
10 - Seal running temperatures acceptable?
For pumps equipped with packed seals:
- Seal water flows within manufacturer’s
11
recommended limits?
- Seal housing temperatures
12
acceptable?
POST TEST CHECKS
Baseframe welds intact (no obvious
13
cracking)?
14 All bolted and screwed connections tight?

Sections 6 & 7 to be retained in all ITPs.

TARGET
6. REMARKS / REMEDIAL / FOLLOW UP ACTIONS ACTION BY STATUS
DATE

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AQUADoc No: 10089641 Document Custodian: Team Leader – Mechanical
Version Date: 03.02.2016 Next Review Date: 03.02.2019
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PUMP
INSPECTION & TEST REPORT

7. SIGNOFFS
NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

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AQUADoc No: 10089641 Document Custodian: Team Leader – Mechanical
Version Date: 03.02.2016 Next Review Date: 03.02.2019
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PUMP
INSPECTION & TEST REPORT

APPENDIX A – SITE SPECIFIC PRE-REQUISITES

A1. MECHANICAL PRE-REQUISITES DONE NO ITR / DOCUMENT REF.

ITP-SV-M-PUMP
ITP-CV-M-PUMP

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AQUADoc No: 10089641 Document Custodian: Team Leader – Mechanical
Version Date: 03.02.2016 Next Review Date: 03.02.2019
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PUMP
INSPECTION & TEST REPORT

APPENDIX A – SITE SPECIFIC PRE-REQUISITES (cont’d)

A2. ELECTRICAL PRE-REQUISITES DONE NO ITR / DOCUMENT REF.

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AQUADoc No: 10089641 Document Custodian: Team Leader – Mechanical
Version Date: 03.02.2016 Next Review Date: 03.02.2019
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INSPECTION & TEST PROCEDURE

APPENDIX B – PUMP PERFORMANCE RECORD SHEET

# PARAMETER UNITS MAX. PRE T0 T1 T2 T3

LIMIT START- (Note 2)
(Note 1) UP
GENERAL
1 Time Hrs:Min +5 min +10 min +15 min
2 Ambient Temperature °C

3 Atmospheric Pressure Pa

4 Pipe Inside Diameters mm

Electrical String Efficency

5 %
(TX,VSD,motor)
PUMP
5 Suction Pressure Pa

6 Suction Head m

7 Discharge Pressure Pa

4 Discharge Head m

Calculated Pump Head

5 m
(Refer to Appendix C)
6 Flowrate m3/hr

7 Suction Temperature °C

8 Discharge Temperature °C

MOTOR
7 Power kW

8 Voltage V

9 Current A

10 Frequency Hz

11 Shaft Speed rpm

Calculated Efficiency of
12 Pump %
(Refer to Appendix C)
BEARING TEMPERATURES
12 Motor NDE °C

13 Motor DE °C

14 Pump DE °C

15 Pump NDE °C

BEARING VIBRATION LEVELS

16 Motor NDE (Vert.) mm/s RMS

17 Motor NDE (Horiz.) mm/s RMS

18 Motor NDE (Axial) mm/s RMS

19 Motor DE (Vert.) mm/s RMS

20 Motor DE (Horiz.) mm/s RMS

21 Motor DE (Axial) mm/s RMS

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INSPECTION & TEST PROCEDURE

# PARAMETER UNITS MAX. PRE T0 T1 T2 T3

LIMIT START- (Note 2)
(Note 1) UP
22 Pump DE (Vert.) mm/s RMS

23 Pump DE (Horiz.) mm/s RMS

24 Pump DE (Axial) mm/s RMS

25 Pump NDE (Vert.) mm/s RMS

26 Pump NDE (Horiz.) mm/s RMS

27 Pump NDE (Axial) mm/s RMS

Notes:
1. Manufacturer recommended limits.
2. Time 0 = the time of the first set of readings (once the pump is operating at its design duty point).

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INSPECTION & TEST PROCEDURE

APPENDIX C – EVALUATION OF TEST VALUES

Flow Rate Q
The measured values from magnetic flowmeter (m3/hour)

Total Head H

pd  ps vd 2 vs 2
H     H Y  H V [ m]
 m .g 2g 2g

s  d
m  [kg / m 3 ]
2
ps  ps measuredvalue  pb  zs.s.g[ Pa ]
pd  pd measuredvalue  pb  zd . d .g[ Pa ]

pb [Pa] Atmospheric pressure

pd [Pa] Static pressure on discharge side, related to shaft centreline of pump
ps [Pa] Static pressure at suction side, related to shaft centreline of pump
zd, zs [m] Height difference between measurement device and shaft centreline on suction and discharge side
HY [m] Height difference between the reference planes of suction and discharge side (geodetic head)
HV [m] Head losses, the sum of all suction and discharge losses
vs [m/s] Velocity in the suction pipe at the measuring point = Q/As
vd [m/s] Velocity in the discharge pipe at the measuring point = Q/Ad
ρs [kg/m³] Density of fluid (water) on suction side at Ts and ps taken from VDI Table of Steam Properties
ρd [kg/m³] Density of fluid (water) on discharge side at Td and pd taken from VDI Table of Steam Properties
g [m/s²] Gravitational constant

Pump Efficiency
Q.H . m .g
 [%]
PP .10 3.3600

Q [m³/h] Flow rate

H [m] Total head
ρm [kg/m³] Average density of fluid (water) taken from VDI Table of Steam Properties
g [m/s²] Gravitational constant
Pp [kW] Pump input power

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