Booster Pump Commissioning

TABLE OF CONTENT

1 Scope

2 Reference Documents

3 Health, Safety, and Environment

4 Key Personnel

5 Sequence of Operation

6 Method And Sequence of Work.

7 Testing and Commissioning Equipment Certification

8 Attachment

1. Scope:

1.1 The systems will be Pre-commissioned and Commissioned in accordance with the approved method of statement.

1.2 Ensure that all permanent wiring has been tested for insulation resistance and continuity prior to connection.

1.3 Ensure that earthing / grounding arrangements are intact and that leakage currents can be effectively discharged.

1.4 Ensure that the Booster pump for domestic water systems are properly installed and shall perform as designed and as per requirement.

2. Reference:

2.1 The Project Specification

AEA-1305-WC-M-S57-P99-LBM-0315 : BASEMENT PLANTROOM HVAC BLOW UP DETAILS

AEA-1305-WC-M-S57-P99-LBM-0315-1 : BASEMENT PLANTROOM HVAC BLOW UP DETAILS

AEA-1305-WC-M-S57-P99-LBM-0315-2 : BASEMENT PLANTROOM HVAC BLOW UP DETAILS

RED-1305-WC-PH-S53-P99-SCH-0101 : DOMESTIC HOT&COLD WATER DISTRIBUTION SCHEMATIC SHEET 1 OF 7






2.2 Material Transmittal 2.3 National Standards (CIBSE & ASRHAE) 2.4 Information for Construction Drawings (IFC)

3. Health, Safety, and Environment:

3.1 ARMA will operate a strict safety policy. ARMA-ELEKTROPANC recognizes the importance of safety on site and will strictly adhere to the safety requirements for working.

3.2 A team of experienced and well qualified safety officers will be assigned to implement and control the Health Safety & Environment Plan on site.

4. Key Personnel:

4.1 The Contractors T&C for Mechanical/Electrical Group has the overall responsibility for the implementation of this Method of Statement.

4.2 The Contractors T&C Manager will ensure that the resources are available to carry-out the works as per approved drawings, method of statement, and work as scheduled.

4.3 The Contractors Site Engineer/Supervisor is responsible to ensure that the work has been carried out as per approved drawings. Method statements and assist inspection.

4.4 The Contractors commissioning technician/s is responsible to ensure that they are abiding the method of statement to achieve the required data as per equipment schedule and project specification.

4.5 The Contractor Safety Officer will assist in all issues related to the HSE.

5. Sequence of Operation

Domestic water system booster pumps are located in the ENGINEERING ROOM (0315) serves water to

guest room hot & cold water. The other one unit booster pump in the Fire room, see sequence of

adjustment and commissioning activity reports on following pages.

5.1 FLT 1 Booster pumps will transfer water from the raw water tank, on the passes through sand filter and activated carbon filter to potable water tank. Booster pumps is driven by pressure switch, pressure is 3.0 bar while the start, stop when 4 bars.

5.2 BP1 booster pumps take water from the potable tank and through the softener and then send it to the domestic system. This booster pump job is to transport water to the domestic use of

the guestroom. This booster pumps is driven by pressure sensor and frequence converter,

pressure is kept constant at 7,0 bar. 5.3 BP2 booster pumps take water from the potable tank and through the softener and then send

it to the domestic system. This booster pump job is to transport water to the domestic use of

the hotel areas. This booster pumps is driven by pressure sensor and frequence converter,

pressure is kept constant at 5,0 bar.

6. Method and Sequence of Work:

Start- up and Commissioning of Booster Pump units will be carried out by Manufacturer/ Specialist

supplier. All check sheets and signed reports from the manufacturer shall be collected and attached.

We will assist their commissioning engineer as required. The main objective is to minimize the risk of injury and damage to personnel and equipment. Electrical test on control panel shall be

implemented and signed off by supplier or responsible contractor and to be attached on

commissioning checklist.

6.1 Pre-Commissioning

6.1.1 Pump & Motor should be properly mounted, making sure that the base of the unit is permanently supported.

6.1.2 Proper piping (outlet & inlet), correct foundations and motor mounts must be implemented to minimize external stress on all piping.

6.1.3 Ensure that all flexible connections are secure. 6.1.4 Lubrication should be observed or implemented as per manufacturers

recommendation.

6.1.5 Ensure sufficient feed water supply. Booster should be thoroughly purged of air before start-up.

6.1.6 Ensure that the piping system pressure leak test, attached on pre-commissioning checklist.

6.1.7 Ensure that the pump motor power requirements are connected to a suitable electrical supply.

6.1.8 Ensure that the pump motor is earth or bonded to earthing system. 6.1.9 Pump control panel is properly commissioned by supplier or installer contractor.

6.1.10 Cables, terminal connections, trunking lines or conduits, cable trays are as per approved materials and installation.

6.1.11 Ensure that complete installation and start up checks is according to manufacturers written instruction.

6.1.12 Clean strainer on suction piping. 6.1.13 Verify that each pump is free to rotate by hand. If pump is bound or drags, do not

operate until cause of trouble is determined and corrected.

6.2 Commissioning

6.2.1 Ensure that the entire pre-commissioning checklists are completely done. 6.2.2 Prime the pump by opening suction/discharge valve and prepare pump for operation. 6.2.3 Turn on the power of the pump in AUTO Mode. 6.2.4 Verify that the pump is running in the correct rotation.

6.2.5 Check the charge on the connected cushion tank. It should be the same (or %10 less then) as the operating pressure: 7.00 Bar for the potable water system for BP1

guestroom, 5,00 bar for BP2 for hotel areasand 3.00 Bar for FLT1 raw water booster.

Recharge or bleed off air if necessary.

6.2.6 Close slowly the discharge valve and record the cut off pressure of the FLT1. 6.2.7 Open the discharge valve slowly and then record the cut in pressure of the FLT1. 6.2.8 With the pump running, check the motor current and volts. 6.2.9 For all pumps, check dry protection level.

6.2.10 Install a temporary bypass line with an isolation valve from the discharge header into the water storage tank (potable or non-potable tank) to which the booster pump set

under commissioning is connected at the suction side. Isolate the discharge header from the domestic water system.

6.2.11 Check the operational order of the pumps. For presostat driven FLT1 ;

6.2.9.1 Switch the booster pump set panel on automatic mode. 6.2.9.2 Open the valve on the bypass line. This would simulate a drop in the system

pressure and the FLT1 should start.

6.2.9.3 Note the pressure at the point in which the FLT1 pump1 starts. 6.2.9.4 Because the discharge line is not feeding into the system, a further drop in

pressure should happen. This would start the FLT1 pump2.

6.2.9.5 Note the order of activation of the pumps. 6.2.9.6 Slowly close the valve on the bypass line. This should raise system pressure

and stop all running pumps.

6.2.9.7 Note the pressure at the point when each pump stops.

For Frequence Converter driven BP1 and BP2; 6.2.9.8 BP1 and BP2 boosters driven with frequence converters.

6.2.9.9 For BP1 and BP2, Switch the booster pump set panel on automatic mode. 6.2.9.10 Open the valve on the bypass line. This would simulate a drop in the system

pressure and BP1 and BP2 should start.

6.2.9.11 Because the discharge line is not feeding into the system, a further drop in pressure should happen. This would start the second pump, and later third pump.

6.2.9.12 Note the order of activation of the pumps.

6.2.12 Repeat 6.2.10 until cyclic changeover function is found to be working properly.

6.3 Performance Test

The objectives of the performance test follow:

6.3.1 To ensure that the Booster pumps are operating automatically as required for system application.

6.3.2 To ensure that the Booster pumps for Potable and Non-Potable Water Systems are performing according to the design data and specification.

6.3.3 A representative from each trade shall be available during the performance test as well as one representative minimum from the owner, engineer, and general contractor. The

trades involved shall include as a minimum Mechanical, electrical, controls, and

commissioning agent.

6.4 Temporary Works during Commissioning Stages

6.4.1 Necessary Permits shall be obtained prior to works. 6.4.2 Location of work to be secured through the use of barricade tapes. Unauthorized

personnel to be excluded from works location.

Testing and Commissioning Equipment Certification The following equipment / tools are to be use during testing and commissioning works:

Items Equipment Nos. Purpose Certificates

1 Multi Tester 1 For Testing of Volts

and Current

To be provided during

commissioning stages

2 Hand Tools (set) 1 Use for related works N/A

3 Pressure Gauge 2 Use for checking the

pressure.

To be provided during

commissioning stages

7. Attachment:

8.1 Booster Pump Pre-Commissioning Checklist 8.2 Booster Pump Pre-Commissioning Punch list 8.3 Booster Pump Commissioning Checklist 8.4 Booster Pump Performance Test Checklist 8.5 Booster Pump Equipment Schedule and Pump Performance Curve 8.6 Riser Diagram Domestic Water 8.7 Material Transmittal Approval

8. Attachments

8.1 Booster Pump Pre-Commissioning Checklist

BOOSTER PUMP PRE-COMMISSIONING / GUEST ROOMS BOOSTER SET

MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer

Commissioning Engineer

Commissioning Manager

Commissioning Authority Comment/s :

Elite Commissioning Commissioning Engineer

CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager

Contact ARMA ELEKTROPANC Ref. DOMESTIC WATER

Client PASHA CONSTRUCTION

Plant Ref. ENGINEERING ROOM (0315)

Location/ Area Serving GUEST ROOMS BOOSTER SET / COR-3-MVI7004-22/2-T-3-E 22

Tick Yes if Acceptable; Provide comment if unacceptable Yes No Comment

General

Installation is as per manufacturers instructions

Manufacturers recommended spare parts are provided

Equipment label permanently affixed

Pump turns freely

Pump foundation is level within manufacturers tolerances

Pumps in place and properly supported

Isolation valves and piping specialties installed

Flexible connections check and secure.

Shaft seal is leak free

Pump detail checked against the drawings and all devices gages and appurtenances are in place

Electrical and Controls

Power isolator is located within site of the unit it controls and labeled

Pump motor connected to a suitable electrical supply

All electric cable and terminal connections tight

Grounding installed for components and unit

Safeties installed and operational

Starter overload breakers installed and correct size

All control devices and wiring complete

Control system interlocks connected and functional

Operation of Control switch checked in all positions

Installation per manufacturers instructions


BOOSTER PUMP PRE-COMMISSIONING / KITCHEN/LAUNDRY Hotel Areas BOOSTER SET MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer





CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager




Location/ Area Serving KITCHEN/LAUNDRY Hotel areas BOOSTER SET / COR-3-MVI3204-7,5/2


General




Pump turns freely



















BOOSTER PUMP PRE-COMMISSIONING / RAW water Booster set MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer





CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager




Location/ Area Serving RAW Water BOOSTER SET / CO-2-MVI5203-7.5/2


General




Pump turns freely


















8.2 Pre- Commissioning Punch List Form

8.3 Booster Pump Commissioning Checklist

BOOSTER PUMP COMMISSIONING / GUEST ROOMS BOOSTER SET

MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer





CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager




Location/ Area Serving GUEST ROOM BOOSTER SET / COR-3-MVI7004-22/2-T-3-E 22 / BP1


General

The Control switch properly activates and deactivates the unit

Pump rotation verified correct

No unusual noise or vibration

No leaking apparent around fittings

Record cut in and cut off pressure of all pumps.

Specified sequences of operation and operating schedules have been

implemented with all variations documented.

Specified point-to-point checks have been completed and documentation

record submitted for this system.

Check cushion tank pre-charge. It should be the same ( or %10 less then) as operational pressure (7.00 Bar for potable water system). Bleed or

recharge as required.

Install a temporary bypass line with valve from discharge header to non-potable or potable water tank, whichever system is being tested.

Sequence of operation

Check and note that the booster set cut in at .. Bar

Check and note that the booster set cut outs at Bar

Check that the pumps cut in when the previous main pump has reached

full speed and line pressure is not restored at 7.00 Bar for potable water system.

Note order of operation of the pumps

Repeat until cyclic changeover function is found to be working properly


BOOSTER PUMP COMMISSIONING / GUEST ROOMS BOOSTER SET MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer





CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager




Location/ Area Serving KITCHEN/LAUNDRY Hotel Areas BOOSTER SET / COR-3-MVI3204-7,5/2 Tick Yes if Acceptable; Provide comment if unacceptable Yes No Comment

General






Specified sequences of operation and operating schedules have been implemented with all variations documented.

Specified point-to-point checks have been completed and documentation record submitted for this system.

Check cushion tank pre-charge. It should be the same ( or %10 less then) as operational pressure (5.00 Bar for potable water system). Bleed or recharge as required.



Check and note that the booster set cut in at .. Bar for potable water system

Check and note that the booster set cuts out at Bar for potable water system


full speed and line pressure is not restored at 7.00 Bar for potable water system.




BOOSTER PUMP COMMISSIONING / GUEST ROOMS BOOSTER SET MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer





CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager




Location/ Area Serving RAW Water BOOSTER SET / CO-2-MVI5203-7.5/2 Tick Yes if Acceptable; Provide comment if unacceptable Yes No Comment

General






Specified sequences of operation and operating schedules have been

implemented with all variations documented.

Specified point-to-point checks have been completed and documentation

record submitted for this system.

Check cushion tank pre-charge. It should be the same ( or %10 less then) as operational pressure (3.00 Bar for RAW water system). Bleed or

recharge as required.



Check and note that the booster set for pump 1 cut in at .. Bar Cut out at.bar

Check and note that the booster set for pump 2 cut in at .. Bar Cut out at.bar


full speed and line pressure is not restored at 3.00 Bar for raw water system.



8.4 Booster Pump Performance Test Checklist

Contract ARMA ELECTROPANC Ref: DOMESTIC WATER


Plant Reference ENGINEERING ROOM (0315)

Location/Area serving GUEST ROOM BOOSTER SET / * COR-3-MVI7004-22/2-T-3-E 22

PU

MP

S

Manufacturer Model No. ART No. Type

Pump 1 WILO DOMESTIC BOOSTER PUMP



PE

RF

OR

MA

NC

E

PU

MP

Design Actual

Cut in (bar) Cut off (bar) Cut in (bar) Cut off (bar)

Pump 1

Pump 2

Pump 3

MO

TO

R

Voltage (volts)

Current (amps)

Speed (rpm)

Power (kW)

Voltage (volts)

Current (amps)

Speed (rpm)

Power (kW)

Pump 1

Pump 2

Pump 3

*The figure to the left of the slash (/) is for potable water system and that at the right is for non-potable water system.

Remarks:

BOOSTER PUMP PERFORMANCE CHECKLIST / GUEST ROOM BOOSTER SET MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer





CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager




Plant Reference MECHANICAL ROOM 1 LEVEL-1

Location/Area serving KITCHEN/LAUNDRY and Hotel Areas BOOSTER SET / *COR-3-MVI3204-7,5/2

PU

MP

S





PE

RF

OR

MA

NC

E

PU

MP

Design Actual


Pump 1

Pump 2

Pump 3

MO

TO

R

Voltage (volts)

Current (amps)

Speed (rpm)

Power (kW)

Voltage (volts)

Current (amps)

Speed (rpm)

Power (kW)

Pump 1

Pump 2

Pump 3


Remarks:

BOOSTER PUMP PERFORMANCE CHECKLIST / KITCHEN/LAUNDRY and Hotel Areas BOOSTER SET MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer





CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager




Plant Reference MECHANICAL ROOM 1 LEVEL-1

Location/Area serving KITCHEN/LAUNDRY and Hotel Areas BOOSTER SET / CO-2-MVI5203-7.5/*

PU

MP

S





PE

RF

OR

MA

NC

E

PU

MP

Design Actual


Pump 1

Pump 2

MO

TO

R

Voltage (volts)

Current (amps)

Speed (rpm)

Power (kW)

Voltage (volts)

Current (amps)

Speed (rpm)

Power (kW)

Pump 1

Pump 2


Remarks:

BOOSTER PUMP PERFORMANCE CHECKLIST / RAW Water BOOSTER SET MEP CONTRACTOR

AE ARMA-ELEKTROPANC

Supervisor

Site Engineer





CLIENT Comment/s :

PASHA CONTRUCTION

Lead Engineer

Senior MEP Manager

8.5 Booster Pump Schedule and Performance Curve

Presented as additional files.

8.6 Riser Diagram Domestic Water


8.7 Material Transmittal Approval


Head

Efficiency

NPSH-values

Shaft power P2

MVI 7004

MVI 7004

MVI 7004

MVI 7004

5101520253035404550556065707580859095

100105110[m]

204060

[%]

246

[m]

51015

[kW]

0 10 20 30 40 50 60 70 80 90 100 110 [m/h]

1

Requested dataFlowHeadFluidFluid temperatureDensityKinematic viscosityVapor pressure

m/hm

Ckg/dmmm /sbar

Pump dataMakeTypePumpe typePressure ratingMin. fluid temperatureMax. fluid tem perature

WILOMVI 7004 PN16 3~

CC

Hydraulic data (duty point)FlowHead

m/hm

Speed 1/m in2950

Materials / Shaft seal

Dimensions per pump

Suction sideDischarge sideWeight

Motordata per Motor/Pump/Rated power P2Nominal speedRated voltageMax. currentDegree of protection

kg

kW1/m in

A

16DN100 / PNDN100 / PN 16214

2900

IP 55

22

Water, pure

0,99821,001

6779,2

20

Single head pum pPN 16

82,973,4

37,5

0,1

Pump baseImpellersStage cham bersPressure casing

EN-GJL 250 KTL beschichtet/covered1.44011.4404

EN-GJL 250 KTL beschichtet/covered

1.4301

H 1446h2 927 M 370X 248K 8x19

mm

Perm itted voltage to lerance +/- 10%

3~400 V, Hz

-15120

Item no. of standard version 4071175

System : High pressure centrifugal pump

kWShaft power P2 21,7NPSH 4,59 m

50

Shaft 1.4404Seals EPDMMechanica l sea l Wolfram carbide/graphit

MVI 7004 PN16 3~

Minimum Efficiency Index (MEI) >=0,10

Reserves to change any technical data. 3.1.13 - 01.09.2013 (Build 29)Software version 01.01.2013data statusUser group TR

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Head

Efficiency

NPSH-values

Shaft power P2

MVI 3203

MVI 3203

MVI 3203

MVI 3203

48

12162024283236404448525660

[m]

102030405060

[%]

4

8

[m]

1234

[kW]

0 4 8 12 16 20 24 28 32 36 40 44 48 [m/h]

1


m/hm

Ckg/dmmm /sbar


WILOMVI 3203/ PN16 3~

CC


m/hm

Speed 1/m in2900


Dimensions per pump



kg

kW1/m in

A

16DN65 / PNDN65 / PN 1688

2900

IP 55

5,5

Water, pure

0,99821,001

3527

20


29,140,8

10,6

0,1


Cast iron1.43011.4301

Cast iron

1.4301

H 814h2 486 M 220X 160K 4x18

mm


>5,5 kW

Y Anlauf

W2

W1V1U1V2U2

L3

L3

L2

L2

L1

L1

3 ~ 230 V

3 ~ 400 V W2W1V1U1V2U2

3~400 V, Hz

-15120




50


MVI 3203/ PN16 3~



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Head

Shaft power P2

Efficiency

NPSH-values

Helix 1603

Helix 1603

Helix 1603

Helix 1603

2468

10121416182022242628303234363840

[m]

0,81,21,6

[kW]

102030405060

[%]

1234567

[m]

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 [m/h]

1


m/hm

Ckg/dmmm /sbar


WILOHelix V 1603-1/16/E/400-50

CC


m/hm

Speed 1/m in2900


Dimensions per pump



kg

kW1/m in

A

16G2 / PNG2 / PN 1641

2900

IP 55

2,2

Water, pure

0,99821,001

3014,14

20


14,632,1

4,5

0,1

Pump housingImpellersStage housingShaft

1.43011.43071.4307

1.4301

1.4301

H 779H2 512X 149 M 193

mm


3~400 V, Hz

-20120




50

O 'R ing EPDM

Helix V 1603-1/16/E/400-50



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Head

Efficiency

NPSH-values

Shaft power P2

MVI 7001

MVI 7001

MVI 7001

MVI 7001

2468

10121416182022242628

[m]

204060

[%]

246

[m]

1234

[kW]

0 10 20 30 40 50 60 70 80 90 100 110 [m/h]

1


m/hm

Ckg/dmmm /sbar


WILOMVI 7001 PN16 3~

CC


m/hm

Speed 1/m in2950


Dimensions per pump



kg

kW1/m in

A

16DN100 / PNDN100 / PN 16106

2900

IP 55

5,5

Water, pure

0,99821,001

16,567,68

20


72,118,7

10,6

0,1


EN-GJL 250 KTL beschichtet/covered1.44011.4404

EN-GJL 250 KTL beschichtet/covered

1.4301

H 867h2 539 M 220X 160K 8x19

mm


3~400 V, Hz

-15120




50


MVI 7001 PN16 3~



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