Lube Oil Console Functional Test Procedure

LUBE OIL CONSOLE FUNCTIONAL TEST PROCEDURE SOK0935951
GENERAL LUBE OIL CONSOLE

FUNCTIONAL TEST PROCEDURE
Electronically approved draw. GE NuovoPignone DT-'N'
TITLE: DOCUMENT CODE REVISION

LUBE OIL CONSOLE FUNCTIONAL TEST PROCEDURE
SOK0935951 0
REVISION DESCRIPTION: APPROVED Carmagnola C.
ISSUED DATE SECURITY CODE

CHECKED Ceccarini M.
28-
28-May-
May-12 N
EXECUTED DE LEO, N
SCALE REPLACES/DERIVED FROM 1st ISSUE ORIGINAL JOB SIZE LANGUAGE
N/A N/A 28-
28-May-
May-12 1908185 4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2012
2012 Nuovo Pignone S.r.l..
S.r.l.. ALL RIGHTS RESERVED. 1 of 10
INTRODUCTION ................................................................................................................................... 2
PREPARATION FOR TEST .................................................................................................................... 3
2. FLUSHING ..................................................................................................................................... 4
3. FUNCTIONAL TEST OPERATIONS.............................................................................................. 4
4. FINAL OPERATIONS .................................................................................................................... 6
5. FUNCTIONAL TEST SCHEMATIC DIAGRAM.............................................................................. 6
6. SHOP TEST REPORT DATA TABLES ........................................................................................... 7
7. JOB REFERENCE VALUES FOR TEST ....................................................................................... 10
INTRODUCTION
This document covers the requirements for the functional tests of a stand-alone lube/control oil
console to be supplied to GE Oil & Gas. It is in compliance with API614 5th edition Ch.2, special
purpose oil systems.
The procedures and steps specified in the following paragraphs shall be followed and tests results
reported against reference performance value. Evidence of successful completion of all applicable
steps shall be provided for a Functional Test to be considered positive.
The purpose of the test is to check for:
• Freedom of stress in the equipment

• System cleanliness
• Absence of leaks in normal operating conditions
• Proper operation of the equipment
REMARK:
Main pump mechanically driven by gearbox is excluded from GE shop functional
test. Only auxiliary pump is tested. Subsequently, a field test shall be performed in
order to conduce below tests according to Chapter 2, par. 7.3.3.8 (API 614 V ed.):
1- It shall be demonstrated that after a failure or trip of the main L.O. pump, the
auxiliary pump will start automatically and return the system to normal operating
pressure without the delivery pressure dropping below the stand-by pump’s
automatic start setting and the equipment’s shutdown pressure
2- It shall be demonstrated that the control valve is capable of controlling the oil
pressure when both, main and auxiliary L.O. pumps are operating at the normal
bearing oil requirements.

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ORIGINAL JOB SIZE LANGUAGE
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PREPARATION FOR TEST
1.1 Check for freedom of stress: check that there is no stress induced between
pipes and main items of equipment. When loosening the flange bolts, the
flanges and mating flanges shall not move with respect to each other.
1.2 Fill the tank with oil up to maximum operating level with test oil ISO VG46.
1.3 Check direction of rotation of each motor is correct.
1.4 Check that all filters’ cartridges are installed; Check operation lever for
change over;
1.5 Install flow meter and a suitable throttle valve at each delivery limit to set
and
measure the flow;
1.6 Install pressure gauges to measure pressure at each delivery limits
1.7 Check availability of calibration certificates of all testing instrumentation

(flow
meters, pressure gauges, etc.) and make them available for inspector’s review
1.8 Clean console surfaces from spilled oil in order to identify any leakage
during
flushing;
1.9 Check that all components and instruments are in conformity with P&I
Diagram; All manual valves shall be in open/closed position as per P&ID
1.10 DC source shall be provided to flush and test emergency line;
1.11 In case of AC motors designed for frequency that is different from shop’s
one (i.e.
50/60 Hz), frequency converter shall be made available for the test. Running
motors / pumps at speeds that are different from design one is not accepted;
1.12 In case of DC motors, pump shall properly run at pump design speed;

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FLUSHING
1.13 Flushing procedure shall follow API 614 V ed., ch.2 par. 7.3.3.9 standard.
Change over filters and coolers, flush either bypass line of filters and coolers.
Run stand-by pump and emergency pump. Pipes shall be frequently
hammered during flushing.
1.14 Oil cleanliness will be verified at all console discharge terminations and
points
mutually agreed on by vendor & purchaser (see diagram at Par.5), according
to API 614 5th Ch.2 Par. 7.3.3.9 and 7.3.3.10.
Additionally, verification could be performed by the analysis of some oil
sample with particles counter.
Acceptable minimum cleanliness grade for particle count monitoring is ISO

4406 20/15/12 grade - NAS 1638 grade 8. After acceptance, equipment will
be run for an additional hour.
1.15 Check all oil system for leaks, excessive vibration, suitability of supports,
etc. Any
issue shall be corrected prior to start the functional test.
1.16 After flushing no line components shall be removed and all reservoir
openings shall be kept shut. Special care shall be brought to the temporary
oil return lines openings.
1.17 If, after flushing, any construction activity (such as welding, drilling, etc.) is
carried
out on console tank or lines that may preclude system cleanliness, flushing
procedure shall be repeated.
FUNCTIONAL TEST OPERATIONS
Equipment shall be tested according to API614 ed. 5th ch. 2, par.7.3.3.
1.18 The running test shall be conducted under normal system operating
condition for at least 4 hours. The operational test may be done
concurrently within the 4h and the values shall be recorded every 30
minutes as per attached table.
1.19 Start the stand-by pump
1.20 Check functionality of pressure reducer control valve by acting on final oil
delivery throttle valve
1.21 Act the throttle valve in order to meet required flow and pressure at
delivery limits.
1.22 Verify that pump delivery pressure meets specification

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1.23 From this point, no further adjustment must be performed on control
valves. If any further adjustment is necessary, tests must be repeated
1.24 Change over filters/coolers and verify that pressure does not reach alarm
(test)
pressure. Record supply pressure evolution during this operation ( min, max
and steady). Record pressure drop across filters
1.25 Check motor pump assembly vibration on the three main axes and
bearing
temperature according to motor vibration reference values. For vibration
acceptance criteria refer to API676 par 6.11.1 - the acceptable value is 3.8
mm/s in R.M.S. value
1.26 Measure current absorbed by motor.
1.27 Check settling out pressure of safety valve at pump delivery by gradually
closing the throttle valve downstream of pump, PSV shall not open above
set pressure +10%
1.28 Close the throttle valve and check the safety valve is not chattering
1.29 Perform sound level measurement. If not otherwise stated on QCP shall be
performed according to ISO9614.2. Noise shall be measured at different
points around the LO @ 1 meter in free condition. Mean value of SPL shall not
exceed 85 db (A).
1.30 It shall be demonstrated that pressure control valve has suitable capacity
of response and stability when stand-by pump is running
1.31 Check lines for excessive vibration and necessary additional supports
1.32 Manually stop the stand-by pump and repeat all previous points where
applicable with emergency pump running.
NOTES :
(a) during functional test the number of motor starts shall not exceed the maximum
informed by motor manufacturer, in cold/hot winding conditions, to prevent winding
insulation life reduction.
(b) During test oil temperature will increase. Tests shall be stopped if oil temperature
reaches 80°C.

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FINAL OPERATIONS
1.33 Stop all running equipment

1.34 Verify that any electrical utility to console is disconnected
1.35 Remove test equipment and put blind flanges at all nozzles
1.36 Drain the whole system
1.37 Replace filter cartridges.
1.38 Remove dirt accumulate in the tank during functional test
1.39 Prepare the unit for shipping according to ITN02175.16
FUNCTIONAL TEST SCHEMATIC DIAGRAM
Following diagram represents a typical test configuration for oil console including control oil line and with
external oil cooler.
Refer to job applicable Piping and Instrumentation Diagram for detailed information on console
instrumentation and battery limits identification.

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SHOP TEST REPORT DATA TABLES
The whole system must run for at least 4 hours according to API 614 standard.
Data must be record every 30 minutes. Record at least one set of data with both pumps running.
½h 1h 1½h 2h 2½h 3h 3½h 4h
Std by Pump discharge

pressure
Pressure drop across

lube oil filter
Lube oil pressure at LO

delivery
Lube oil flow at LO

delivery
Oil temperature °C
inside oil tank
Emergency pump
delivery press
Emergency pump
delivery flow
Drop of press. across

emerg. filter
Drop of press. across

control oil filter
Oil flow after control oil

filter
Oil pressure after control

oil filter
Manufacturer responsible Inspector
__________________________ _____________________________

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Measure at least once : TEST DATA NOTES
Standby motor/pump <3.8 mm/sec RMS as per

vibration API676
Standby motor absorbed As per LV motor

current datasheet
Emergency pump <3.8 mm/sec RMS as per

vibration API676
Emergency pump As per LV motor
absorbed current datasheet
Noise emission dbA <85 dbA @ 1 mt free
with stand-by pump tield cond.
14 barg +10% as per set

PSV valve opening press.
value
PSV valve on emergency 4 barg +10% as per set

line opening press. value
CONFORMITY
NOTES
(Y/N)
Dimensional check Lube oil console G.A. latest revision conformity
System check P&ID latest revision conformity
Test oil type ISO VG46

Check with API mesh 100 (additional check with
Cleanliness ratio
particles counter, if available)
Electric heater check Check for proper working
Check for no foaming in tank
Check for piping vibration
Check for leakages

Check for correct lifting at set pressure. Valves shall
PSVs performarce
not chattering
PCV (console delivery) performance Check for system pressure stability
PCV (backpressure) performarce Check for system pressure stability
We herewith acknowledge that all applicable steps of this functional test procedure has been followed
and checks performed positively.

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NOTES:
Manufacturer responsible Inspector
______________________________ ___________________________

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JOB REFERENCE VALUES FOR TEST
The following data and documents shall be considered as reference during the functional test of the oil
console. A paper copy of all recalled documentation shall be made available at test for inspector to
review.
Functional Piping and Instrumentation diagram (P&I) SOK0880038

Oil console purchase specification SKO2593635
Oil console general arrangement SOK6733815
Painting specification SOS2998973

Instrumentation for lube oil console SOS9976372
FUNCTIONAL DESIGN DATA
Lube oil delivery

2.75 barg Lube oil supply Flow 1633.8 l/min
pressure
Expected ∆P across oil Expected ∆P across oil

0.3 / 1.5 barg 0.781 bar
filters min/max cooler
PSV set pressure Emergency oil delivery
14 barg 817 l/min
Main pump flow
PSV set pressure Emergency motor

14 barg See datasheet
Std-By pump nominal current
Operating oil
50°C Control oil supply Flow 340 l/min
temperature (TCV set)
Emergency oil delivery PCV (back pressure) set
2 barg 10 barg
pressure point
Main/standby motor
See datasheet
nominal current
PSV set pressure

4 barg Oil type ISO VG46
Emergency pump
Lube oil alarm/trip

1.6/1.2 barg
pressures
Max noise level 85 dbA

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Lube Oil Console Functional Test Procedure

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LUBE OIL CONSOLE FUNCTIONAL TEST PROCEDURE SOK0935951

GENERAL LUBE OIL CONSOLE

Electronically approved draw. GE NuovoPignone DT-'N'

TITLE: DOCUMENT CODE REVISION

ISSUED DATE SECURITY CODE

The purpose of the test is to check for:

• Freedom of stress in the equipment

TITLE: DOCUMENT CODE REVISION

1.3 Check direction of rotation of each motor is correct.

1.6 Install pressure gauges to measure pressure at each delivery limits

1.7 Check availability of calibration certificates of all testing instrumentation

1.10 DC source shall be provided to flush and test emergency line;

TITLE: DOCUMENT CODE REVISION

Acceptable minimum cleanliness grade for particle count monitoring is ISO

FUNCTIONAL TEST OPERATIONS

Equipment shall be tested according to API614 ed. 5th ch. 2, par.7.3.3.

1.19 Start the stand-by pump

1.22 Verify that pump delivery pressure meets specification

1.26 Measure current absorbed by motor.

TITLE: DOCUMENT CODE REVISION

1.33 Stop all running equipment

FUNCTIONAL TEST SCHEMATIC DIAGRAM

TITLE: DOCUMENT CODE REVISION

½h 1h 1½h 2h 2½h 3h 3½h 4h

Std by Pump discharge

Pressure drop across

Lube oil pressure at LO

Lube oil flow at LO

Drop of press. across

Drop of press. across

Oil flow after control oil

Oil pressure after control

Manufacturer responsible Inspector

TITLE: DOCUMENT CODE REVISION

Standby motor/pump <3.8 mm/sec RMS as per

Standby motor absorbed As per LV motor

Emergency pump <3.8 mm/sec RMS as per

14 barg +10% as per set

PSV valve on emergency 4 barg +10% as per set

System check P&ID latest revision conformity

Test oil type ISO VG46

Check for no foaming in tank

Check for piping vibration

Check for leakages

PCV (backpressure) performarce Check for system pressure stability

TITLE: DOCUMENT CODE REVISION

Manufacturer responsible Inspector

TITLE: DOCUMENT CODE REVISION

Functional Piping and Instrumentation diagram (P&I) SOK0880038

Painting specification SOS2998973

FUNCTIONAL DESIGN DATA

Lube oil delivery

Expected ∆P across oil Expected ∆P across oil

PSV set pressure Emergency motor

PSV set pressure

Lube oil alarm/trip

Max noise level 85 dbA

TITLE: DOCUMENT CODE REVISION

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