VP No.

Shop Test Procedure for Turbine

Job No.
Project Title
Client
Location

Item No.
Page No.
Rev. No.

SEP-15-101ALL-G-0011
COMMON

1 OF 9
2

110670
Saudi Elastomers Project U&O, Carbon Black and MTBE Decomposition Unit
Al-Jubail Petrochemical Company (KEMYA)
Jubail Industrial City, KSA

Shop Test Procedure for Turbine

Saudi Elastomers Project
U&O, Carbon Black and MTBE Decomposition Unit

P.O. NO.

PO-110670-15-101-001-A01
Centrifugal Pumps(API 610 10th,
P.O. DESCRIPTION
OH2)
ITEM NO.
COMMON
ITEM DESCRIPTION
CENTRIFUGAL PUMP(API 610, OH2)
DOCUMENT NO
SEP-15-101-ALL-G-0011
DOCUMENT TITLE.
Shop Test Procedure for Turbine
DAELIM INDUSTRIAL CO., LTD. SEOUL, KOREA
Job. NO.
110670
A

Approved without comments

AAN

Approved As Noted

RFC

Returned for Correction

U&O
SIGNED BY :

CB

MTBE

DATE :

PURCHASER PERMISSION TO PROCEED OR REVIEW TAKEN

ON VENDOR PRINTS SHALL NOT RELIEVE VENDOR FROM ITS
RESPONSIBILITIES OR LIABILITIES UNDER THE PURCHASE
ORDER.

SULZER KOREA

2014-03-19

ISSUED FOR APPROVAL

W.H.CHOI

W.H.CHOI

S.H.CHA

2013-11-18

ISSUED FOR APPROVAL

P.R.LAKSH

S.H.CHA

S.H.CHA

2013-06-12

ISSUED FOR APPROVAL

P.R.LAKSH

S.H.CHA

S.H.CHA

REV

DATE

DESCRIPTION

PREPARED BY

CHECKED BY

No part of this document or the information it contains may be

reproduced or transmitted in any form or by any means electronic or
mechanical,
including photocopying, recording, or by any information storage and
retrieval system, without permission in writing from KEMYA or DAELIM

APPROVED BY

JOB NO.

ITEM NO.

PURCHASE ORDER NO.

STEAM TURBINE
MECHANICAL RUN TEST PROCEDURE
API 611

45013020006

DOCUMENT NO.

DOC000000091725

REVISION NO.
PAGE

DATE

1
OF

CHECKED

19-Feb-2014

BY

ONDO

APPROVED

1
2 FOR

Al Jubail Petrochemical Co. (KEYMA)

3 SITE

Al Sinaiyah, Saudi Arabia

4 SERVICE

CONDENSATE PUMP

5 MANUFACTURER

UNIT

DRIVEN EQUIPMENT
MODEL

ELLIOTT

UW-PST-41A

NO. REQUIRED

CENTRIFUGAL PUMP

BYRHPE IIIB

SERIAL NO.

F302403

6
7
8

PURPOSE

The Purpose of this test is to prove the mechanical running of the turbine.

SPECIFICATIONS

Elliot Group standard practices and procedures, API 611 5th edition.
G06-S01 & G06-T01 General purpose only with previously noted exceptions.

PROCEDURE

Prior to the test, the turbine assembly clearances are checked and recorded.

9
10
11

12
13
14
15
16
17
18
19
20
21
22

1. The turbine will be started and accelerated to low speed idle under manual control. During the time the
turbine is being held low speed idle, the oil rings (if supplied), will be checked to verify proper operation.
2. The trip system will be operated to verify proper operation. The overspeed trip setpoint will be set to a value
determined by the test leader. During the operation of the trip system, proper seating of the trip valve will be
verified.

23
24
25
26
27
28
29
30
31

3. The turbine will be accelerated to a minimum speed that the governor will control. In order to stabilize
speed, exhaust pressure may be applied. This will be determined at the discretion of the test leader. The
governor will be verified to be functioning properly by holding this minimum governor speed for a period of (15)
minutes. During this time, 2 sets of data will be taken:
0:00 START MINIMUM GOVERNOR
0:15 END MINIMUM GOVERNOR

32
33
34
35
36
37

38
39
40
41
42
43
44
45
46
47

4. The turbine will be accelerated to maximum continuous speed (MCS) in increments of approximately 10%.
The time for each increment is at the discretion of the test leader. Maximum continuous speed will be held for a
(1) hour uninterrupted run with design exhaust pressure applied (NOTE A). The governor will maintain the
desired speed. During this time, (17) sets of data will be taken:
0:00
0:15
0:30
0:45
1:00
1:15

START (4) HOUR RUN

DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN

1:30
1:45
2:00
2:15
2:30
2:45

DURING (4) HOUR RUN

DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN

3:00
3:15
3:30
3:45
4:00

DURING (4) HOUR RUN

DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
END (4) HOUR RUN

During the uninterrupted run the turbine will be checked for both steam and oil leaks (NOTE B).

48

49
50
51
52
53
54
55
56
57
58

5. After completion of the (4) hour run, the turbine will be accelerated to a speed approximately 100 RPM
below the overspeed trip set point and held for (15) minutes. During the overspeed test, exhaust pressure will
not be applied, unless it is required to stabilize speed. During this time, (2) sets of date will be taken:
0:00 START OVERSPEED
0:15 END OVERSPEED
If the turbine trips during the overspeed test, the test resumes from the point that the turbine tripped.

JOB NO.

ITEM NO.

PURCHASE ORDER NO.

STEAM TURBINE
MECHANICAL RUN TEST PROCEDURE
API 611

45013020006

DOCUMENT NO.
REVISION NO.
PAGE
CHECKED

DOC000000091725
DATE

1
OF

19-Feb-2014

BY

ONDO

APPROVED

1
2
3
4
5
6
7

6. After the completion of the overspeed run, the trip system will be re-checked and adjusted until (3) nontrending trips are recorded within the specified speed range.
7. Following the completion of the mechanical run test, hydrodynamic bearings (as applicable) will be
inspected.

8
9
10
11
12

PROCEDURE NOTES:

13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

NOTE A: Steam conditions shall be as close to design as practical. Due to no-load operation for extended
periods of time during the test, the inlet steam conditions and/or exhaust pressure may need to be reduced to
prevent overheating of the turbine and exceeding design clearances. This is also subject to test stand
limitations. This is to be determined at the discretion of the test leader.
NOTE B: If any steam or oil leaks arise during testing, the test will be stopped at an appropriate time, at the
discretion of the test leader, and the leaks will be corrected. If it is necessary to repair any leaks, the turbine wil
be operated for a suitable time period to verify that the leaks are repaired. This verification may be done as a
continuation of the test or in a separate phase of testing, as determined by the test leader.
*** Any test deviations will be corrected. Any test deviations do not nullify previously completed steps***

JOB NO.

ITEM NO.

PURCHASE ORDER NO.

STEAM TURBINE
MECHANICAL RUN TEST PROCEDURE
API 611

REVISION NO.
PAGE

DOC000000091725
DATE

1
OF

BY

CHECKED
1
2
3
4
5

1. Equipment to be used during test:

Primary Speed Readout for Test
Overspeed Trip Type

7
8
9
10
11
12
13
14

2. Steam Conditions for test:

(Note 1)

15
16
17
18
19

3. Speed Parameters for test:

(Note 2)

20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

19-Feb-2014
ONDO

APPROVED

TEST SCOPE / ACCEPTANCE CRITERIA

45013020006

DOCUMENT NO.

4. Lubrication Monitioring:

Use Contract Governor

Use Contract Trip Valve
Use Contract Shaft Seals
Use Contract Bearings
Use Contract Bearing Seals
Use Contract Coupling

YES
YES
YES
YES
YES
NO

Inlet Steam Pressure

Inlet Steam Temperature
Exhaust Steam Pressure
Exhaust Steam Temperature

550
550
174
481

PSIG
F
PSIG
F

Minimum Governor Speed

Maximum Continuous Speed
Overspeed Test Speed
Mechanical Trip Speed

1513
1869
1956
2056

RPM
RPM
RPM
---

Turbine Lubrication Type

Oil Supply Pressure
Oil Supply Temperature
Steam End Oil Flow
Exhaust End Oil Flow
Allowable Oil Drain Temperature Limit
5. Bearing Temperature Monitioring:
Use Contract Contacting Probes
Allowable Bearing Temperature Limit
6. Vibration Monitioring:
(Note 4,5)
Use Contract Non Contacting Probes
Allowable Peak to Peak Vibration
7. Additional Testing:
(Note 6)
Sound Pressure Level
Spare Rotor Mechanical Run Test
(Note 3)

Test Stand Tachometer

MECHANICAL

2097

RPM

PRESSURE LUBE
7-9
PSIG
70-130 F
1
GPM
1
GPM
< 170 F
YES
225

YES
2.00

MILS

YES
YES, SAME AS UNIT ROTOR

39
40
41
42
43
44
45

Note 1: Steam conditions shall be as close to design as practical. Due to no-load operation for extended periods of time during the test, the
inlet steam conditions will be reduced to prevent overheating of the turbine and exceeding design clearances. Exhaust pressure may also be
adjusted as needed. These conditions are also subject to test stand limitations. Any adjustments will be at the discretion of the test leader.
Note 2: Some speed float may be present under no load conditions, therefore, only general speed control is verified. Linearity or sensitivity of
the control signal, or governor response speed range is not measured. These points are generally evident in the operation of the governor
during the test.

46
47
48

Note 3: Due to the larger size of the test stand lube system, all parameters may not stabilize. If the parameters have not stabilized after a
reasonable amount of time, the test will continue. This is at the descretion of the test leader.

49
50
51
52
53
54
55
56
57
58

Note 4: At any speed greater than the maximum continuous speed, up to and including the trip speed of the driver, the vibration shall not
exceed 150 % or 0.5 mil above the maximum value recorded at the maximum continuous speed, which ever is greater.
Note 5: If non-contacting vibration probes are not provided or if vibration cannot be measured on the shaft, the peak vibration velocity
measured on the bearing housing shall not exceed 0.12 in./s (3.0 mm/s) (unfiltered).
Note 6: Sound pressure levels recorded during the test are not an indication of future levels during operation. With no load the governor
valve is close to the seat and causes increased levels during the test.

JOB NO.

ITEM NO.

PURCHASE ORDER NO.

STEAM TURBINE
MECHANICAL RUN TEST PROCEDURE
API 611

45013020006

DOCUMENT NO.

DOC000000091702

REVISION NO.
PAGE

DATE

2
OF

CHECKED

19-Feb-2014

BY

ONDO

APPROVED

2 FOR

Al Jubail Petrochemical Co. (KEYMA)

3 SITE

Al Sinaiyah, Saudi Arabia

NO. REQUIRED

4 SERVICE

Demin Water Pump Driver

DRIVEN EQUIPMENT

5 MANUFACTURER

UNIT

MODEL

ELLIOTT

UW-PST-35A
1
CENTRIFUGAL PUMP

BYRHPE IIIB

SERIAL NO.

F302402

6
7
8

PURPOSE

The Purpose of this test is to prove the mechanical running of the turbine.

SPECIFICATIONS

Elliot Group standard practices and procedures, API 611 5th edition.
G06-S01 & G06-T01 General purpose only with previously noted exceptions.

PROCEDURE

Prior to the test, the turbine assembly clearances are checked and recorded.

9
10
11

12
13
14
15
16
17
18
19
20
21
22

1. The turbine will be started and accelerated to low speed idle under manual control. During the time the
turbine is being held low speed idle, the oil rings (if supplied), will be checked to verify proper operation.
2. The trip system will be operated to verify proper operation. The overspeed trip setpoint will be set to a value
determined by the test leader. During the operation of the trip system, proper seating of the trip valve will be
verified.

23
24
25
26
27
28
29
30
31

3. The turbine will be accelerated to a minimum speed that the governor will control. In order to stabilize
speed, exhaust pressure may be applied. This will be determined at the discretion of the test leader. The
governor will be verified to be functioning properly by holding this minimum governor speed for a period of (15)
minutes. During this time, 2 sets of data will be taken:
0:00 START MINIMUM GOVERNOR
0:15 END MINIMUM GOVERNOR

32
33
34
35
36
37

38
39

1
1
1
1
1
1
1

40
41
42
43
44
45
46
47

4. The turbine will be accelerated to maximum continuous speed (MCS) in increments of approximately 10%.
The time for each increment is at the discretion of the test leader. Maximum continuous speed will be held for a
(1) hour uninterrupted run with design exhaust pressure applied (NOTE A). The governor will maintain the
desired speed. During this time, (17) sets of data will be taken:
0:00
0:15
0:30
0:45
1:00
1:15

START (4) HOUR RUN

DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN

1:30
1:45
2:00
2:15
2:30
2:45

DURING (4) HOUR RUN

DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN

3:00
3:15
3:30
3:45
4:00

DURING (4) HOUR RUN

DURING (4) HOUR RUN
DURING (4) HOUR RUN
DURING (4) HOUR RUN
END (4) HOUR RUN

During the uninterrupted run the turbine will be checked for both steam and oil leaks (NOTE B).

48

49
50
51
52
53
54
55
56
57
58

5. After completion of the (4) hour run, the turbine will be accelerated to a speed approximately 100 RPM
below the overspeed trip set point and held for (15) minutes. During the overspeed test, exhaust pressure will
not be applied, unless it is required to stabilize speed. During this time, (2) sets of date will be taken:
0:00 START OVERSPEED
0:15 END OVERSPEED
If the turbine trips during the overspeed test, the test resumes from the point that the turbine tripped.

JOB NO.

ITEM NO.

PURCHASE ORDER NO.

STEAM TURBINE
MECHANICAL RUN TEST PROCEDURE
API 611

45013020006

DOCUMENT NO.
REVISION NO.
PAGE
CHECKED

DOC000000091702
DATE

2
OF

19-Feb-2014

BY

ONDO

APPROVED

1
2
3
4
5
6
7

6. After the completion of the overspeed run, the trip system will be re-checked and adjusted until (3) nontrending trips are recorded within the specified speed range.
7. Following the completion of the mechanical run test, hydrodynamic bearings (as applicable) will be
inspected.

8
9
10
11
12

PROCEDURE NOTES:

13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

NOTE A: Steam conditions shall be as close to design as practical. Due to no-load operation for extended
periods of time during the test, the inlet steam conditions and/or exhaust pressure may need to be reduced to
prevent overheating of the turbine and exceeding design clearances. This is also subject to test stand
limitations. This is to be determined at the discretion of the test leader.
NOTE B: If any steam or oil leaks arise during testing, the test will be stopped at an appropriate time, at the
discretion of the test leader, and the leaks will be corrected. If it is necessary to repair any leaks, the turbine wil
be operated for a suitable time period to verify that the leaks are repaired. This verification may be done as a
continuation of the test or in a separate phase of testing, as determined by the test leader.
*** Any test deviations will be corrected. Any test deviations do not nullify previously completed steps***

JOB NO.

ITEM NO.

PURCHASE ORDER NO.

STEAM TURBINE
MECHANICAL RUN TEST PROCEDURE
API 611

2
3
4
5

PAGE

DATE

2
OF

BY

1. Equipment to be used during test:

Primary Speed Readout for Test
Overspeed Trip Type

7
8
9
10
11
12
13
14

2. Steam Conditions for test:

(Note 1)

15
16
17
18
19

3. Speed Parameters for test:

(Note 2)

20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

19-Feb-2014
ONDO

APPROVED

TEST SCOPE / ACCEPTANCE CRITERIA

REVISION NO.

DOC000000091702

CHECKED
1

45013020006

DOCUMENT NO.

4. Lubrication Monitioring:

Use Contract Governor

Use Contract Trip Valve
Use Contract Shaft Seals
Use Contract Bearings
Use Contract Bearing Seals
Use Contract Coupling

YES
YES
YES
YES
YES
NO

Inlet Steam Pressure

Inlet Steam Temperature
Exhaust Steam Pressure
Exhaust Steam Temperature

550
550
174
481

PSIG
F
PSIG
F

Minimum Governor Speed

Maximum Continuous Speed
Overspeed Test Speed
Mechanical Trip Speed

1513
1869
1956
2056

RPM
RPM
RPM
---

Turbine Lubrication Type

Oil Supply Pressure
Oil Supply Temperature
Steam End Oil Flow
Exhaust End Oil Flow
Allowable Oil Drain Temperature Limit
5. Bearing Temperature Monitioring:
Use Contract Contacting Probes
Allowable Bearing Temperature Limit
6. Vibration Monitioring:
(Note 4,5)
Use Contract Non Contacting Probes
Allowable Peak to Peak Vibration
7. Additional Testing:
(Note 6)
Sound Pressure Level
Spare Rotor Mechanical Run Test
(Note 3)

Test Stand Tachometer

MECHANICAL

2097

RPM

RING OILED - CIRCULATION

7-9
PSIG
N/A
N/A
N/A
N/A
YES
225

YES
2.00

MILS

YES
YES, SAME AS UNIT ROTOR

39
40
41
42
43
44
45

Note 1: Steam conditions shall be as close to design as practical. Due to no-load operation for extended periods of time during the test, the
inlet steam conditions will be reduced to prevent overheating of the turbine and exceeding design clearances. Exhaust pressure may also be
adjusted as needed. These conditions are also subject to test stand limitations. Any adjustments will be at the discretion of the test leader.
Note 2: Some speed float may be present under no load conditions, therefore, only general speed control is verified. Linearity or sensitivity of
the control signal, or governor response speed range is not measured. These points are generally evident in the operation of the governor
during the test.

46
47
48

Note 3: Due to the larger size of the test stand lube system, all parameters may not stabilize. If the parameters have not stabilized after a
reasonable amount of time, the test will continue. This is at the descretion of the test leader.

49
50
51
52
53
54
55
56
57
58

Note 4: At any speed greater than the maximum continuous speed, up to and including the trip speed of the driver, the vibration shall not
exceed 150 % or 0.5 mil above the maximum value recorded at the maximum continuous speed, which ever is greater.
Note 5: If non-contacting vibration probes are not provided or if vibration cannot be measured on the shaft, the peak vibration velocity
measured on the bearing housing shall not exceed 0.12 in./s (3.0 mm/s) (unfiltered).
Note 6: Sound pressure levels recorded during the test are not an indication of future levels during operation. With no load the governor
valve is close to the seat and causes increased levels during the test.

JOB NO.

ITEM NO.

PURCHASE ORDER NO.

STEAM TURBINE
HYDRO TEST PROCEDURE

45013020006

DOCUMENT NO.
REVISION NO.
PAGE

DOC000000091724
DATE

0
OF

BY

CHECKED

5/3/2013
HDEGRAY

APPROVED

AONDO

1
2 FOR

Al Jubail Petrochemical Co. (KEYMA)

3 SITE

Al Sinaiyah, Saudi Arabia

4 SERVICE
5 MANUFACTURER

UNIT

UW-PST-41A

NO. REQUIRED

Boiler Feed Water Pump Driver

MODEL

ELLIOTT

DRIVEN EQUIPMENT

CENTRIFUGAL PUMP

BYRHPE IIIB

SERIAL NO.

F302403

7
8
9

PURPOSE

The Purpose of this test is to prove the integrity of the pressure containing
components as defined below.

SPECIFICATIONS

Elliot Group standard practices and procedures (BMS WI-00039, available for
on-site review only), NEMA SM23-1991, ASME BPV Code, API 611 5th edition.

PROCEDURE

The steam turbine components are isolated and filled with pressurized water as
defined below. Testing is to be performed per Elliott Group standand
procedure. The time duration of the hydro test is 30 minutes.

10
11
12
13
14
15
16
17
18
19
20
21
22

SHOP ORDER

23

FRAME

F302403

BYRHPE IIIB

24

INLET

25
26

Max Allowable Working Pressure

700

PSIG

27

Max Allowable Working Temperature

900

28

Hydro Test Pressure

1550

PSIG

EXHAUST
250

PSIG

400

PSIG

29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57

ACCEPTANCE CRITERIA

This test will permit a make up of pressure and/or a flow of water to maintain a
hydro test pressure. The intent is only to accomplish the purpose of the test - a
test for strength and leaks. There shall be no leakage to any permanent joints
(example, any two machined surfaces permanently assembled with sealant and
not to be disassembled at any time afterwards). Leakage may be evident on
temporary joints such as blank off covers, etc., as noted. No leakage shall be
visually evident to the internal or external walls of the component.

JOB NO.

ITEM NO.

PURCHASE ORDER NO.

STEAM TURBINE
HYDRO TEST PROCEDURE

45013020006

DOCUMENT NO.
REVISION NO.
PAGE

DOC000000091701
DATE

0
OF

BY

CHECKED

5/3/2013
HDEGRAY

APPROVED

AONDO

1
2 FOR

Al Jubail Petrochemical Co. (KEYMA)

3 SITE

Al Sinaiyah, Saudi Arabia

4 SERVICE
5 MANUFACTURER

UNIT

UW-PST-35A

NO. REQUIRED

Boiler Feed Water Pump Driver

MODEL

ELLIOTT

DRIVEN EQUIPMENT

CENTRIFUGAL PUMP

BYRHPE IIIB

SERIAL NO.

F302402

7
8
9

PURPOSE

The Purpose of this test is to prove the integrity of the pressure containing
components as defined below.

SPECIFICATIONS

Elliot Group standard practices and procedures (BMS WI-00039, available for
on-site review only), NEMA SM23-1991, ASME BPV Code, API 611 5th edition.

PROCEDURE

The steam turbine components are isolated and filled with pressurized water as
defined below. Testing is to be performed per Elliott Group standand
procedure. The time duration of the hydro test is 30 minutes.

10
11
12
13
14
15
16
17
18
19
20
21
22

SHOP ORDER

23

FRAME

F302402

BYRHPE IIIB

24

INLET

25
26

Max Allowable Working Pressure

700

PSIG

27

Max Allowable Working Temperature

900

28

Hydro Test Pressure

1550

PSIG

EXHAUST
250

PSIG

400

PSIG

29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57

ACCEPTANCE CRITERIA

This test will permit a make up of pressure and/or a flow of water to maintain a
hydro test pressure. The intent is only to accomplish the purpose of the test - a
test for strength and leaks. There shall be no leakage to any permanent joints
(example, any two machined surfaces permanently assembled with sealant and
not to be disassembled at any time afterwards). Leakage may be evident on
temporary joints such as blank off covers, etc., as noted. No leakage shall be
visually evident to the internal or external walls of the component.