INTRODUCTION

This procedure covers the Factory Acceptance Test of the chemical injection package.
The chemical injection pumps have been tested as per Project ITP in accordance with testing
procedures by pump manufacturer Williams (Milton Roy) and test reports will be available
during FAT.
The test described in this procedure is mainly to verify the function and system capacity.
The pump flow rate shall be verified for flow rate through the Rotameter installed in the
Pump discharge. Following this procedure. Prior to the FA-test all pressure containing parts
including pipe spools have been pressure tested to a test pressure equal to design pressure x
1,5 Test certificates shall be available during FAT.
All relevant documents as mentioned under reference document such as datasheets,
certificates and drawings will be available under FAT.
Caution
The system contains electrostatically sensitive equipment that may be damaged if correct
handling procedures are not observed.
Mechanical Warning
The system contains heavy items or equipment. Care is required when removing and
replacing heavy equipment. Failure to observe reasonable safety precautions may result in
personal injury.
Fluid Warning
The system includes equipment containing fluid under pressures. It is essential for personnel
to become familiar with pressurised equipment before working on the equipment.
Failure to observe reasonable safety precautions may result in personal injury.
Caution
Equipment may be damaged if correct pressure ratings are not obeyed.
Environment
All reasonable precautions have been taken to ensure that "Controls of substances hazardous
to health regulations" is met. Equipment supplied as part of the system has been made of
materials that do not contain.
Test Media:
Test Media used for the Testing is Water (DM Water)

Varicon/Milton Roy will provide the following for test performance:

I. Responsible Testing/ Inspection Engineer.
II. Technicians, as necessary.
III. Utility Supplies as necessary.
IV. Auxiliary equipment, as necessary (including test equipment, tools Etc.).
V. All relevant drawings.

REFERNCE DRAWINGS & DOCUMENTS

Document No

Tag No

Document Title

RS18-P&ID-584-002-0

002-5

P&ID for RS 18 Platform

RS20-P&ID-584-003-0

003-5

P&ID for RS 20 Platform

RS21-P&ID-584-004-0

004-5

P&ID for RS 21 Platform

RS18-GA-584-005-0

005-2

General Arrangement for RS 18 Platform

RS20-GA-584-006-0

006-2

General Arrangement for RS 20 Platform

RS21-GA-584-007-0

007-2

General Arrangement for RS 21 Platform

5090-DTS-001-A

001 A

Data Sheets - Pump

5090-DTS-001-B

001 B

Data Sheets - Pressure Indicator

5090-DTS-001-C

001 C

Data Sheets - Pressure Safety Valve

5090-DTS-001-D

001 D

Data Sheets - Pressure Control Valve

5090-DTS-001-E

001 E

Data Sheets - Rotameter

5090-DTS-001-F

001 E

Drawing - Strainer

RS18-GA-584-005A-0

005A-2

General Arrangement for Drumrack

RS20-GA-584-006A-0

006A-2

General Arrangement for Drumrack

RS21-GA-584-007A-0

007A-2

General Arrangement for Drumrack

Instruments, equipment Used for test

The instruments used for the performance test shall be checked for Calibration validity and
same shall be recorded in the FAT report table
Before Start up
1. Ensure that all equipments are assembled and Flanges are tightened properly.
2. Ensure the Correctness of the Check valve Flow direction.
3. Ensure Back pressure regulator to the Pump discharge is not set at pressure.
The Following are the tests to be performed in Chemical Injection Skid.
I.

Visual Inspection:
The Visual Inspection Shall be carried out for the Cleanliness and Completeness
of the Assembly of the Skids & Piping. The Installation of the items as per

drawings. Check for any hassle free operation of valves and instruments are
visible for normal operation.
II.

P&ID Verification:
The Equipments & Components are checked for its presence in the skid. The Qty
of Pumps, Valves, Instruments and Piping line sizes shall be checked.
The Tag nos for the Components and instruments shall be checked.

III.

Dimension Inspection:
Dimensions, of the Skid Shall be verified according to the approved drawings.
Record the actual dimensional measurements in the below table (Table-1 of FAT
REPORT) as per GA drawing.
Flanged Tie in points dimensions shall also be measured and verified against
approved drawings.

IV.

Functional/Performance Test of Chemical Injection Pump:

Each pump will be tested for performance by pressure and volume at varying
stroke length.
1. Check for Valve Position.
Pump Suction Header/Line Isolation Valve Closed.
Strainer Drain valve - Closed.
Pump Discharge valve - Open.
Instrument manifold Valves-Open.
Open all valves in Pump Discharge line. Close Rotameter By-pass line valve.
Close Discharge Drain Valve
Pump Actuation Line isolation Valve.
PG isolation manifold open
Pump actuation Vent Line Valve Open
2. Check oil level in pump.
3. Connect the Compressed air/Nitrogen Line to the Pump actuation Line. Ensure
that actuation pressure is maintained as per the Pump required actuation pressure.
4. Ensure the Pump Stroke is at 0% or 0 stroke
5. Open the Pump actuation line valve and let the Pump start Running.
6. Slightly increase the Stroke Length of the Pump and shall run at 10% for
minimum 2 minutes.
7. To simulate discharge pressure/ mount test facility back pressure regulator on
injection manifold and open the back pressure regulator.
8. Slowly increase the stroke length to 100% for the discharge line to be filled
with the liquid and the required discharge pressure is achieved

9. Let the pump run for approx. 10 min at 100% stroke length and 100% discharge
pressure.
10. Set the pump discharge pressure via test facility back pressure regulator which
will be mounted during test. See test sheet for set pressure.
11. Set the stroke length on the pump to 25%.
12. Measure and the flow rate of the pump in Rotameter.
13. Repeat step 11 & 12 for stroke length of 50%, 75%, 100%.
The pump performance readings are tabulated in the Below FAT Report Table.
The test reports for all procurement items and fabrication equipments shall be reviewed for
confirmation to Project Specifications
PUNCH LIST:
SL
NO
.

PUNCH

PUNCHED
BY

DATE

FACTORY ACCEPTANCE TEST REPORT

SYSTEM TAG NO: ____________________________
Operating parameters
Description

Units

Skid operating Pressure

Kg/Cm2

Pump Flow rate

LPH

PSV Set Pressure

Kg/Cm2

Pump Actuation Pressure

Kg/Cm2

Value

Instruments & Equipment

SL.
NO

Description of Instrument

Sl. NO

Calibration
Certificate No.

Visual & P&ID Inspection:

Sl
No
1

Description

Complete /
Incomplete

Over all Cleanliness of the Skid

Skid assembly as Per GA Drawing

Tag Nos for Equipments & Instruments

Skid Earthing

Hydro test Reports

Dimensions:
System

Description

Chemical
Injection
System

Overall Length Of the Skid

Drum
Rack

Overall Length Of Drum Rack

Overall Width of the Skid

Overall Height of the Skid
Overall Width of Drum Rack
Overall Height of Drum Rack

Required
Actual
Dimensions Measurement
(mm)
(mm)

Remarks

Tie In Point Dimensions

System

TIE in
Point Tag

Required Dimensions
mm
X
Y
Z

Actual Measurement
mm
X
Y
Z

Remarks

Chemical
Injection
System
Pump Performance Report
Pump Tag No: ________________________
Stroke
Length
%

Outlet
Pressure
Bar

Flow Rate LPH

Theoretical
Actual
(Rotameter
Measurement)

Actuation
Supply
Pressure
Kg/Cm2

Remark
s

Remarks:

List of Participants
1.
2.
3.
4.
Completion & Approval of this FAT
Varicon
Name
Designation
Signature
Date & Stamp

MRI / TPI

SKCL / TPI