5578-E1-EPC-PC-091_0 (Installation Procedure for Rotating Equipment).pdf

ABU DHABI

OIL REFINING COMPANY

PROJECT PROCEDURE

INSTALLATION PROCEDURE FOR

ROTATING EQUIPMENT

DOC. NO. : 5578-E1-EPC-PC-091

RUWAIS REFINERY

EXPANSION PROJECT

EPC WORKS

PROJECT NO.: 09-5578-E-1

Rev. 0

SK ENGINEERING & CONSTRUCTION CO., LTD. Page 2/22

This page is a record of all revisions of this document. All previous issues are hereby superseded

and are to be destroyed.

REV DATE DESCRIPTION PRED CHKD REVD

REVD

(PQAM)

APPRD COMPANY

0 20/07/2010 For Construction H.K.PARK M.H. CHOI H.S. KIM Y.S. KIM Y.C KIM

A 18/05/2010 For Information H.K.PARK M.H. CHOI H.S. KIM Y.S. KIM Y.C KIM

SIGNED (Initials)

NOTES;

Revision(s) after Rev. A issue, will be denoted as follows ;

(a) By a vertical line in the right-hand margin against the revised text.

(b) By a triangle symbol for graphics, the revision number being denoted within the symbol.

Revision symbols are positioned adjacent to the revision.

(c) PRED=Prepared by, CHKD=Checked by, REVD = Reviewed by, APPR`D = Approved by

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REVISION LOG

REV.

NO. REV. DATE

REVISED

PAGE REVISION DESCRIPTION

0 20/07/2010 2 Revised due to change of document class from 1 to 3

0 20/07/2010 6(3) Incorporated COMPANY Comments(Ref. No T-PASH/5578-E1/1.5.5/2439)

0 20/07/2010 7(4.1.14) Incorporated COMPANY Comments(Ref. No T-PASH/5578-E1/1.5.5/2439)

0 20/07/2010 8(4.1) Incorporated COMPANY Comments(Ref. No T-PASH/5578-E1/1.5.5/2439)

0 20/07/2010 N/A Issued for Construction at REV. 0

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TABLE OF CONTENTS

1. PURPOSE-----------------------------------------------------------------------------------------5

2. SCOPE---------------------------------------------------------------------------------------------5

3. CODES AND STANDARD--------------------------------------------------------------------5

4. REFERENCE AND DOCUMENTS--------------------------------------------------------7

5. REPONSIBILITIES----------------------------------------------------------------------------8

6. GENARAL---------------------------------------------------------------------------------------8

7. PREPARATION FOR INSTALLATION-------------------------------------------------9

8. INSTALLATION------------------------------------------------------------------------------13

9. LEVELING OF EQUIPMENT-------------------------------------------------------------13

10. GROUTING------------------------------------------------------------------------------------15

11. ALIGNMENT OF EQUIPMENT---------------------------------------------------------17

12. INSPECTION AND PREPARATION BEFORE TEST OPERATION ----------20

13. INSPECTION AFTER TEST OPERATION--------------------------------------------21

14. INSPECTION ---------------------------------------------------------------------------------22

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1. PURPOSE

The purpose of this procedure is to establish the methods for the field installation of

rotating equipment at Ruwais Refinery Expansion Project.

2. SCOPE

This procedure describes the requirements for installation, leveling, alignment work of

pumps, compressors including their drivers and auxiliary equipment and other rotating

equipment.

This procedure describes only general requirement for installation, so the manufacturer’s

installation manuals/instructions shall also be applied for execution of installation.

3. CODES AND STANDARDS

The latest editions of codes and standards listed below shall be considered as integral

parts of this procedure. If the additional codes and standards to the below is stipulated

and referenced in the attached specifications, data sheets and drawings, those also shall

be considered as integral parts of this procedure.

- ASTM & ASME Section II : Materials

- ASME Section IX : Welding and brazing qualification

- ASME Section V : Nondestructive examination

- ASME B16.5/ 16.47 : Steel pipe flanges and flanged fittings

- ASME B31.3 : Process piping

- AWS : American welding society

- NACE MR0103 : Material resistance to sulfide stress cracking

corrosive petroleum refining environment

- ASME Section VIII, Div.1 : Pressure vessels (2007 edition/latest)

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- API 610, 10th

Edition : Centrifugal pumps

- API 682 : Shaft sealing system

- API 550 : Manual on installation of refinery

Instruments and control system

- API 554 : Process instrumentation and control

- API 611 : General purpose steam turbines

- API 613 : Special purpose gear units

- API 614 : Lubrication, shaft sealing, and control

oil system

- API 617 Chapter 1 & 2 : Centrifugal compressors

- API 618 : Reciprocating compressors

- API 661 : Air cooled heat exchanger

- API 671 : Special purpose coupling

- API 673 : Centrifugal fans

- API 670 : Vibration, axial position, bearing

temperature monitoring system

- API 674 : Positive displacement pumps –

reciprocating


controlled volume


rotary

- IEEE : Institute of electrical and electronics

engineering

- IEC : Electrical apparatus

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- IP15 : Institute of petroleum model code of

safe practice

- CENELEC/ATEX 100a : Explosion protection

- EEMUA 140 : Noise procedure specification

4. REFERENCE DOCUMENTS

4.1 Project Specifications

1) 5578-SP-MD-001 Pressure vessels – general

2) 5578-SP-MU-001 General equipment requirement

3) 5578-SP-MU-002 Preservation and export packing

4) 5578-SP-MU-004 Lubrication requirements

5) 5578-SP-MU-005 Maintenance philosophy

6) 5578-SP-MU-006 Rotating equipment – minimum general requirement

7) 5578-SP-MU-007 Rotating equipment – system integration

8) 5578-SP-MU-008 Plant noise control

9) 5578-SP-MU-009 Equipment noise control

10) 5578-SP-MN-004 Cold & acoustic insulation of piping & equipment

11) 5578-SP-MA-001 Oil mist lubrication system

12) 5578-SP-MG-001 Centrifugal pump(amendments/supplement to API 610 10th

edition)

13) 5578-SP-MG-002 Reciprocating positive displacement pumps

(amendments/supplement to API 674)

14) 5578-SP-MG-003 Centrifugal pumps for general service(Non API )

15) 5578-SP-MG-004 Positive displacement rotary pumps(API 676)

16) 5578-SP-MG-005 Positive displacement pump controlled volume(API 675)

17) 5578-SP-MG-006 Liquid ring vacuum pumps & compressor


18) 5578-SP-MK-001 Axial & centrifugal compressor


19) 5578-SP-MK-002 Reciprocating compressor (amendments/supplement to API 618)

20) 5578-SP-MK-003 Centrifugal fans (amendments/supplement to API 673)

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21) 5578-SP-MP-002 Air cooled heat exchange equipment

22) 5578-SP-MT-002 General purpose steam turbine


23) 5578-SP-MM-001 Electric motor cage – induction and synchronous

24) 5578-SP-CU-011 Grouting

25) 5578-E1-SP-MV-002 Special purpose gear units

(amendments/supplement to API STD 613)

4.2 5578-E1-QA-PA-001 Project Quality Plan

4.3 5578-E1-HSE-PA-001 Project HSE Plan

4.4 Applicable CONTRACTOR’s documents

5. RESPONSIBILITIES

5.1 This procedure shall be provided by the CONTRACTOR’s mechanical engineer,

reviewed by the QA/QC department and approved by COMPANY before use.

5.2 The CONTRACTOR’s mechanical engineer is responsible for supervising these

activities required by this procedure.

6. GENERAL

6.1 The installation work shall comply with the requirements specified herein, the relevant

drawings and the requirements of the applicable safety codes or regulations of the

locality. Any conflicts or questions would be found among this specification, the

drawings and the others shall be referred to CONTRACTOR for resolution.

6.2 All work shall be performed under the CONTRACTOR engineer or his authorized

representative.

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6.3 Instruments and tools to be used in leveling and alignment shall satisfy the conditions

shown in the Table 1.

Table 1

7. PREPARATION FOR INSTALLATION

Prior to starting the work, the following shall be conformed to be satisfactory under

witness of the CONTRACTOR engineer. Any defects found shall be referred to be

CONTRACTOR engineer and repaired or improved properly and immediately in

accordance with the instruction of the CONTRACTOR engineer.

7.1 Foundation

7.1.1 Foundation shall be checked before installation for the following items.

Instruments Service Item Size and Accuracy

Leveling

Spirit level made of steel

Length 200mm and longer, sensitivity 2/100mm Length 200mm and longer, sensitivity 5/100mm

Straight edge made of steel Length 1,500mm(Ｉbeam type)

Length 500mm(Ｉbeam type)

Alignment

Dial gauge with magnetic base Min. graduation 1/100mm

Thickness gauge made of steel Length of leaf 100-150mm, width of leaf 10-15mm Length of leaf 200-300mm

Taper gauge made of steel Length of leaf 150mm, width of leaf 10-15mm

Right angle rule made of steel Effective length 300mm, width 300mm

Vernier caliper Length 200mm, graduation 5/100mm(inner and outer use)

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1) Curing period of foundation concrete.

2) Dimensions.

3) Positions (center marking) and height (level marking).

4) Disorders in the foundation concrete, such as abnormal concentration of

aggregates, porous state.

5) Size of anchor bolts, and damage or rust of threaded parts.

6) Dimension and cleanliness of anchor boxes, if anchor box type is applied.

7.1.2 Treatment of the surface of the foundation, such as chipping and fitting, shall be

carried out as follows.

1) Foreign matters shall be completely removed.

2) Foundation surface shall be chipped slightly for the part on which the mortar pad

for liner plates is formed.

7.2 Anchor Bolts

7.2.1 The following conditions of the anchor bolts embedded in the foundation shall be

checked against the drawings or with a steel template for the major equipment.

1) Position - Tolerance shall be 1.5mm from the dimension indicated on the related

equipment drawing.

2) Projection - The projection of the bolts above the foundation surface shall be

proper length relative to the final level of the foundation finish.

3) Inclination - There must be no inclination of the bolts which may prevent the

equipment base plate from fitting smoothly.

4) Condition of bolts and nuts - Threaded parts shall be completely coated with

grease or machine oil allowing the nuts is unscrewed smoothly.

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7.2.2 Anchor bolts with pipe sleeves to allow adjustment of the final positioning of the bolt

shall be checked with the following.

1) Position - Anchor bolts shall be accurately located as shown on the related

equipment drawing.

2) Projection - The projection of the bolts above the foundation surface shall be

proper length relative to the final level of the foundation finish.

3) Sleeve - Unless otherwise specified in the Instruction Manual, pipe sleeves shall

be approximately 50mm larger in diameter than anchor bolt.

7.2.3 When anchor holes are used for anchor bolts, the anchor bolts shall be installed in the

anchor hole after the equipment is temporarily placed in the right position.

After the grouted mortar has sufficiently hardened, leveling work shall be provided.

Anchor holes shall be cleaned before temporary installation of the equipment.

7.3 Liners

7.3.1 Liners to be used, in general, shall be made of carbon steel, unless otherwise specified

in the specific instructions by the manufacturer, etc.

7.3.2 Liners shall be arranged so that the load of the equipment is uniformly distributed on

the foundation within allowable load. In general, the liners shall be placed as near as

possible to both side of each anchor bolt.

7.4 Checking of Equipment

7.4.1 Prior to the installation, the following check to the equipment shall be made:

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1) Appearance of equipment, such as damage and rust free condition.

2) The number and appearance of auxiliaries.

3) Size of the anchor bolts and damage and rust of the threaded parts, if anchor box

type is applied.

4) Orientation marking.

5) Marking of center of gravity.

6) Lifting points.

7.4.2 Oil and other foreign matters stuck on the surface of legs, beds, frames, etc, which

will be in contact with the grouting mortar, shall be entirely removed.

7.5 Condition and Protection of Equipment

7.5.1 Unpacking shall be performed under witness of the CONTRACTOR Engineer. All

spare parts and dismantling tools, etc., shall be repacked and returned to the

warehouse as instructed by the CONTRACTOR Engineer. Delicate parts, such as

level oilers, capillary tubes, etc., shall be removed in accordance with the instructions

of the CONTRACTOR Engineer.

The removed parts shall be stored and maintained in the warehouse properly.

7.5.2 After being thoroughly inspected, the equipment shall be transported to the jobsite.

7.5.3 The condition of the machined surfaces shall be checked, and if necessary, the

machined surfaces shall be coated properly with a suitable rust preventative.

7.5.4 Temporary covers on all openings shall be tightened firmly and shall not be removed

during installation until the related pipelines are to be connected thereto.

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7.5.5 The bottom face of the base plate shall be cleaned. When oil, grease, dirt or any loose

particles are found, it shall be washed off by water or other suitable solvents before

installation.

7.5.6 Coupled equipment shall be uncoupled and left uncoupled until the no-load test for the

driver is finished.

Coupling elements with clear identifications shall be stored properly in the warehouse.

8. INSTALLATION

Installation of equipment shall be executed in accordance with this procedure taking

precautions so that the anchor bolts and foundations will not be damaged and the

equipment not distorted.

When anchor holes are used, the curing time of the grout mortar filled in the holes

shall be checked before the starting of the leveling work.

9. LEVELING OF EQUIPMENT

9.1 Liners and Wedges

9.1.1 In general, liners and wedges shall be prepared as indicated in Table 2.

The dimensions may be modified as necessary or each application

Table 2. (unit : mm)

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9.1.2 A pair of wedges shall be used and the inclined surface of each wedge shall be contact

with each other more than 60 percent of the surface.

9.1.3 Liners and wedges shall be located on both sides of each anchor bolt and shall be

placed close to the anchor bolts. Where the distance between the anchor bolts is larger

than 80cm, extra liners and wedges shall be located between the anchor bolts to

prevent the base plate from bending.

9.1.4 The concrete surface where the liner plates will be placed shall be chipped smoothly

and be cleaned completely.

9.1.5 A final check shall be made to ensure that the center of the equipment matches the

center line marked of the foundation.

9.2 Leveling

9.2.1 Leveling shall be performed using a spirit level on the machined surface of the driver

base plate, or on the suction flange or discharge flange of the vertical nozzles on the

top of the equipment unless otherwise specified.

Leveling shall be measured laterally in the direction of the shaft. Adjustments shall be

made by inserting or removing liners and wedges.

9.2.2 The maximum tolerance from the level shall be 0.5mm, unless otherwise specified in

Item Length Width Thickness Slope

Liner 100 - 150 50 - 70 1.6, 2.3, 3.2, 4.5, 6, 9,

12, 16, 19 -

Wedge 100 - 150 50 - 70 6, 9, 12 4°- 5°

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the Instruction Manual.

9.2.3 After leveling is finished the lockouts of the anchor bolts shall be tightened firmly.

9.2.4 After the lockouts of the anchor bolts are tightened firmly, the liners and wedges shall

be tack-welded to each other, and any excess in the liners and wedges shall be cut off

with a gas cutter.

10. GROUTING

10.1 Preparation for Grouting

The top of surface of the foundation shall be wetted thoroughly with fresh water prior

to the grouting work. If pipe sleeves are used for anchor bolts, standing water in the

sleeves shall be removed by a manual air pump, etc.

10.2 Material

10.2.1 Non-shrinking mortar shall be used under the outer frame of the base plate and in the

sleeves. Portland cement may be used in the base plate and in the sleeves to grout the

equipment, unless otherwise specified in the Instruction Manual.

10.2.2 The mixing ratio of non-shrinking mortar, portland cement, and clean fine sand, and

the ratio of water to cement shall be as specified by the non-shrinking mortar

manufacturer.

10.2.3 The mixing ratio of portland cement and clean fine sand shall be 1 : 2 in volume, and

the ratio of water, to cement shall be less than 40 percent in volume, unless otherwise

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specified. Compressive strength of epoxy and non-shrink cementations is 630㎏/㎠

at 7 days.

10.3 Grouting Procedure

10.3.1 Sleeves used for anchor bolts shall be filled with grouting mortar under witness of the

CONTRACTOR engineer after which, grouting for the outer frame of the base plate

shall be done in accordance with par. 4.2.1, unless otherwise specified in the

Instruction Manual.

10.3.2 The base plate shall be grouted as follows :

1) The base plate shall be grouted ram the grout hole.

2) The grout shall cover all wedges and liners.

3) All trapped voids under the base plate shall be vented to allow full penetration of

the grouting mortar.

10.3.3 The surface of the mortar outside the base plate shall be finished smoothly.

10.3.4 All liners and wedges shall not be removed.

10.3.5 Grouting shall be inspected using light hammering to confirm that the mortar is filled

fully in the base plate voids and no cracks shall occur on the hardened surface.

10.3.6 Compressive Strength Test

Grouting shall be sample, cured, and tested for compressive strength in accordance

with ASTM C172, C31 and C39. Compressive test cylinder shall be prepared in one

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set cylinder per each mixing batch for test/and all tests must be carried out in testing

laboratory.

10.4 Epoxy Grouting

10.4.1 Grout for base-mounted or skid-mounted reciprocating machinery or critical

centrifugal/rotary compressors and pumps including drivers shall be epoxy type.

Compliance with minimum requirements of equipment vendors regarding grout

materials and installation is mandatory. Handling and placement of proprietary grouts

shall be in strict accordance with the manufacturer's recommended practice.

10.4.2 Procedure

1) All surfaces must be clean, free from standing water and all loosely adhering

particles. Cement latency must be removed, by mechanical means.

2) Mix with a slow speed electric drill for 1-2 minutes. Then add the aggregate and

continue mixing until a homogeneous mortar is achieved.

3) Application

- When grouting under bearing hates, ensure there is sufficient pressure to

maintain movement of the grout. Air must be allowed to escape.

- For large volumes, apply in more than one layer, ensuring that the previous

layers have hardened and cooled.

4) Clean all tolls and equipment immediately after use with thinner.

11. ALIGNMENT OF EQUIPMENT

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11.1 Initial Alignment

11.1.1 After completion of the grouting and prior to connecting piping, alignment of

equipment shall be performed as follows :

11.1.2 The parallelism of the end surface of the equipment coupling hub and the driver

coupling hub, the clearance between the coupling hubs, and the parallelism of the

center lines of the shafts hall be measured with a dial gauge at the four points at 90

degree intervals, and shall be adjusted by inserting shims under the lug or the saddle

of the driver and/or speed exchanger.

11.1.3 Tolerance of alignment shall be indicated in Table 3. The material of the shims for

alignment shall be of brass or of stainless steel. The size of the shims shall be at least

150mm in width, and 0.03, 0.04, 0.05, 0.1, 0.2, 0.5, 1 and 2mm in thickness, and if

legs or saddles of the equipment are smaller than 150mm in which, the size of the

shims shall be the same as the width of the equipment.

Table 3.

11.2 Alignment after Connecting Piping

After the suction and discharge nozzles are connected to piping, and the

CONTRACTOR engineer informed that all piping work such as installation of

permanent supports, and hydraulic testing, if any, are completed for the connected

Item Tolerance

Parallelism of center lines of shafts 0.05mm

Parallelism of surfaces of coupling hubs 0.1mm(diameter of coupling)

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piping, alignment of the equipment shall be rechecked as follows :

11.2.1 Prior to commencing the final cold alignment, the suction and discharge piping shall

be disconnected and piping alignment such as off center, clearance, and parallelism

between the piping and connection flanges of the equipment nozzles shall be checked

by visual inspection.

11.2.2 When any misalignment is found in the piping during the above inspection, the

information shall be given to the CONTRACTOR engineer.

11.2.3 After the piping alignment check is completed and/or misalignment of piping is

corrected, the suction and discharge piping shall be connected to the equipment

nozzles and the final cold alignment of the equipment shall be checked with a dial

gauge.

11.2.4 Any offset on the alignment of the equipment found as a result of the piping

connections shall be corrected as follows :

1) Offset values of 0.2mm or less shall be adjusted by inserting or removing shims

under the lug or saddle or the driver and/or speed exchangers without correcting

and piping alignment.

2) Offset values exceeding 0.2mm shall be reduced by correcting the suction and/or

discharge piping by burning or re-adjusting the pipe support, and, if necessary,

the suction and/or discharge piping shall be disconnected and be welded again to

correct alignment of the equipment and this welding joint shall be done NDE and

hydraulic testing.

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11.3 Final Check

After completing alignment, the follow shall be ascertained :

11.3.1 By revolving the coupling by the hand or a turning device in the direction of the

arrow mark, the equipment should rotate easily,

11.3.2 The direction or rotating of the driver shall be the same as indicated by the arrow

mark.

11.3.3 After the above and an instrumental check and a no-load test of the drive, the

equipment shall be coupled and be capable of being rotated again easily by the hand

or a turning device. If the equipment has any protection device such as a turbine trip

system, it shall be tested before coupling.

11.3.4 The setting of the coupling guard shall be checked.

12. INSPECTION AND PREPARATION BEFORE TEST OPERATION

12.1 General

Prior to the test operation of the equipment, the following confirmation shall be made

under witness of the CONTRACTOR engineer and vendor.

12.1.1 Chemical cleaning and oil flushing, if specified, have been finished.

12.1.2 The equipment can be rotate easily in the direction of the arrow mark by the hand.

After this inspection, the coupling shall be installed and lubricated properly. The

coupling guard shall be installed firmly.

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12.1.3 All just preventatives, oil, grease, etc., used to protect the equipment during

construction shall be removed using solvents.

12.1.4 The equipment shall be filled with the proper lubricants as instructed in the

Instruction Manual.

12.1.5 All accessories, such as pressure gauges, safety valves etc., shall be installed properly.

12.2 Running Test

After completing the installation work, a running test for each equipment, without

load shall be done under the witness of the Engineer's/Company's representative. If

any unusual sound, vibration of oil leakage in found during the running test, the

operation shall be stopped until the corrective countermeasures are taken.

12.3 Hot Alignment

12.3.1 For equipment operated at high temperatures, if so specified in the Instruction Manual,

the difference in height between the centers of the equipment and driver shall be

checked and adjusted to operate under hot conditions.

12.3.2 The value of the hot alignment shall be clearly indicated on the name plate to be

attached to the coupling guard or shall be clearly painted of the coupling.

13. INSPECTION AFTER TEST OPERATION

13.1 Inspection of Alignment

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13.1.1 The equipment shall be test operated under normal condition. After a steady operation

is attained, the driver shall be stopped and the hot alignment of the coupling shall be

inspected immediately. Any re-adjustment necessary shall be made by inserting or

removing the shims under the saddle of the driver or numbers the pedestal of the

equipment. After adjustment, the equipment shall be operated under normal

condition for several hours and the alignment shall be rechecked in accordance with

para. 11.1 through para.11.3.

13.1.2 The equipment shall be operated only with prior permission of the CONTRACTOR

Engineer.

14. INSPECTION

Inspection shall be made to assure that all the requirement prescribed in para. 7.0

through 13.0 have been done satisfactorily. All inspection and alignment records of

the equipment shall be submitted to Engineers.

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