- PURPOSE
- SCOPE
- REFERENCES
- RESPONSIBILITIES
- MATERIALS
- WORK METHODOLOGY
- QUALITY CONTROL
- SAFETY INSTRUCTIONS & PRECAUTIONS
- ATTACHMENT
1. PURPOSE
The purpose of this Method Statement for Rotating Equipment is to ensure that the work activities such as material handling, equipment installation and test & inspection shall be carried out safely, efficiently and in accordance with the project requirements in plants and refineries.
2. SCOPE
The scope of works covers under this method statement applies to all installation of rotating equipment covered under in plants and refineries.
3. REFERENCE
SAES-K-402 Centrifugal Compressor
SAES-K-403 Reciprocating Compressor
SAES-K-511 Diesel Engines
SAES-G-005 Centrifugal Pumps
SAES-G-006 Positive Displacement Pumps
SAES-G-115 Lubrication, Shaft Sealing and Control Oil Systems
SAES-G-116 Cleanliness Standards for Lube/Seal Oil and Fluid Power Systems
31-SAMMS-001 Axial and Centrifugal Compressors and Expander-Compressors
31-SAMMS-003 Reciprocating Compressors for Process Air or Gas Service
31-SAMMS-004 Centrifugal Pumps
31-SAMMS-009 Positive Displacement Pumps – Controlled Volume
31-SAMMS-012 Shaft Sealing Systems for Centrifugal and Rotary Pumps
API 686 Recommended Practices for Machinery Installation and Installation Design
S-000-3150-002 Construction Procedure for Installation of Rotary Equipment
01-SAMMS-017 Auxiliary Piping for Mechanical Equipment
SAES-Q-010 Cement Based, Non-Shrink Grout for Structural and Equipment Grouting
SAES-Q-011 Epoxy Grout for Machinery Support
PIP-STS03600 Nonshrink Cementitious Grout Specification
PIP-STS03601 Epoxy Grout Specification
4. RESPONSIBILITIES
Site Manager
Ensure full implementation of this Method Statement and identifies the work and safety requirements including add on resources for the effective accomplishment of the Mechanical Work.
Mechanical Supervisor
Ensure full work and safety compliance by all foremen, erectors and helpers regarding the execution of the work in accordance with the project specification and requirements. Confirm the availability of all materials, tools, equipment and required personnel who will carry out the work.
Quality Control Manager
Ensure full implementation of the required quality control procedures and maintain the required documentation as per the approved inspection test plan for the final acceptance and handover of the system.
Quality Control Inspector
Conducts daily surveillance and inspections in accordance with this procedure and prepares quality control records and final acceptance of documents when required for final handover.
Construction Manager
Check the work areas and monitor from time to time in the implementation of safety procedure and assuring that all safety equipment and tools are present at site and in proper good condition.
Safety Officer
Check the work areas and monitor from time to time in the implementation of safety procedure and assuring that all safety equipment and tools are present at site and in good working condition.
5. MATERIALS
5.1 Provision
All Mechanical Equipment and miscellaneous are to be supplied by Contractor / Company and in accordance with the specification of Schedule “Q” and SAMMS.
5.2 Material Handling and Storage
5.2.1 Upon receipt of the materials, visual inspection shall be performed for any damages during the transport and if there is any defect found, it shall be reported to JGC/DAEWOO.
5.2.2 All materials shall be unloaded, stored and handled in a manner that will prevent distortion, deterioration and damages. Materials shall be kept free of dirt, grease and other foreign materials.
5.2.3 All materials shall be verified and match to the number and markings of all the components against packing list and AFC drawings.
5.2.4 Vendor instructions necessary to preserve the integrity of the storage preparation for equipment at the jobsite and before start up are provided and applied.
6. WORK METHODOLOGY
6.1 General
6.1.1 Check all construction drawings are of latest revision and have “AFC”.
6.1.2 All necessary permits shall be obtained prior to start of work activities. All safety measures and precautions are visible in the work area.
6.1.3 Check foundation and other connection point to confirm their locations, coordinates and elevation.
6.1.4 Any damage components of the mechanical caused during erection shall be reported to Contractor / Company and an approved corrective measure shall be applied to rectify it.
6.1.5 Loose timbers, metal sheeting, bolt buckles, tools, debris and temporary scaffolding shall be kept restrained or removed from work areas. The erector shall be responsible in securing the equipment and materials in his custody including its control during erection operation.
6.1.6 The erector shall maintain the job site in a clean and safe condition at all times and shall properly dispose of all crating and waste materials that are accumulated as a result of the erection activities.
6.2 Chipping and Pad Plate Elevation
6.2.1 Concrete surface to be grouted shall be prepared for chipping using chipping hammer, grit blasting or high pressure water jetting whichever is applicable in order to leave a rough textured. Use of bush hammering or any similar method that can fracture or damage the integrity of the surface and foundation is not permitted.
6.2.2 Chipping should cover the full extent of the surface intended to be in contact with grout. This will enable the grout to have a strong adhesion to the chipped surface of the concrete.
6.2.3 The height of chipped concrete under the base plate shall be at least 25mm unless otherwise specified by vendor.
6.2.4 Surface of the chipped concrete, base plates and holding down bolts, etc. shall be cleaned and free from any oil, dust, dirt, paint and any residual curing compound that can cause bond impairment.
6.2.5 Padding plate material shall be in accordance with ASTM A283 Gr. C or equivalent. It shall be hot dip galvanized in accordance with ASTM A123 or coated with zinc rich epoxy primer in APCS-1C of SAES-H-101.
6.2.6 Padding plate shall be set so that the elevation of the base of the equipment is within the specified height.
6.2.7 Padding elevation tolerance is ±3mm.
6.2.8 Liners and wedges shall be located on both sides and closer to each anchor bolts. When the distance between anchor bolts is larger than 800mm, extra liners and wedges shall be located between to prevent bending of the base plate.
6.3 Setting, Centering (Equipment) and Leveling of Machine Skid
6.3.1 A final check shall be made to ensure that the center of the equipment matches the center line marked on the foundation. Centering shall conform to client inspection standards corresponding to the type of the equipment being installed.
6.3.2 Where the liners are used in multi layers, it shall be intermittently welded to each other after completion of the centering of the equipment. Position shall be measured on the basis of flange within ±3mm.
6.3.3 Leveling shall be performed using appropriate and accepted instrument on the machined surface of the driver base plate or on the suction/discharge flange of the vertical nozzle on top of the equipment unless otherwise specified.
6.3.4 Leveling shall be adjusted by inserting and/or removing the liners. When jack bolts are provided on the equipment base frame, liners and/or wedges are not required.
6.3.5 The leveling tolerance is within ±0.2mm/m for API pumps and to within ±0.4mm/m for general purpose equipment (API 686)
6.3.6 Sole plate installation and levelling as per API 686.
6.4 Grouting and Anchor Bolt Tightening
6.4.1 Grouting for the base plate shall be done after completion of the shaft pre-alignment and leveling inspection of the equipment. The top surface of the foundation shall be cleaned and blown with compressed air. All contaminants shall be removed. For epoxy resin grout, the surface must be completely dry before application of the grout. Grouting materials application and procedure shall be performed in accordance with the approved Method Statement for Grouting.
6.4.2 For pocket type anchor bolts, it shall be set to the base of the equipment. Check and adjust the anchor bolt before pouring the appropriate quantity of mortar.
6.4.3 Curing time of the grout mortar shall be checked prior to commencing the anchor bolt torquing.
6.4.4 Anchor bolts shall be set to a minimum three threads protusion from the lock nut.
6.4.5 Anchor bolts shall be adequately protected to prevent threaded parts from being covered with mortar.
6.5 Shaft Alignment
6.5.1 General
6.5.1.1 After curing grout and before piping Works, the driver and speed change gear shall be adjusted for shaft alignment and the machinery without piping connection to suction and discharge nozzle shall be aligned.
6.5.1.2 Alignment shall be adjusted by fixator or inserting (0.1 ~ 0.5mm) thick shim plates made of brass or stainless steel.
6.5.1.3 On completion of piping system installation and testing, final alignment shall be carried out and checked in accordance with vendor’s recommendations.
6.5.1.4 Following points shall be checked prior to the final alignment of the equipment :
– Alignment shall all for potential movements such as thermal growth, hydraulic loading, gears with rising pinions, etc. Manufacturer’r recommendations shall be followed.
– Check that coupling hubs are correctly installed.
– Check and record the distance between shaft ends and/or distance between hubs (axial float, pre-stress, etc.)
– Confirm that the equipment has been shimmed correctly with stainless steel shims.
– Confirm that no soft feet (maximum dial movement value follows Manufacturer’s recommendation.
– Axial and transverse keys are properly located and secured.
– Level and alignment adjustment screws/jack screws are removed.
– Bolting shall be checked by using torque wrench.
– On base plate mounted equipment, a dial gauge attach to the coupling hub shall be used during the tightening of anchor bolts, to detect any deformation.
6.5.2 Requirement
6.5.2.1 Final alignment shall not exceed to Manufacturer’s requirement or the following whichever is more stingent:
6.5.2.2 For all rotating equipment, the preferred method of alignment shall be the reverse dial indicator method. A graphical plot of the shaft position shall be made as follows :
– 2 axial dial gauges
– 1 radial dial gauge
– Both shaft turned simultaneously
6.5.2.3 Readings shall be demonstrated to be repeatable. Dial bracket sag shall be taken into account and shall not be more than 0.05mm.
6.5.2.4 Alignmnent checks shall include :
– Check of the number of shims used underneath each foot or shim point.
– Soft foot check (maximum dial movement 0.03 at the foot and the coupling hub)
– A preliminary check to ensure that alignment is possible with regard to shim limitations, bolt and bolt holes positions, etc.
6.5.2.5 An alignment check without piping connected to the equipment.
6.5.2.6 An alignment check with bearing brackets support loose (eg. Overhung pumps)
6.5.2.7 Final alignment check.
– For the final check, the dial indicators should be on the equipment before and during the tightening of the piping brackets, in order to highlight the cause of any distortion. The final reading shall be taken with all process piping and auxilliary piping connected with proper gaskets in place.
6.5.2.8 The alignment shall begin with a single shim of at least 3mm thickness underneath each foot or shim point. When the alignment is completed, there shall be no more than 3 single shims under each foot or shim point. One sollid, precision-machined shim with lapped surfaces shall be used when necessary to replace a larger shim stack.
6.5.2.9 Final alignment data shall be recorded, filed and handled over to JGC/DAEWOO Quality Team.
6.5.2.10 Alignment after the connecting pipe
– After the suction and discharge nozzle are connected to piping, the Mechanical Supervisor shall be informed that all piping works such as installation of permanent supports and hydro testing, if any, are completed for the connected piping. The alignment of the equipment shall be checked as follows :
o 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 piping and connection flanges of the equipment nozzles shall be checked by visual inspection.
o If there are misalignment found in the piping during the above inspection, the information shall be given to the Piping Supervisor.
– Corrections shall be made on any offset on the alignment of the equipment found due to piping connections.
– After the piping alignment check is completed, the suction and discharge piping shall be connected to the equipment nozzles and the final cold alignment shall be checked with a dial gauge.
7.0 QUALITY CONTROL
7.1 Inspection shall be conducted and recorded in accordance with the Job Specification Inspection and Test Plan.
9.0 SAFETY INSTRUCTIONS AND PRECAUTIONS
9.1 Make sure that all necessary work permits are issued.
9.2 Check all lifting equipment prior to commencing lifting activities.
9.3 Stay away from any suspended load/falling objects.
9.4 Wear full body harness when working at elevated platform.
9.5 Ensure that barricades and warning signs are properly installed.
9.6 Ensure that there are no hazardous or combustible gases present in the work area.
9.7 Install flashing lights to traffic.
9.8 Copy of approved JSA to be maintained at work site by Work Supervisor. Conduct daily Tool Box Talk and discuss work methodology prior to commencement of work.
9.9 Implement and monitor safety instruction on site.
9.0 ATTACHMENT
9.1 JSA (Job Safety Analysis)