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Revision: 1
Name
Prepared by:
Date
G Ralls
8/1/09
13/1/09
Custodian:
28/1/09
Godfrey Howard
Concurrence (Agreement that must be obtained if an item is prepared external to, but impacts, a department or division. If
concurrence is required, it must be noted within the body of the item).
1.
2.
3.
Woodside Management System Sub-processes MUST obtain concurrence endorsement from BopCom. The date of the BopCom
meeting where endorsement is granted should be indicated below.
BopCom Endorsement
REVISION HISTORY
Revision
Description
Date
Prepared by
Approved by
03/2007
D Gomes
M Hackett
01/2009
G Ralls
M Hamblin
INFORMATION SECURITY
CONFIDENTIALITY CLASSIFICATION
REVIEW STATUS
(Check one box only)
PREPARED
(Check one box only)
Unclassified
Review on/by
(03/2012)
By WEL
Restricted
For WEL
Confidential
(Shared With Selected Personnel)
Most Confidential
(Strict Need-to-Know Basis)
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DOCUMENT DISTRIBUTION
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Peter Nalepa(3019)
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Mike Hamblin(3227)
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Clive Saxton(3606)
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PREFACE
Woodside Energy Ltd. (WEL) has developed a suite of Engineering and Technical Standards
and Guidelines. It is intended that these reflect the most suitable engineering practices for
use on all new WEL facilities as well as the modification of existing facilities. The application
of the Standards is mandatory. The application of Guidelines is to support the
implementation of the Standards, and are considered best practice, but are not mandatory.
The Standards are based on the experience acquired by WEL personnel and contractors
during WELs involvement with the design, construction, operation and maintenance of WEL
processing units and facilities. Where appropriate, the Standards are based on or make
reference to national and international standards and codes of practice.
The objective of this publication is to ensure the overall integrity of engineering design and to
achieve maximum technical and economic benefits through the standardisation of
engineering and technical practices.
The use by WEL contractors or manufacturers/suppliers of the Engineering and Technical
Standards contained in this publication does not relieve them of any responsibility
whatsoever for the quality of design, materials and workmanship that they have been
engaged to provide.
Where the standards to be used for a certain application are not provided for in this
publication, WEL expects that the standards that are used will achieve the same level of
integrity as reflected in this publication. If WEL contractors or manufacturers/suppliers have
any doubt as to the relevant standard to use, then they must consult WEL, however they will
remain responsible at all times for the use of the most appropriate standard. Specific
requirements may be added as an addendum to these Standards and Guidelines for various
projects. Project specific requirements must not depart from the requirements of the
Engineering and Technical Standards contained in this publication. Where changes or
additions to these Standards are required, they must be raised as a deviation and presented
to the WEL Technical Authority for consideration.
WEL grants the right to use these Standards and Guidelines to WELs consultants,
contractors and suppliers who are contractually authorised to do so and to any tier of
contractor to its consultants, contractors and suppliers who are contractually required to
comply with them.
DISCLAIMER
WEL and its joint venture partners disclaim any liability of whatsoever nature for any damage
(including injury or death) suffered by any company or person whomsoever as a result of or
in connection with the use, application or implementation of any standard, combination of
standards or any part thereof contained in this publication.
This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
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TABLE OF CONTENTS
1. INTRODUCTION ................................................................................ 5
1.1
1.2
1.3
1.4
1.5
SCOPE ........................................................................................................ 5
REGULATORY CONSIDERATIONS........................................................... 5
DEFINITIONS .............................................................................................. 5
ABBREVIATIONS ....................................................................................... 5
APPLICATION............................................................................................. 6
GENERAL ................................................................................................... 6
FINAL CLOSURE ...................................................................................... 11
PRESERVATION OF EQUIPMENT........................................................... 12
ACCEPTANCE OF EQUIPMENT .............................................................. 12
3. HEAT EXCHANGERS...................................................................... 12
3.1 ERECTION ................................................................................................ 12
3.2 TESTING ................................................................................................... 14
4. VESSELS ......................................................................................... 14
4.1 ERECTION ................................................................................................ 14
4.2 TESTING ................................................................................................... 15
5. ROTATING EQUIPMENT................................................................. 15
5.1
5.2
5.3
5.4
6. APPENDICES .................................................................................. 26
6.1 EXHIBIT 1 - PREVENTATIVE MAINTENANCE OF ROTATING
EQUIPMENT INITIAL PRESERVATION ................................................... 27
6.2 EXHIBIT 2 - PREVENTATIVE MAINTENANCE OF ROTATING
EQUIPMENT WEEKLY PRESERVATION ................................................ 28
6.3 EXHIBIT 3 - PREVENTATIVE MAINTENANCE OF AIR FIN COOLER
INITIAL PRESERVATION ......................................................................... 29
6.4 EXHIBIT 4 - PREVENTATIVE MAINTENANCE OF AIR FIN COOLER
WEEKLY PRESERVATION ...................................................................... 30
6.5 EXHIBIT 5 - PREVENTATIVE MAINTENANCE OF MOTORS INITIAL
PRESERVATION....................................................................................... 31
6.6 EXHIBIT 6 - PREVENTATIVE MAINTENANCE OF MOTORS WEEKLY
PRESERVATION....................................................................................... 32
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1.
INTRODUCTION
1.1
SCOPE
This standard supersedes the requirements of L0000SM143497.
1.2
REGULATORY CONSIDERATIONS
If international and/or regional regulations exist in which some of the
requirements may be more stringent than in this Standard an assessment shall
be made to determine which of the requirements are the more stringent and
which combination of requirements will be acceptable as regards safety,
environmental, economic and legal aspects. In all cases the Contractor shall
inform the WEL Technical Authority
1.3
DEFINITIONS
The definitions below shall apply:
1.4
The Contractor is the party that carries out all or part of the design,
engineering, procurement, construction, commissioning or management of a
project, or operation or maintenance of a facility. The Principal may
undertake all or part of the duties of the contractor.
The Principal is the party that initiates the project and ultimately pays for its
design and construction. The Principal will generally specify the technical
requirements. The Principal may also include an agent or consultant
authorised to act for, and on behalf of, the Principal.
ABBREVIATIONS
WEL
TA
Technical Authority
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1.5
APPLICATION
This standard describes the minimum requirements for loading, unloading,
transportation, erection, installation, maintenance, testing and pre-startup
preparation of mechanical equipment including but not limited to:a) Electric motor driven pumps, compressors, and auxiliary equipment.
b) Pressure vessels, including associated internals.
c) Heat exchangers
d) Other special mechanical equipment.
2.
2.1
GENERAL
2.1.1
2.1.2
Equipment and tools for transport, lifting and the assembly of equipment shall be
of adequate design, the correct type and of suitable size/capacity to perform the
work professionally and safely.
2.1.3
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2.1.4
Prior approval from Company shall be obtained before any item of equipment is
erected, grouted, opened, rotated or operated.
2.1.5
2.1.6
2.1.7
2.1.8
2.1.9
The dimensions, lines and levels of the equipment foundations and anchor bolt
positions and projections shall be checked against the applicable civil or
steelwork drawings and equipment drawings or data sheets before erection
commences. Company shall be informed of any discrepancies prior to erecting
the equipment.
2.1.10
Levelling
a) Levelling plates shall be made, machined, set and grouted.
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2.1.12
Anchor Bolts
Before the equipment is placed on the respective foundations a detailed
inspection/check shall be conducted to ensure that all anchor bolts are vertical,
that the threads are not damaged and the nuts run free on the threads, and that
the anchor bolts are complete with the specified number of nuts and washers. If
damaged the Company must be informed for rectification procedures.
The dimensions of the washers and the number of nuts shall be in accordance
with Companys standard drawings for foundation bolts and anchor bolts with
sleeves.
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2.1.13
The
c) Sleeved bolts are installed with a metal plug to centralise bolts during pouring
of concrete. This shall be removed after pour and before final grouting of
equipment.
d) Before grouting the equipment base frame or base plates the sleeve pockets
shall be filled with non metal base and flowable non shrink grout, to within 50
mm of pocket top (masterflow 870A).
e) Company shall direct the usage of epoxy grout (Araldite K80) and to which
equipment it shall be applied.
2.1.14
2.1.15
An erection proposal shall be prepared for all heavy and/or difficult lifting and
transport operations.
The proposal shall include but not be limited to a rigging study, the details and
ratings of equipment proposed for lifting and transportation, ratings of lifting and
rigging components, an erection procedure and a list of personnel involved and
their individual function/responsibility. The erection proposal and procedure,
supported by detailed technical data, drawings and calculations shall be
submitted to Company for approval not less than 14 days prior to the
commencement of the unloading, lifting and transport operation.
2.1.16
Equipment shall be set, aligned, levelled and grouted in accordance with the
relevant drawings, data sheets or Vendors manuals.
Levels, setting and alignment shall be re-checked after the grouting is
completed.
2.1.17
Prior to placing the grout, checks shall be made to ensure the equipment is set at
the correct level and plumb and aligned. For rotating equipment the shaft
alignment shall be within the tolerances specified in this standard or the
Manufacturers installation and maintenance manuals, whichever is the more
stringent.
Only after the requirements of this standard and Manufacturers requirements
are fully complied with in every detail shall Company be invited to inspect the
installation.
Approval to proceed with grouting shall be given after Company has inspected
and accepted the installation.
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2.1.18
Company shall specify the type of grout, the brand name, method and extent of
application.
Non shrink grout or Epoxy grout shall be used for all rotating and static
equipment (i.e. columns vessels), unless otherwise directed by the Company.
For steel structures a sand-cement grout may be used.
2.1.19
Minor base plates and piping supports bolted direct to the concrete paving shall
have packers installed to provide a 25 mm minimum and not more than 30 mm
gap for grouting. All grout will taper away at 45 from base plate to foundation or
concrete paving.
2.1.20
Cavities in base plates of rotating equipment and base plate mounted package
units shall be filled solid with grout. Company shall specify the grout system to
be utilised. Holes may have to be drilled in the top of the base plate to facilitate
the placing of the grout and to vent the cavities. After grouting, the base plates
shall be checked for any voids. Voids shall be filled using the epoxy pressure
grouting techniques before final alignment activities commence.
2.1.21
2.1.22
All equipment skids, base plates, skirts, slide plates, saddles or other contact
surfaces shall be clean and free from burrs, damage, debris or mill scale. A joint
inspection with Company on receipt of equipment is required to determine the
condition of contact surfaces.
The areas in contact with cementitious grout shall be free from oil and grease.
The areas in contact with epoxy grout shall be free of paint, and roughened by
sand/grit blasting in cases where no special vendor preparation has been done
to underside of skid.
2.1.23
2.1.24
2.1.25
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unit. The earthing clamp positioned at the point of weld shall be considered in
such case.
2.1.26
2.1.27
Prior approvals shall be obtained from Company in writing before any welding,
cutting, drilling or grinding is undertaken in whatever method or form.
2.1.28
Equipment shall be kept in a clean and tidy condition at all times. Rubbish,
redundant and scrap materials or unused construction equipment/materials shall
be removed daily and the equipment preserved and maintained in a safe
condition. Internal areas of vessels and exchangers shall be cleaned and swept
dust free with a broom or vacuum cleaner.
2.1.29
Manholes shall be kept closed and temporarily secured with a few bolts at all
times when the work or inspection inside the vessels is complete or temporarily
suspended. This is to prevent the ingress of rubbish or foreign matter and to
stop unauthorised entry.
2.1.30
2.1.31
2.1.32
2.2
FINAL CLOSURE
Authorisation for the final closure is required for all vessels, exchangers, ducts,
etc. and shall be given by Company after Companys construction and precommissioning disciplines have completed the inspection and the Final Closing
Authorisation Form has been signed by all parties.
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2.3
PRESERVATION OF EQUIPMENT
2.3.1
2.3.2
Refer to attached Exhibits F-1 to F-6 for preservation item check lists.
2.4
ACCEPTANCE OF EQUIPMENT
Final inspection and checks shall be performed by Company prior to acceptance
of equipment.
3.
HEAT EXCHANGERS
3.1
ERECTION
3.1.1
3.1.2
Exchangers shall be rigged and erected, together with all auxiliary items to the
correct elevations, centre lines and orientations. Contractor shall also check
major piping connections. After final alignment anchor bolts shall be tightened in
accordance with specifications and drawings.
3.1.3
3.1.4
To protect the tube expansion in the tube plates of air cooled heat exchangers
the tube bundles shall be stored and lifted level and horizontal. Bundles shall
only be lifted at the points indicated by Manufacturer. Contractor shall verify the
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levelness and all diagonal measurements etc. before lifting to ensure the frame
has not been twisted.
3.1.5
During erection, exposed fins of air cooled tube bundles shall be covered with
plywood boards to protect fins from damage by workers walking on top of the
bundles. Any damage to the tube fins shall be made good by combing, by the
Contractor.
3.1.6
Shipping stops shall be removed from the air cooled heat exchanger bundles as
soon as the bundles are installed and located in the structure. No piping shall be
connected to nozzles until the exchanger is firmly anchored to the steel structure.
3.1.7
Air cooler fans and drivers shall be installed, aligned, have blades set at the
correct angle, all bolts tightened to correct torque and correct air gaps set
between blade tips and cowling/plenum, as per following criteria:1)
Final alignment shall not exceed the following values: 0.05 mm T.I.R. for direct drive fan.
0.5 mm/m pulley to pulley in case of belt drive.
2)
Fan blade setting criteria shall be as follows: 0.5 degree blade angle tolerance from Vendor design blade angle
setting.
Vendor design minimum tip clearance value. The tip clearance shall be
measured at one position on the cowling with all blades passing for
measurement. The longest blades will then be used to determine the
narrowest air gap in at least 8 locations around the cowling
circumference. Adjustments shall be carried out if the clearance is out
of tolerance.
3)
4)
3.1.8
Equipment shafts shall be rotated at least once a week. To ensure that all
rotating elements are rotated a record shall be kept. Refer to attached Exhibits
F-3 and F-4 for preservation item check lists.
3.1.9
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3.2
TESTING
3.2.1
Shell and tube exchangers shall be delivered tested and complete with shell
heads bolted in position. Retesting shall only be carried out on the specific
instructions of Company. Test rings, if supplied should be coated with a
protective grease and kept in storage until hand over to Company.
3.2.2
Exchangers shall not be included in piping tests without the written authorisation
of Company. Test blinds shall be installed at flanged connections to isolate
equipment from the piping tests.
3.2.3
Post erection testing of air cooled heat exchangers shall be required. Company
shall specify procedures and which exchangers shall be hydrotested and which
shall be pneumatically tested.
4.
VESSELS
4.1
ERECTION
4.1.1
Prior to the erection of the equipment onto the foundation, the levelling
plates/packers shall be installed and grouted, sliding plates placed and located.
4.1.2
Vessels shall be rigged and erected, together with all auxiliary items, set on
packers to the correct elevations, centre lines and orientations.
After final alignment anchor bolts shall be tightened in accordance with
specifications and drawings. Contractor shall check all main piping connections.
All flanges shall be protected from rust and damage by placing denso tape over
the raised face portion and held in position with a temporary blind.
4.1.3
4.1.4
4.1.5
Preassembly and erection shall be carried out in accordance with the details in
the drawings, data sheets and Vendors manuals.
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4.2
TESTING
4.2.1
4.2.2
Vessels shall be supplied with the internals already fitted, the internals shall be
inspected on site for transport damage and completeness against the applicable
drawings, data sheets and specification. Internals shall again be inspected in the
equipment after placement on foundation in final position. The Contractor shall
inspect and adjust if necessary the internals to correct level, alignment and
clearances in accordance with these documents.
5.
ROTATING EQUIPMENT
5.1
5.1.1
5.1.2
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d) A set of rigging gear shall be reserved and used only for the assembly and
inspection of rotating equipment i.e. set of clean nylon slings, lifting eyes,
shackles, chain blocks (2 to 4 tonne capacity), hydraulic jacks. The lifting
gear will be required for the removal of bearing caps, installation and
inspection of piston rods, rotating assemblies etc.
e) Special tools supplied with the equipment shall be properly stored and
maintained and replaced at the Contractors expense if misplaced.
The tools shall only be used for the service for which they are intended and shall
be returned to Companys warehouse immediately after completion of the
assembly of the equipment.
5.1.3
Foundations
a) Foundations shall be free of oil, grease and dirt and shall be prepared by
scabbling the surface and installing the levelling plates prior to placing the
skid or base plate. Packers shall be placed on each side of the anchor bolts
and midway if the anchor bolts are over 1 metre apart. The skids/base plates
shall be levelled using composite packers.
b) Anchor bolts for all rotating equipment shall be fitted with locknuts tightened in
accordance with Vendors instructions.
5.1.4
Shaft/Coupling Alignment
a) Shaft alignment check shall be made for supplied rotating equipment including
pumps, compressors, fans, pullies, gear units and drivers.
Shaft alignment check shall also be made for all auxiliary equipment installed
on skids or package type units, i.e. lubricating oil pumps, hydraulic power
pack pumps, cooling water pumps etc.
A range of shaft alignments shall also be conducted throughout the erection of
the equipment to ensure that shaft alignment is not disturbed when the
various piping and/or equipment components are installed.
Final misalignment shall not exceed the Manufacturers tolerances or the
following tolerances whichever are the more stringent:-
Equipment Condition
All speeds and coupling
spacer lengths up to 250
mm.
All speeds and coupling
spacer lengths above 250
mm.
Radial (Parallel)
Misalignment
Axial (Angular)
Misalignment
0.05 mm T.I.R.*
0.05 mm**
0.02 mm T.I.R.*
per 100 mm of spacer
length
0.05 mm**
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0.10 mm T.I.R.*
0.05 mm**
b) Method of alignment shall be one of the following methods: the reverse periphery method whereby a graphical plot of shaft position
shall be made.
the three dial method using 2 axial gauges and 1 radial dial gauge with
both shafts turned simultaneously.
Reading shall be demonstrated to be repeatable. Dial bracket sag shall be
taken into account and shall not be more than 0.05 mm which should be
checked i.e. on a lathe.
Alignment checks include: A preliminary check to ensure that alignment is possible with regard to
shim limitations, bolt and bolthole positions, etc. before grouting of base.
An alignment check with bearing bracket support loose (overhung pumps)
and without piping connected to the equipment after grouting.
A soft foot measurement on each driver holding down bolt must be
measured at no greater than 0.04 mm when the dial indicator is in the
vertical position on the driven coupling hub.
Final alignment check. For this check the coupling mounted dial indicators
should be on the equipment before and during the tightening of the piping
and bearing brackets, to highlight the cause of any distortion. The final
reading shall be taken with all process piping and auxiliary piping
connected with proper gaskets in place, all pipe supports in their respective
final positions and spring supports with cold setting stoppers intact if
insulation has not bee installed and removed if installed. Company will
arbitrate in the decision.
With piping connected, the relative movement of shaft centrelines shall not
exceed 0.025 mm (= 0.05 mm T.I.R.) over and above the measured misalignment with pipes disconnected.
Hot/cold alignment checks shall be agreed with Company on a case to case
basis, taking into account the operating temperature and/or the
Manufacturers recommendations. For the final hot/cold alignment, the
tolerances for misalignment as per 5.1.4.a. shall apply.
Final alignment data shall be recorded, filed and handed over to Company.
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This document is protected by copyright. No part of this document may be reproduced, adapted, transmitted, or stored in any form by
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5.1.6
Lubrication System
The type, grade and volume of lubricants for flushing and initial filling of the
lubricating systems shall be specified by Company unless otherwise
specifically stated.
All lubricants shall be made available by Company.
Contractor shall clean the equipment, fill the system, flush the system, drain
and collect the flushing oil and fill the system with the final lubricating oil.
Flushing shall be in accordance with the Vendors procedures.
The oil levels in the equipment shall be continuously checked and topped-up if
necessary, during the course of the construction.
a) Splash oil ring or grease lubrication: Lubricating oil reservoirs for bearing housing shall be inspected for
cleanliness and leaks.
Lubricating or oiler rings, lubricators, breathing valves shall be inspected
for correct installation and/or damage.
Oil level in reservoirs shall be checked and verified with Manufacturers
operation/maintenance instructions.
Bearing caps of grease lubricated bearings shall be removed and the
grease examined. If deterioration of the grease is suspected the bearing
shall be cleaned and packed with new grease.
b) Pressurised lubricating oil systems and hydraulic oil systems: Lubricating piping, coolers, filters, heaters, reservoirs, crankcases and air
cooled heat exchanger header boxes shall be inspected for cleanliness
and leaks prior to filling the systems with oil.
All field fabricated pipes are to be air blown clean prior to commencement
of flushing activities and inspected by the Company.
Systems shall be checked against the drawings to verify the correct
installation of restriction orifices, filters, vents, control/recording/alarm
instrumentation, safety and safety relief devices.
All temporary piping, hoses, flanges, valves, connections and fittings to
complete a satisfactory flush shall be supplied by the Contractor.
Lubricating oil and hydraulic systems shall be flushed in accordance with
Manufacturers commissioning and operating manuals.
For lubricating oil and hydraulic systems, the systems shall be
demonstrated to be clean by installing 120 mesh filters upstream of each
bearing and circulating oil for at least 12 hours at a temperature of
approximately 70C. Company shall inspect each filter after this procedure
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Bearings
a) Equipment may be shipped with temporary or shipping bearings installed.
Electric motors may be fitted with locking devices to lock the rotor for
shipping.
Shipping bearings and locking devices shall not be removed until the
assembly of the equipment has reached the stage of preparation for the initial
shaft alignment.
b) Shipping bearings shall not be removed and replaced by the permanent or
service bearings unless a lubricating system can be established and
maintained to preserve the bearings. Prior approval shall be obtained from
Company for the removal of shipping bearings or locking devices.
c) Bearing housings shall be checked for cleanliness and to ensure that
lubricating or oiler rings are correctly installed and have adequate free
movement. The Company must be informed of any irregularities and
corrective action approved.
d) Bearings shall be inspected for ingress of dirt, water and corrosion. Ball and
roller bearings shall be checked for transport and/or vibration damage causing
brinelling of the bearing surfaces.
5.1.8
Shaft Seals
a) The installation of the mechanical seals and associated piping shall be
checked against the relevant pump manufacturers and mechanical seal
manufacturers drawings for the correct installation of the piping, restriction
orifices, cooling and cyclone separators.
b) Piston rod packings shall be inspected, cleaned and reinstated in accordance
with Manufacturers installation and maintenance manuals prior to initial run of
the equipment.
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5.1.9
5.1.10
5.1.11
Piping
Process piping and utility piping connected to the equipment shall be checked to
ensure:a) Cooling water supply and return have been connected correctly.
b) Piping is flushed and cleaned before being connected to the equipment. All
mill scale removed either by sandblasting or chemical cleaning. Company will
arbitrate requirement.
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c) Strainers are installed in the suction lines and that strainers have been
checked for the correct mesh, cleanliness and fitting to ensure correct
operation. Mesh dimensions and opening size will be determined by the
Manufacturer and the Company.
d) Temporary blinds are removed prior to the initial test run.
5.1.12
In conjunction with the electrical and instrument disciplines the safety shutdown
devices shall be checked and proven, relief valves in lube oil systems shall be
set in accordance with Manufacturers specification prior to the initial run of the
equipment or any auxiliary system of the equipment (eg. lubricating oil system).
5.2
5.2.1
Centrifugal horizontal pumps will, unless otherwise stated, arrive on site with
drivers mounted on the base plates and the initial pump to driver alignment
complete. These pumps shall be placed on the concrete foundations which have
been previously scabbled, and located on embedded anchor bolts. These bolts
will be sleeve type and some movement is possible to correct small inaccuracies
in bolt position. Steel packers shall be placed under the base plate using one
packer on each side of each holding down bolt. The base plate shall then be
levelled using composite packers on top of the existing packer. A preliminary
alignment check of the couplings shall be done before grouting. Grouting of the
base plate shall be carried out as per this standard.
5.2.2
When the grout has cured the anchor bolts shall be finally tightened to the
required tension and the pump to driver alignment rechecked prior to pipe
erection. Any readjustment shall be made by shimming the driver only.
Full faced packers of stainless steel shall be used when setting up drivers for
alignment to their respective driven units. The total number of packers used in
achieving levels shall be kept to a minimum. In all cases a minimum ship pack
thickness of 3 mm is required to allow for subsequent adjustment to the motor
driver without machining either the motor or bed plate pads.
Final alignment shall be carried out subsequent to piping hydrostatic testing and
prior to pre-commissioning, at which time the piping must be stress free and
supports correctly set at cold position.
All piping shall be checked against Vendors drawings.
5.2.3
If the driver is delivered separately from the base plate and pump, the pump and
base plate shall be set up as described in Section 5.2.2. The installation of the
electric motor on the base plate and the initial alignment shall be carried out
before grouting.
5.3
5.3.1
For vertical pumps, the foundations will be either steel or concrete. Where
pumps are mounted on steel sections, anchor bolt holes will be provided in the
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Page 22 of 32
5.3.3
Grout pump feet to the depth of the packers/underside of base plate and when
grout has cured, tighten anchor bolts to the required tension. Check alignment of
motor to pump coupling.
5.3.4
When the motor driver is delivered separate from the pump, the pump shall be
installed and aligned in accordance with the above procedure.
The motor driver shall be installed after the pump installation has been
completed. For pumps installed on concrete foundations requiring grouting the
motor shall be installed after the grout has cured.
5.4
RECIPROCATING COMPRESSORS
5.4.1
5.4.2
All rotating equipment has been fully assembled at Manufacturers works for
running and performance testing.
After completion of the running/performance test at Manufacturers works the
equipment is dismantled into sub-assemblies to facilitate transport/shipping to
the worksite. The various modes of subassembly in which the equipment is
expected to be shipped to the worksite are illustrated hereunder.
a) Completely knocked down in small parts.
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Page 23 of 32
5.4.4
5.4.5
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Page 24 of 32
Skid mounted equipment fully assembled with main and auxiliary equipment on
the same skid.
The skid shall be unpacked and the equipment cleaned. The parts shipped
loose shall be identified and stored under cover in a lockup store.
The skid shall be placed on the prepared foundations. Alignment check, grouting
and all necessary mechanical erection work shall be carried out in accordance
with this standard and the Manufacturers installation manual.
Miscellaneous equipment not limited to coupling guards, operating platforms,
acoustic enclosures, vents, drains shall be installed in accordance with the
relevant drawings.
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Page 25 of 32
6.
APPENDICES
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6.1
PR E V E N T A T IV E M A IN T E N A N C E O F R O T A T IN G E Q U IPM E N T
IN IT IA L PR E S E R V A T IO N
SU B C O N T R A C T N o.:
IT E M N o .:
SIG N A T U R E A N D D A T E
P R E S E R V A T IO N IT E M S
SU B C O N T R A C T O R
1
A ttached is a copy of m anufacturer's recom m ended R ust P revention P rocedure w hich shall be follow ed unless noted otherw ise.
D ism antle all vulnerable accessories such as Trico O ilers, Local Instrum ent gauges, M ethanol P ot level gauges, C oupling
S pacer etc. and coat exposed m etal surfaces w ith S hell E nsis 30 O il, label, record and store in secure w eatherproof enclosure.
Leave the shipping blinds intact except on com m encem ent of piping, all flanges including m ain suction and discharge flange
shall be fitted w ith 1 to 3 m m alum inium spades (D ust B lind).
M etal plugs or caps shall be fitted to screw ed openings. O ther openings including M otor Junction box shall be sealed i.e.
D enso tape.
E nsure that all tank level gauges and any other special instrum ents (Transm itters etc.) are w ell covered and protected in its
place.
A ll exposed m etal surfaces including Shaft, C oupling H ub, P ulley shall be sprayed w ith E nsis 30. S eal P um p/m otor shaft w ith
D enso tape at bearing.
O il filled bearings housing shall be filled w ith light oil or sprayed internally.
Lube/seal oil reservoirs and tanks shall be filled w ith light oil or sprayed internally.
10
11
12
G eneral inspection of equipm ent/accessories for dam age and painting inspection.
13
M A IN C O N T R A C T O R
R E M A R K S:IT E M S T O B E C H E C K E D A N D
IM P L E M E N T E D W H E R E IN D IC A T E D T H U S
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Page 27 of 32
6.2
EXHIBIT
HIBIT 2 - PREVENTATIVE MAINTENANCE OF ROTATING EQUIPMENT WEEKLY PRESERVATION
E X H IB IT N o .:
P R E V E N T A T IV E M A IN T E N A N C E O F R O T A T IN G E Q U IP M E N T
W E E K L Y P R E S E R V A T IO N
F -2
S U B C O N T R A C T N o .:
Flange face protection with Denso tape and dust blinds in place
IT E M N o .:
S IG N A T U R E
REM ARKS
DATE
SU B C O N TR AC TO R
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Page 28 of 32
M A IN C O N T R A C T O R
6.3
EXHIBIT
HIBIT 3 - PREVENTATIVE MAINTENANCE OF AIR FIN COOLER INITIAL PRESERVATION
EXHIBIT No.: F-3
SUBCONTRACT No.:
ITEM No.:
PRESERVATION ITEM S
Wherever possible, seal motor shaft with "Denso" tape. For equipment mounted motors with difficult shaft access, spray
exposed shaft with Shell Ensis 30 (M V, HV).
For air fin cooler mounted motors, check for presence of water on top bearing area (M V).
For air fin cooler mounted motors fitted with "porous drain plugs", ensure passage of possible water out of the motor i.e. do not
cover/seal of the fan air intake (M V).
Seal off all cable gland entry holes to terminal boxes (M V, HV).
Check terminal box(es) covers are bolted down and provide a proper seal, particularly after "megger testing of windings (M V,
HV).
M egger test motor windings intially and at 3 monthly intervals there after. M ore frequent testing if readings are progressively
lower, indicating moisture in the windings (M V, HV ).
For protection against dust and weather treat motors as follows:a. HV motors and large skid mounted motors, cover complete motor with waterproof cover.
b. HV motors, cover and seal-off fan cowl air intake opening (excluding item 3 above).
10
Lubricate bearings in accordance with manufacturer's instructions, or in the absence of them. At 6 monthly intervals (M V , HV).
M AIN CONTRACTOR
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Page 29 of 32
6.4
SUBCONTRACT No.:
ITEM No.:
SIGNATURE
REM ARKS
DATE
SUBCONTRACTOR
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Page 30 of 32
M AIN CONTRACTOR
6.5
EXHIBIT
HIBIT 5 - PREVENTATIVE MAINTENANCE OF MOTORS INITIAL PRESERVATION
E X H IB IT N o.: F-5
PR E V E N T A T IV E M A IN T E N A N C E O F M O T O R S
IN IT IA L PR E SE R V A T IO N
SU B C O N T R A C T N o.:
IT E M N o.:
PR E SE R V A T IO N IT E M S
SIG N A T U R E A N D D A T E
SU B C O N T R A C T O R
W herever possible, seal m otor shaft with "D enso" tape. For equipm ent m ounted motors w ith difficult shaft access, spray
exposed shaft w ith Shell E nsis 30 (M V , H V ).
For air fin cooler mounted m otors, check for presence of w ater on top bearing area (M V ).
For air fin cooler mounted m otors fitted with "porous drain plugs", ensure passage of possible w ater out of the motor i.e. do not
cover/seal of the fan air intake (M V ).
C heck term inal box(es) covers are bolted down and provide a proper seal, particularly after "m egger testing of windings (M V ,
H V ).
M egger test m otor windings initially and at 3 monthly intervals there after. M ore frequent testing if readings are progressively
lower, indicating m oisture in the windings (M V , H V ).
For protection against dust and w eather treat m otors as follows:a. H V m otors and large skid mounted m otors, cover com plete m otor w ith w aterproof cover.
b. H V m otors, cover and seal-off fan cow l air intake opening (excluding item 3 above).
10
Lubricate bearings in accordance w ith m anufacturer's instructions, or in the absence of them . A t 6 m onthly intervals (M V , H V ).
M A IN C O N T R A C T O R
R E M A R K S:IT E M S T O B E C H E C K E D A N D
IM P LE M E N T E D W H E R E IN D IC A T E D T H U S
H V = H IG H V O LT A G E M O T O R S
M V - M E D IU M V O LT A G E M O T O R S
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Page 31 of 32
6.6
PR E V E N T A T IV E M A IN T E N A N C E O F M O T O R S
W E E K L Y PR E S E R V A T IO N
S U B C O N TR A C T N o .:
ITE M N o.:
S IG N A TU R E
REM ARKS
D A TE
SU B C O N TR A C TO R
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Page 32 of 32
M A IN C O N TR A C TO R