Method Statment For Installation of Rotating Machinery Equipment - 032613
Method Statment For Installation of Rotating Machinery Equipment - 032613
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'WJPetrobel tellil 0 eni SpA
Project Zohr Development Project - Phase I Contract No. 032195
Contractor The Petroleum Projects and Technical Consultations (Petrojet) Date 14/06/2017
Transmittal
From PETROJET To Petrobel
Position Chairman Assistant for Zohr Project Position
Name Eng. : l<adry Osman Attn.
Issue for
• Approval • Review an d Comment D l uformation
D Others
Submittal Description
No.Of
S.N Description Rev. Remarl<s
Copies
Method Statement' for Installation of Rotating Machinery Equipment
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(Doc. No.: PTJ-ZH-MS-0011)
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Remarks :
Prepared By:
Position DC
Name: Mr. Ibrahim Elhaddad
Signature:
Date: 14/06/2017
Action by Petrobel
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Position Name Signature Date
Page 1 of 1
Project ZOHR Onshore Dcv~1opment Project
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METHODSTATEMENTFOR
INSTALLATION OF ROTATING
MACHINERY EQUIPMENT
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0 113/06/2017 1 PAGE 1 OF191
The Petroleum Projects and
Job Title
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Table of Contents
3. References ........................................................................ 3
4. Definitions ........................................................................ . 3
5. Responsibilities .................................................................... .4
6. Procedures ..........................................................................4-12
8. Attachments ........................................................................... 13
Proje.a ZOHR Onshore Development Project , . ....
Client
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PETROBEL /ENI ':I
~ Document description Rev. I Date [ {'age
1-l.ocatron . PETROJET
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1. Purpose
The purpose of this Method Statement is to set the minimum requirements for the installation and
alignment of rotary equipment to meet the specific contractual specification and requirements of the Luberef
Yanbu Refinery Expansion Project
2. Scope
This Method Statement applies to the Luberef Yanbu Refinery Expansion project installation and
alignment of rotary equipment in compliance with project specification. This also covers foundation check,
fixing of shims, bolting, coupling alignment, inspection and testing. Installation of equipment shall also
include preservation of equipment from storage until commissioning stages.
3. Reference
4. Definition
CONTRACTOR : PETROJET.
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Pro1e.ct ZOHR Onshore Development Project
Client . PETROBEL /ENI
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I Lon;,t1on PETROJET
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5. Responsibility
Site HSE Manager : Responsible for all safety matters and safety monitoring.
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Construction : To keep records of production and also oversee the
Engineer procedure is implemented. To raise RFI notifying readiness for
QC inspection to all parties via QC department.
6. PROCEDURE
6.1 PREPARATION FOR INSTALLATION
All concrete foundations shall be released by civil Quality Control to Mechanical prior to start of the works.
This release is controlled and documented in applicable civil procedure.
i) The following conditions of the concrete foundation shall be checked with reference to the relevant and
latest revision drawing with IFC stamped.
ii) The top of the concrete foundation shall be chipped to obtain the 25 mm minimum grout thickness
indicated on the foundation drawings.
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Project ZOHR I Onshore Development Project ~Dri.
C/ierr= PETROBEL /ENI fl1/1
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Job I Document description I Rev. [ Date Page
_Location -1- ~ : : PETl10JET
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'\i~':i~frl' I METHODSTATEMENTFOR I The Petroleum Projects and
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INSTALLA1"/0N OF ROTATING PAGE 6OF19
Port said MACHINERY EQUIPMENT Technical Consultations Co.
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iii) Padding plates shall be set to levelness and elevation as specified on vendor drawing. Pad plates
elevation should be submitted for inspection prior to machinery installation its dimension 10*10 mm with 10
mm thickness .and shall be painted or galvanized
iv) The surface of the concrete foundation shall be checked to see that the area to be covered by grout
was chipped properly.
v) For epoxy r-esin grout, the surface is required to be completely dry before application.
vi) When applying cementations grout, thE• foundation surface shall be thoroughly soaked with fresh water
for 24 hours prior to placement of the grout mortar.
vii) Water on the foundation and in the anchor boxes shall be removed by dry and oil free compressed air
blowing, or other means, immediately before grouting.
i) The following conditions of the anchor bolts embedded in the foundation shall be checked against the
drawings.
• Position
Tolerance shall be± 3 mm from the dimension indicated on the related equipment drawing.
• Projection
Variation in elevation of the tops of anchor bolts shall be equal to or less than plus or minus Y, inch or
13mm.
• Inclination
Variation in dimensions between the canters of any two anchor bolts within an anchor bolt group shall be
less than 1/8"(3mm) (as per PIP-STS05130,Para.6.2.1).
Project ZOHR Onshore Development Project ,.llllt.
Client PETROBEL /ENI 'II
Jo~ n Document description j Rev; i Date I Page .
Locat10 PETROJET
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iii) When anchor boxes are prepared the anchor bolts shall be placed first inside these boxes. It shall be
set on the base plate bolts hole before setting the equipment on the pad plates. Confirm the centering and
adjust anchor bolts projection in accordance to vendor or Saudi Aramco Standard drawing.
I) All shims under equipment feet shall be stainless steel material. The number of shims under any
equipment support foot is five. Mixing of carbon steel and stainless steel shims is not allowed. The shims
shall be full bearing and cover the entire width of the base plate.
II) The use of tapered shims, laminated shims, brass & aluminum shims and shims thinner than 0.05 mm
is not permitted. Shims are generally supplied by vendor. If shims must be made at site, they shall be
patterned from the vendor's shim or the support foot.
Ill) The movable machine shall have a minimum of three millimeters of 300 series stainless steel shims
under each support foot The maximum shims stack height shall not exceed 12 mm. Only one three
millimeter or thicker shim is allowed per mounting foot.
IV) An adequate assortment of stainless steel shim thicknesses are to be available to allow the number
of shims used at each location to be minimized.
Project ZOHR Onshore Development Project
Client PETROBEL /ENI
Job
Location
Document description Rev.
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Date Page
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METHOD STATEMENT FOR . The Petroleum Projects and
. INSTALLATION OF ROTATING
0 13/06/2017 PAGE 8 OF19
Port smd I MACHINERY EQUIPMENT Technical Consultations Co.
6.2.1 Unpacking shall be performed slowly and with completely attention. All spare parts and special
tools, etc., shall be repacked and returned to the warehouse for proper storage.
6.2.2 The condition of the machined surfaces shall be checked, and if necessary, the machined surfaces
shall be coated properly with suitable rust preventive.
6.2.3 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.
6.2.4 Coupled equipment shall be uncoupled before installation. Coupling elements shall be properly
wrapped and labeled before to store in the warehouse.
6.2.5 The equipment shall not be placed directly on the earth (soil or mud), after removing from packing
box, without using adequate wooden blocks.
6.2.6 Protection and preservation of machinery shall be implemented from storage up to commissioning.
6.3 INSTALLATION
Installation of equipment shall be executed in accordance with this procedure or Vendor/ Manufacturer
instructions, taking precautions so that the anchor bolts and foundations will not be damaged and the
equipment not distorted.
Project ZOHR Onshore Development Project , . 1111.
Client PETROBEL /ENI :I
Job_ 1
Document description Rev. Dote Page
Location ; PETROJET
6.3.1 Before installation, all locations, elevations and orientations of the equipment foundations shall be
checked and verified in accordance with installation drawings and specifications.
6.3.2 Reference elevations and/centerlines shall be marked I identified on the foundations. Before
installation of equipment, chipping shall be done on all the required surfaces of the foundations in
preparation for grouting and there shall be no remains of curing agents or other substances which hamper
grout cure.
6.3.3 Pad plates shall be installed preferably by the equipment group on either side of each anchor bolt
(Refer to attachment 2). The number of pad plates, size and lay out is decided based upon the size and
weight of the equipment load the pad plates are required to carry. It is essential that pad plates be fixed to
the foundation surface using the same grout material that the foundation will be eventually grouted with. The
material for pad plate shall be hot dip galvanized.
6. 3.4 The elevation difference between top of concrete and top of pad plate shall allow for at least 1"
(25.4mm) of grout under the base plate or more if it is so required. It must be ensured that pad plate grout is
cured prior to loading the foundation.
6.3.5 The bottom of the base plate shall be cleaned by suitable means to remove mud, oil or grease prior
to installation. It shall also be ensured that the mating surface of the pad plate is free of any grease or oil and
rough edges.
6.3.6 Grout expansion joints shall be provided if required, dimension & spacing as per project procedure.
The material shall be made from 25mm thk. closed cell neoprene foam rubber.
6.3.7 Once it is confirmed that the foundation as a whole is ready to receive the equipment, it shall be
installed in accordance with manufacturer's installation manual, approved method statement and project
specifications as applicable
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PETR OJ ET
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6.4.1 After machinery is placed on the pad plates, confirm the centering and snug tight the anchor bolts.
Check machine levelness and if necessary to correct the leveling, adjust the jack bolts provided on the base
plate. Any clearance in between padding plate and base plate a stainless shim shall be inserted. Snug tight
the anchor bolts and re-checks again the levelness.
6.4.2 After leveling is finished, the foundation anchor bolts should be on snug tight only, final tightening
shall be done after base grouting is completed and cured.
6.4.3 Unless otherwise specified, leveling of rotating equipment shall be carried out with a calibrated
precision machinist level on the machined surfaces of the driver base plate and on the machined surfaces of
the equipment pedestals (or, if that is not possible, on the surface of the suction flange or discharge flange of
the vertical nozzles on the top of the equipment).
6.4.4 Base plate maximum out-of-level tolerance shall be in accordance to vendor manufacturer's
installation manual or Saudi Aramco Standard.
6.5 GROUTING
6.5.1 Grouting of foundation shall be applied after finish leveling of the mounting plate and the preliminary
shaft alignment of the machinery.
6.5.2 If the compressive strength of the grout is required testing, it shall be done in accordance with PIP
STS03600 4.2 and 34.5Mpa at 28 days.
Project
Client
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ZOHR Onshore Development Project
PETROBEL /ENI .
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Document description Rev. Dote Page
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6.5.3 Material
6.5.4 Grout shall not be placed in a gap of less than 25 mm for base plates.
6. 5. 5 Base plates and metallic items shall be cleaned and free from oil, grease, or scale.
6.5.6 Vent holes shall be provided to allow the release of air from isolated spots.
6.5.7 At ambient temperatures above 23 and± 3 degrees centigrade, chilled water shall be used for
mixing the grout before placing.
6.5.8 Material for grouting shall be stored properly in accordance with manufacturer's instruction and pay
strict attentions to its validity.
6.5.9 No load shall be applied for at least 3days or as per manufacturer's recommendation after padding
and grouting.
6.5.1 OPour mixed grout in temperature 23 and± 3 degrees centigrade, considering that the mixed grout
should placed continuously from one direction to avoid air entrapment, segregation and/or bleeding (SAIC-
Q-1049/SATIP-Q-010-01 ).
Project ZOHR Onshore Development Project
Client PETROBEL/ ENI
Job
Location
Document description Rev. Date
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METHOD STATEMENT FOR , The Petroleum Projects and
. INSTALLATION OF ROTATING PAGE 12 OF
Port sotd I MACHINERY EQUIPMENT 0 13/06/2017 Technical Consultations Co.
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i) The alignment fixtures and brackets shall be suitable to each specific coupling apparatus and shall be
accordingly tagged. Suitable brackets need to be fabricated for operating temperature alignment. Use of
magnetic alignment fixtures is not permitted.
ii) The maximum allowable sag for dial indicator brackets/fixtures used for alignment is 5 0.8 millimeters
per meter of span.
iii) To ensure that all indicator readings (from top to bottom of shaft or from bottom to top position) are
correctly taken, the bracket sag present in the fixture must be determined before starting the alignment
process.
i) All hold down bolts shall first be tightened using vendor specified criteria and measurement shall be
taken as each bolt t is loosened. The hold down bolt shall be re-tightened before proceeding to the next foot.
The maximum tolerance for soft foot is 0.05 mm as per APl-686,chapter07,para.5.4.4.1, measured with a
dial indicator placed on each foot.
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ii) Soft foot measurement check shall be carried out at each foot and not at the coupling shaft unless the
situation warrants it and in which case, it must be permitted by the designated authority.
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Project ZOHR Onshore Development Project
Client PETROBEL /ENI
Job
Location
Document description Rev. Date Page
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METHOD STATEMENT FOR The Petroleum Projects and
.d I INSTALLATION OF ROTATING
0 13/06/2017
PAGE 13 OF
Port soi MACHINERY EQUIPMENT 19 Technical Consultations Co.
6.6,3.1 Preliminary alignment shall be done to confirm that the axial, horizontal and vertical tolerances are
achievable during the final alignment without modification to the machinery or hold down bolts.
6.6.3.2 Equipment centering and leveling should be inspected and approved. Anchor bolt position should
be on snug tight only.
6.6.3.3 Provide proper lubrication as per vendor recommendation to machinery bearings before to start
turning the shafts for alignment.
i) The alignment tolerances shall be in accordance with the following table unless a closer tolerance is
specified by manufacturer:
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ii) Shaft alignment readings shall not exceed the manufacturer's recommendations or project
specifications whichever is more stringent or as applicable.
iii) Distance between shaft ends (DBSE) or coupling gap length shall be measured during preliminary and
final shaft alignment.
iv) Precision tools and instrument shall have a valid calibration certificate on the date of use.
!)The dial gauges shall be mounted on the periphery of the coupling hubs of both the driver and the driven
equipment and the needles touched to the flange rims of the coupling hubs. The shafts shall be rotated at
the same time and in the direction of rotation simultaneously. The measuring points shall be at four points at
90 degrees intervals.
II) The equipment shall be turned by hand whenever possible and strap wrenches may be used as
required. Pipe wrenches are not permitted.
Ill) For readings to be considered valid, the readings and zero shall repeat within 0. 02 millimetres. The
algebraic sum of the horizontal reading shall be equal to the algebraic sum of the vertical readings shall be
within 0. 05 millimetres.
Rim and Face Alignment is recommended when the coupling hub or shaft end flange diameter is greater
than the spacing between indicators or when one of the train elements cannot be turned
Project ZOHR Onshore Development Project
Client
Job
PETROBEL /ENI ~'
Document description Rev. Date Poge
Locatinn
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I) The parallelism of the end surface of the equipment coupling hub, and the offset values at the periphery
of the hub shall be measured respectively with dial gauges with readings taken at four points at 90 degrees
intervals. Both shafts shall be rotated simultaneously unless it is not possible and in the direction of rotation
and the readings recorded.
II) The equipment shall be turned by hand whenever possible and strap wrenches may be used as
required. Pipe wrenches are not permitted.
Ill) Face readings shall be taken with a dial indicator as well unless there is insufficient space.
a) Prior to the commencement of final cold alignment, grouting is required to be completed 100%.
Additionally all anchor bolts/nuts are also required to be tightened 100% of total final torque.
b) Soft foot check shall be measured with piping disconnected from the equipment body and during
final alignment (Refer to item 6.6.2).
c) The equipment shall. remained uncouple until the motor solo run is completed. This is also a
requirement before conducting the final shaft alignment.
d) Final reinstatement of suction and discharge piping to machine shall be prepared after the pipeline
has been hydrotested, air blown and cleaned.
e) Check motor and machinery shaft alignment. If out of tolerance the motor shall be adjusted to the
required alignment reading.See item 6.6.4 for the tolerance.
Project ZOHR Onshore Development Project ~ llti.
Client PETROBEL /ENI ':I
Job. Document description Rev. Date Page
1 location PETROJET
f} Flange alignment inspection shall be performed before bolting-up piping and pump flanges together.
To ensure that pipe strain imposed by the piping on machine casing are minimized after flanges are tighten.
Measurement & tolerances shall be as per Saudi Aramco Standard or vendor manual.
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g) Any piping misalignment found during the inspection is required to be rectified. The rectification shall
be carried out without disturbing the equipment alignment.
h) Bolting-up of piping and pump flanges shall be continuous without disturbing the dial indicator placed
to monitor shaft movements. The maximum shaft movements in either the vertical or horizontal direction
after the flanges are fully tighten shall not exceed 0.05 mm.
i) Final shaft alignment reading shall be taken as soon as the pipe stress inspection has been
completed and accepted.
j) After final alignment, the coupling spacer and protective cover shall be installed. All coupling bolts
should be lubricated before installation and tighten to torque value indicated on the vendor drawing.
k) All inspection and installation data shall be recorded as per ITP (Inspection Test Plan) requirements.
Installation of auxiliary equipment, vendor piping, and other accessories shall be carried out in accordance
with approved project drawings and vendor manual.
7. SAFETY Requirement
• All personnel involved in equipment installation and alignment works shall follow all safety procedures
• PPE (Personal Protective Equipment) such as hard hats, safety shoes, safety glass (goggles) hand
gloves etc. Shall be worn by all personnel and fall protection devices shall be used when needed as
Project ZOHR Onshore Development Project
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Client PETROBEL/ ENI
Job
Document description Rev. Date Page
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• Access to working areas for unauthorized persons shall be restricted by barriers warning signs &
controlled close supervision.
• Petrojet shall ensure that the working areas are clearly delineated and barricaded, Access to the
working areas by heavy equipment shall be provided in compliance with approved plans, permits and safety
requirement to perform the work.
8. ATTACHMENTS
Project ZOHR Onshore Development Project
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Client PETROBEL /ENI
Job
Location
I Document description Rev. Dote Page
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METHOD STATEMENT FOR - The Petroleum Projects and
INSTALLATION OF ROTATING PAGE 18 OF
Port soid I MACHINERY EQUIPMENT
a 13/06/2017
19 Technical Consultations Co.
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