PDOC-476-CTRU-06 Rotating Equipment Installation Procedure

Client PMC:
PETRODAR OPERATING
COMPANY LIMITED
Contractor
CHINA PETROLEUM
ENGINEERING & CONSTRUCTION DOCUMENT No.:
PDOC/476-CTRU-06
CORPORATION
CONTRACT No: PDOC/23/06-476

GUMRY Field Production Facilities Project
ROTATING EQUIPMENT INSTALLATION

PROCEDURE
REVISION RECORD
Submission
Rev. NO. Da Revision Details Prepared By Approved By OWNER
te
A 2007-9-23 Submitted for reviewed Li Yonggang
MELUT BASIN OIL DEVELOPMENT
QA/QC DEPARTMENT PROCEDURE PROJECTGUMRY FIELD
PRODUCTION FACILITIES PROJECT
SUBJECT Rotating Equipment PROCEDURE NO.:
Installation Procedure PDOC/476-CTRU-06
CONTENTS
1.0 Scope
2.0 Reference Documents
3.0 General
4.0 Rotating equipment installation
5.0 Pumps
6.0 Packaged Compressors
7.0 Installation of Crane
8.0 Quality record and review reports
9.0 Revision note
Rev. A 2
1.0 Scope
To define and establish procedures for on site handling, movement and installation of
mechanically rotating equipment.
2.0 Reference Documents

Approved for Construction Engineering Drawings
Piping & Instrument Drawings (P&ID)
Piping Arrangement Drawings
Isometric Drawings
Piping Support & Pilling Layout Drawings
API Std 610 Seventh Edition, February 1989-Centrifugal Pumps for General Refinery
Services
API Std 674 Maximum Allowable Speed Rating for Power Pumps in Continuous
Services
API RP 521 Guide for Pressure Relieving and Depressuring System
Project Standards, Codes & Specifications
PDOC-SP-MEC-039 Specification for Multiphase Pumps
PDOC-SP-PIP-002 Specification for Piping Design and Layout
PDOC-SP-CIV-011 Specification for Piling Installation
Project Quality Plan
Vendor Installation Manuals
Materials Handling Procedure
Rev. A 3
3.0 General
3.1 Foundations shall be completed and checked for correctness and levelness as per drawings
and specifications. Prior to installation, foundation shall be clean with correct anchor
boltholes location, centerlines marked, elevations and levels established for correctness.
Shimming and wedging shall be carried out as per drawings and specifications.
3.2 As required, perform on-site installation of the various equipments as per approved
construction drawings and specifications, and instruction by a manufacturer/vendor
representative.
3.3 Final insulation jacketing shall be completed so that there will not be an excessive amount
of scaffolding erected in the plant areas where operators will work during start-up. The
number of insulation crews still working in the area shall not be excessive.
3.4 At the time of Mechanical Completion all fire proofing and rough insulation shall be
completed, i.e. all equipment, piping, instruments, instrument leads, etc. requiring
insulation for heat conservation shall be covered so that start-up operations will not be
delayed due to excessive heat loss. Insulation required for personnel protection shall also
be completed. Only areas that would be required to be open for tightness testing (flanges,
valve stems, etc.) will not be covered prior to Mechanical Completion. Exposed
insulation is to be properly protected and sealed.
4.0 Rotating Equipment Installation

4.1 Prior to installation, inspection for equipment acceptance to be carried out. Equipment
installation includes loading, hauling, unloading, inspection, lifting, shimming, aligning,
placing, and securing in its final position.
4.2 Remove all temporary supports, bracing or other foreign objects that were installed in the
equipment or machinery to prevent damage during shipment, storage and erection, and
repair any damage sustained. This may need vendor assistance.
4.3 Before positioning the equipment, it shall be checked against the drawings to verify the
pipe installation of flanges, nozzles, junction boxes, couplings and other items that
require external connection.
4.4 CPECC to prepare lifting and rigging plan for all heavy lifts taking into consideration
location and other activities such as equipment insulation, structural platforms and
ladders, instrumentation, piping erection and other work which can possibly be
accomplished prior to final erection of equipment, saving scaffolding and basket work.
4.5 The foundation and anchor bolts preparation shall be completed and checked by CPECCs
QC inspector prior to installation of equipment.
4.6 Prepare foundation surface, install equipment, and level the equipment as per approved
drawings and specifications.
4.7 Inspect and check the work during the construction stage, and perform such non-
operational tests as are necessary to assure the integrity of the installation in accordance
with the issued for construction drawings, specifications and vendor instructions.
4.8 Flush systems and perform initial charge of all lubricants. Dispose of all flushing oil to
an area approved by OWNER.
4.9 Conduct all operational tightness tests.
4.10 Qualified craftsman with experience in installing rotating equipment will be assigned at
site during the erection, installation, commissioning and start-up period with vendor
assistance as required for all special equipment.
5.0 Pumps
Rev. A 4
5.1 Rotate pumps by hand to ascertain that they turn freely.

5.2 Align pump with driver after coupling installation; ensure that the axial and radial
deviations, and axial clearances are within the approved tolerances.
5.3 Disconnect the coupling, check motor for rotation, run-in for two (2) hours uncoupled
and check bearings. Submerged pump/motor may be run-in coupled. After motor No-
load test, re-couple pump to motor.
5.4 Install proper lubricants (fuel, coolant) prior to commissioning after review with
OWNER.
5.5 If the pump is to be used for flushing, install temporary packing if permanent packing or
mechanical seal is not suitable for flushing.
5.6 Install strainers in the suction piping to prevent foreign objects from entering the pump
during commissioning and initial operating period.
5.7 Reinstall permanent packing or mechanical seal on any pumps used for flushing.
5.8 Check that machinery guards are available and should be fitted as per drawings and
vendors recommendations.
5.9 Check and run-in pumps, maintain them after Mechanical Completion.
5.10 When necessary, clean strainers by operators after pumps have been in operation for a
reasonable period.
5.11 Check the general compatibility of the pumps with respect to any cavitations problem,
discharge head, excessive vibrations, excessive noise, etc. which may hint at abnormal
operation of the pump.
5.12 Obtain the assistance of manufacturers if required.
6.0 Packaged Compressors

6.1 Vendor equipment drawings shall be reviewed together with the specification requirements
before commencing work.
6.2 Foundation surfaces shall be clean prior to install.
6.3 Before installation, all locations, elevations and orientations of the equipment
foundations, anchor bolts shall be checked and verified in accordance with approved
drawings and specifications.
6.4 Remove all the protective covers from all openings.
6.5 Data lines of levels, and/or axis shall be marked/painted on the foundation.
6.6 Ensure steel packs/shims of adequate number are provided and leveled to the required
elevation on each side of holding down bolt as per specifications and vendors
recommendations.
6.7 Level the compressor sets with packs/shims supporting the base plate near the foundation
bolts and at any point of the base plate carrying a substantial weight load.
6.8 It is very important that the compressor set base be set level to avoid any mechanical
difficulties with the compressor sets. Since all compressor set base is flexible, they may
spring and twist during shipment.
6.9 Check alignment in accordance with vendors recommendations. When the unit has been
leveled and aligned, the holding down bolts should be gently and evenly tightened.
Rev. A 5
6.10 Check rotation of driver and compressor is correct and rotating freely after the final
tightening of holding down bolts and pipe flange bolts.
6.11 Chemically clean any completed lube and seal oil system, when specified. Dispose of
wastes and cleaning media in accordance with OWNER instructions.
6.12 When specified, the lube oil, control oil and oil cooling systems with flushing oil and
circulate for cleaning purposes. Dispose of any flushing oil in accordance with OWNER
instructions.
6.13 Arrange for pipe work to be finalized to the compressor sets. Support the suction and
discharge pipes independently by the use of proper pipe supports.
6.14 Charge the lube oil, control oil and oil-cooling systems with the operating oil
recommended by manufacturer in accordance with OWNER specifications.
6.15 Operate the auto-changeover of the oil coolers and oil filters to ensure that it is operating
correctly.
6.16 Install the compressor casing drains and vents as per approved drawings and
specifications.
6.17 Check that machinery guards are available and fitted as per drawings and vendors
recommendations.
6.18 Check that all safety devices and controls are functioning properly as per drawings and
vendors recommendations.
6.19 Install other auxiliary equipment as per drawings and vendors recommendations.
6.20 Rotate compressor and driver periodically after installation as per vendor
recommendations and recorded on the appropriate form.
6.21 Perform all the tests as specified in the relevant data sheets and specifications.
7.0 Installation of Crane

7.1 Prior to the installation, the following inspection shall be executed:
a. The welded seam surface quality.
b. Parallelism of the two rail beams used for longitudinal crane traveling.
c. Height difference between the two rail beams.
d. The above shall be in conformity with drawings requirement.
7.2 Lay rail on the steel structure crane beams and ensure the following items to comply with
conformity with manufacture specification.
a. Distance between the two rails.
Rev. A 6
b. Parallelism of the two rails.

c. Height difference between the two rails.
d. The gap in different rails shall not be in line; the longitudinal distance between gaps in
different rails shall not bigger than that between the front and the rear wheels.
e. Use the specified clamp and tighten anchor bolts with proper torque and in proper
sequence.
f. Install the stop blocks as per the requirement.
7.3 Crane inspection
a. Check crane Beam Bridge for correct dimension, proper welded seam and good
appearance without twisting.
b. Check the convexity of the crane bridges beams.
c. Components shall be fixed solidly and connected correctly.
d. An inspection shall be made for wire rope winding and hook movement.
7.4 Putting the crane in position, hoist the crane onto the rails and cover the roof of shelter.
7.5 Complete all the required inspection and test
a. Dead load test.
b. Longitudinal traveling test.
c. Transverse traveling test.
d. Load-bearing of monorail test.
8.0 Quality Records and Inspection Reports

8.1 Records and inspection reports shall be legible, correctly identified, readily retrievable
and traceable to the materials, components and equipment for which they were
produced.
8.2 Inspection sign-off forms for alignment of rotating equipment; motor run-ins, etc. will be
submitted to OWNER for approval prior to the start of equipment installation.
8.3 For the forms of construction quality inspection and test, please refer to PDOC/476-QC-
05
9.0 Revision Note

9.1 This procedure shall be revised if it is found to be inadequate for the purposed work upon
completion of engineering / new construction practice / new site information or as
requested by OWENER.
Rev. A 7

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Client PMC:

CONTRACT No: PDOC/23/06-476

ROTATING EQUIPMENT INSTALLATION

2.0 Reference Documents

4.0 Rotating Equipment Installation

5.1 Rotate pumps by hand to ascertain that they turn freely.

6.0 Packaged Compressors

7.0 Installation of Crane

b. Parallelism of the two rails.

8.0 Quality Records and Inspection Reports

9.0 Revision Note

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