Doc. No.

WSM-MSRP-03
MECHANICAL STATIC and ROTATING Rev. 0 15/03/19
PROCEDURE Page 1 of 13

PT. WISESA MANDIRI

MECHANICAL STATIC and ROTATING

PROCEDURE

WSM-MSRP-03

15/03/19 0 Issued for Approval MKY MKY AA

Date Revision Revision Description Prepared Checked Approved

 Doc. No. WSM-MSRP-03
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PROCEDURE Page 2 of 13

Revision Summary

Date Revision Revision Description Prepared Checked Approved

15/03/19 0 Issued for Approval MKY MKY AA

 Doc. No. WSM-MSRP-03
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PROCEDURE Page 3 of 13

INDEX

1 SCOPE ......................................................................................................................................... 4
2 PURPOSE .................................................................................................................................... 4
3 REFERENCE ................................................................................................................................. 4
4 RESPONSIBILITIES ....................................................................................................................... 4
5 PROCEDURE ............................................................................................................................... 4
5.1 Equipment Receival ........................................................................................................... 4
5.2 Handling of Equipment ...................................................................................................... 5
5.3 Equipment Preparation ...................................................................................................... 5
5.4 Installation of Equipment................................................................................................... 5
5.4.1 Static Equipment ........................................................................................................ 5
5.4.2 Rotating Equipment ................................................................................................... 9
5.5 Final Check for Static Equipment ..................................................................................... 13
5.6 Final Check for Rotating Equipment ................................................................................ 13
6 SAFETY ...................................................................................................................................... 13
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1 SCOPE
This method statement contains the general requirements for the equipment site erection
and alignment.

2 PURPOSE
The purpose of this procedure is to provide a general guide line for the receiving and
installation of all kind of equipment static and rotary in accordance with the project specification
and applicable standard.

3 REFERENCE
API 610 : Centrifugal Pumps for Petroleum, Petrochemical
and Natural Gas industries.
API 686 : Recommendation Practice for the installation of
machinery and installation design.
ANSI/ASME B30.5 : Safety Code for Crawler, Locomotive and Truck Cranes
ASNI/ASME : Safety Standard for Sling

4 RESPONSIBILITIES
The following site personal shall be involved as responsible for the equipment erection.
 Section Engineer Equipment
 Rigging Superintendent
 Equipment Superintendent
 Equipment Supervisor
 QC Engineer
 QC Equipment Inspector
 Surveyor
1. Section Engineer is over all responsible for monitoring equipment erection operation in
accordance with the procedures, specification and construction drawing.
2. QC Inspectors in conjunction with the QC Engineer are responsible for the inspection in
accordance with specification and procedure of the equipment erection and the
compilation of equipment reports and records.
3. The equipment supervisor shall be responsible for the safe operation and quality of work
and shall ensure that the procedures are adhered to and that technical standard is
maintained.
4. The rigging superintendent is responsible for all rigging operation that includes off loading,
transporting, and erection and for the selection of proper crane capacity and rigging gear.
5. The surveyor is responsible for checking elevations and verticality as per construction
drawing.

5 PROCEDURE
5.1 Equipment Receival
1 All equipment received at site shall be inspected in accordance with vendor’s instruction
for site storage, installation and preservation.
2 Equipment shall be off loaded from trailer using the vendor recommended lifting point
and approved techniques.
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3 All loose items that are not required for immediate installation shall be suitably identified
and retained in the stores.
4 Protective covers on all equipment’s shall be removed if they appear damage and
equipment inspected before replacing the cover, if any damage has occurred, Discrepancy
report shall be issued with photograph showing damages as necessary.
5 Preservation of rotary equipment will be maintained during storage period, by shaft
rotation as per vendor manual.
6 Preservation for static equipment will be maintained during storing period by observing
the gauge of Nitrogen and recording on weekly basis.
5.2 Handling of Equipment
1 The shall be unpacked in the presence of QC Inspector and Client representative or
vendor representative. All spare parts and tools shall be unpacked clearly marked with
equipment numbers and stored in the warehouse. Fragile parts such as level oiler,
capillary tubes, small piping shall be removed from the equipment after match marked
and stored. The parts shall be clearly identified by the tags with equipment number.
2 All machined surfaces shall be checked and applied with rust-preventatives.
3 The equipment should not be placed directly on the earth, wooden blocks to be used.
4 All couplings shall be uncoupled and coupling elements shall be clearly marked with
equipment numbers matching the shaft hub and stored in the warehouse.
5 After checking the equipment and confirming that there are no discrepancies, equipment
shall be stored or delivered to installation site.
6 Bottom of the base plate shall be cleaned or wiped by suitable means to remove mud oil
or grease before installation.
5.3 Equipment Preparation
1 Dress up to be completed as much as possible in horizontal position, dress up for
platforms and ladders for all elevations from top to bottom including all insulation
required.
2 Before installation, all location, elevation and orientation of the equipment foundation
and support structures shall be checked and verified in accordance with installation
drawing.
3 All documents related to the equipment should be at job site with the concerned crew
following erection.
4 Dress up items, which cannot be erected in horizontal position will be erected in vertical
position after make alignment and vertically.
5.4 Installation of Equipment
5.4.1 Static Equipment
5.4.1.1 Preparation
 Before erection of equipment, the job site shall be thoroughly surveyed and the
activity carefully planned, taking into consideration the following items.
o Equipment shape, dimension, weight and material, centre of gravity as well as
confirming the latest vendor drawings information to rigging plan.
o Cranes swing radius, crane movements and work space around the lifting area.
 Any backfilling, laying of load spreading mats for the cranes shall be in accordance
with the allowable Ground Bearing Pressure (GBP) for the unit/area. This need to
be identified by EPC contractor and supplied to subcontractor (XXX).
 Area ground compaction shall be done as per the requirement shown in the rigging
plan.
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 Ground compact test report shall be presented prior to lifting.

 The crane positioning area shall be cleaned up & all unnecessary material shall be
removed from the area before locating the crane.
 Work area and exclusion zones involved the lifting operations shall be identified
and demarcated using appropriate hazard tape/barriers.
 Crane positions to be surveyed and clearly marked on the plot as per the approved
lifting study.
 Check weather condition and wind speed if found within limit then activity will
proceed, allowable wind speed is 9.8 m/s (as per the crane manufacturer’s manual)

5.4.1.2 Foundation Preparation

 Before installing the equipment, foundation shall be checked to ensure that
foundation prepared in accordance with design drawing.
 The concrete surface of the foundation shall be thoroughly chipped and then
cleaned completely with compressed air, etc.
 The foundation surface shall be thoroughly dampened with fresh water for at least
two hours before installing the pads.
 All liners shall be made of carbon steel. In general the liners and wedges shall be
prepared by machining or grinding.
 Anchor bolt spacing to be verified as per equipment saddle plates or skirt.
 Installation of shim plate for foundation or equipment supporting structure to be
verified as per design drawing.
 Orientation, Level and verticality to be achieved as per construction drawings and
utilizing theodolite, shims and wedges.
 Confirm that foundation is released for equipment installation before proceeding
with the installation activities.

5.4.1.3 Preparation of lifting tackles

 All lifting tackles, as per attached drawing will be placed adjacent to their crane
location.
 Before attaching any tackles with the crane, lifting supervisor together with main
rigger will physically inspect all the tackles.
 Lifting supervisor and main rigger shall ensure the third party certification validity
and colour coding of the month.
 Auxiliary cranes & man lift will be used for attaching the tackles with both lifting
crane.
 HSE supervisor will ensure all certification must be attached with work permit.
 HSE supervisor will also ensure proper colour coding on each lifting tackle.
 HSE supervisor will barricade the lifting area and ensure: “No entry of unauthorized
person"

5.4.1.4 Installation Equipment by Tailing Lifting

 Park the main and the tailing mobile crane according to the lifting plan approved
by vendor.
 Prepare and setup lifting tackles to the lifting cranes hook and the tailing cranes
hook.
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 Hook up the lifting tackles using the platform ladder or A-Frame ladder on both
the lifting lugs and tailing lugs of the tank.
 During the tilting procedure, do note, not to jerk so as to ensure the titling is
smooth.
 When the equipment is almost in vertical position, slowly release the tailing
cranes hook till there is no tension, and after which, lower the tank till its
approximately 500mm away from the ground.
 Remove all the tailing lifting gears away from the equipment.
 The signalman will instructed the crane operator to swing the telescopic boom
towards the designate equipment foundation for installation work.
 After which follow as per direct lifting procedure for installation on the
foundation.

5.4.1.5 Installation of Equipment by Direct Lifting

 Upon receiving all permits, hook up the lifting tackles to the respective equipment
with approved rigging plan for lifting
 Ensure the rigging is done properly and lifting supervisor will confirm and check
the rigging are according to the planning and design.
 Guide ropes (tag line) to be tied to the equipment base to arrests swinging
movements during lifting work.
 All equipment will be hoist high enough to clear any structure or obstacles while
manoeuvring to its designated installation location.
 Rigger will also be station to look out for any obstruction during the lifting work.
 Upon confirmation of the lifting supervisor, the signalman will instruct the crane
to lower the equipment, at a maintained speed without any jerking.
 Equipment is to be lowered to a height of 200mm above the foundation packer
plate for the fitter to check its alignment and orientation.
 Fitters will use plumb-bob and auto-level for orientation check.
 Upon confirmation from the supervisor on site. Lifting supervisor will take over
and coordinate the lowering of the equipment on its packer plate and anchor
bolts.
 Fitter will now tighten the anchor bolts nut to secure the equipment to the
ground, hand tight, to ensure that its safe.
 After confirmation from the lifting supervisor, the signalman will instruct the
crane to lower its hook after swinging to the left or right so that the hook can be
lowered and cleared from the equipment to remove the ware/ webbing sling and
shackles can be remove from the equipment.

5.4.1.6 Lifting Through Existing Structure

 Ensure the rigging is done properly and lifting supervisor will confirm and check
the riggings are according to the plan and design.
 Guide ropes (tag line) to be tied to the equipment base or to the lifting shackles
to arrests unnecessary swinging movements during lifting work.
 Signalman and the crane operator will communicate through the walkie talkie at
all time during lifting.
 All equipment will be hoist high enough to clear the structure top.
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 Rigger with walkie talkie and/or whistle will also be station to look out for any
obstruction during the lifting work.
 If any obstruction is identified, rigger will notify by walkie talkie or by blowing the
whistle to stop the lifting work.
 The equipment will now be hoist down slowly through the structure beam as
directly by the signalman communicating with the crane operator.
 Equipment is to be lowered to a height of 200mm above the foundation packer
plate for the fitters to check its alignment and orientation.
 Fitters will use plumb-bob and auto-level for orientation check.
 Upon confirmation from the supervisor on site, lifting supervisor will take over
and coordinate the lowering of the pump on its packer plate and anchor bolts.

5.4.1.7 Lifting of Equipment Using a A-Frame and Existing Structure I-Beam

 Ensure A-Frame and existing structure I-Beam is certified before used.
 Set up the A-Frame on a flat surface and ensure that it seat firmly without any
jacking motion.
 Secure a beam clamp (1 ton and above rating) on the horizontal beam of the A-
Frame.
 After which secure a chain block that has a rating of less than the clamp and the
SWL of the A-Frame onto the beam clamp.
 Rigger will rig the lifting shackles onto the equipment to the chain block hook.
 After all lifting shackles is secure, slowly hoist up the equipment using the chain
block.
 Once equipment on top of foundation, slowly hoist down and fitter will check the
orientation and tag no. before the equipment is hoist down onto the foundation.
 For I-Beam the procedure will be the same as an A-Frame.

5.4.1.8 Equipment Centering and Positioning

 Centering shall be performing in two direction at right angle or mare than two
direction.
 Fine adjustment liners shall be used so that the entire liners are evenly loaded.
 When installation load is large and heavy, wedges shall be driven between the
liners for adjustment.
 Never adjust the levelness by loosening or retightening anchor bolts or set bolts.
 Installation shell be performed accurately at the location and in the direction and
with angle specified in the drawing.
 Foundation centreline and equipment centreline shall be aligned within the
deviation and elevation tolerance as per spec.
 For horizontally installed equipment with elongated anchor bolt holes, thermal
expansion or the equipment shall be taken into consideration and anchor bolts
shall be set, obstruction at the sliding face being completely removed.
 On placing a slide plate, adjustment of linier shall not be made on the slide plate.
 Until the equipment on the foundation is permanently bolted of fixed with
brackets, temporary stay or other appropriate method shall be used to prevent
unexpected overturning or the equipment.
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5.4.1.9 Method of Centering

Vertically installed equipment

 Any intersecting two direction at the right angle as to the equipment

centreline mark end the measuring line of the equipment shall be measured
with a transit levelling machines (when elevation is low, plumb bob will be
used)
 The equipment centreline mark shall be confirmed before installation either
with white line or punched marks.
 When the positions, elevation, vertically and level are interface with each
other, priority shall be given as following table below:

1 Vertically
2 Level
3 Installation Position
4 Elevation

Horizontally Installed Equipment

 Equipment centreline mark in horizontal direction and equipment horizontal

line shall be measured with a level.
 Top and bottom main nozzles shall be used for true vertically.
 When the positions, elevation, vertically and level are interface with each
other, priority shall be given as following table below:

1 Vertically
2 Level
3 Installation Position
4 Elevation

5.4.2 Rotating Equipment

5.4.2.1 Preparation
 Supervisor shall conduct a check for the following items:
a. Appearance of equipment for damage and rust free condition.
b. Orientation marking.
c. Marking of centre gravity.
d. Lifting point.
e. Verify/Conduct dimensional check of anchor bolt and bolt holes on the
equipment.
 Any packing material or filling material for transportation shall be remove and
disposed of correctly. All restraining clamp and attachments used for
transportation and storing shall be kept until pre-commissioning.

Temporary cover on all opening shall remain on the item until the related
pipelines are to be connected. Oil and foreign matters stuck on the surface of
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legs, beds, frames etc. which will come in contact with grouting mortar shall
be completely removed.

5.4.2.2 Foundation
Foundation shall be checked for the following items, before starting the
installation:

 Dimensions.
 Positions (center marking) and height (level marking).
 Disorders in concrete such as cracks, abnormal concentration of
aggregates, porous state, surface condition etc.
 Dimensions and cleanliness of anchor bolts pockets, if applicable.

Surface of foundation shall be conditioned for proper seating and bonding of the
grouting material with foundation. The surface shall be chipped around area of the seating
equipment. Foreign matters such as oil, grease, dirt, dust, loose concrete etc. shall be
completely removed from the surface.

Packing plate, i.e. liner plates, to be used, in general, shall be made of carbon steel,
unless otherwise specified by manufacturer or process requirement. Packing plate shall be
arranged so that the load of the equipment is uniformly distributed on the foundation.

5.4.2.3 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 levelling work.
5.4.2.4 Leveling of Equipment
 Liners and Wedges
In general, liners and wedges shall be prepared as indicated in below:
The dimensions may be modified as necessary or each application

 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.
 Liners and wedges shall be located on both sides of each anchor bolt and shall
beplaced 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.
 The concrete surface where the liner plates will be placed shall be chipped smoothly
and be cleaned completely.
 A final check shall be made to ensure that the center of the equipment matches the
center line marked of the foundation.
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5.4.2.5 Grouting
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.
Material

 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.
 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.
 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 specified. Compressive strength of epoxy and non-shrink cementations is
630㎏/㎠ at 7 days.
Grouting Procedure
 Sleeves used for anchor bolts shall be filled with grouting mortar under witness of
the CONTRACTOR engineer after which, unless otherwise specified in the Instruction
Manual.
 The base plate shall be grouted as follows:
o The base plate shall be grouted ram the grout hole.
o The grout shall cover all wedges and liners.
o All trapped voids under the base plate shall be vented to allow full penetration
of the grouting mortar.
 The surface of the mortar outside the base plate shall be finished smoothly.
 All liners and wedges shall not be removed.
 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.
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 oneset
cylinder per each mixing batch for test/and all tests must be carried out in testing
laboratory.
5.4.2.6 Epoxy Grouting
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.
Procedure
 All surfaces must be clean, free from standing water and all loosely adhering particles.
Cement latency must be removed, by mechanical means.
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 Mix with a slow speed electric drill for 1-2 minutes. Then add the aggregate and
continue mixing until a homogeneous mortar is achieved.
 Application
o When grouting under bearing hates, ensure there is sufficient pressure to
maintain movement of the grout. Air must be allowed to escape.
o For large volumes, apply in more than one layer, ensuring that the previous layers
have hardened and cooled.
 Clean all tolls and equipment immediately after use with thinner.
5.4.2.7 Alignment of Equipment
Initial Alignment
After completion of the grouting and prior to connecting piping, alignment of
equipment shall be performed as follows :
1. 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.
2. 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
least150mm 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.

5.4.2.8 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 piping, alignment
of the equipment shall be rechecked as follows:
1. Prior to commencing the final cold alignment, the suction and discharge piping hall
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.
2. When any misalignment is found in the piping during the above inspection, the
information shall be given to the CONTRACTOR engineer.
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.
4. Any offset on the alignment of the equipment found as a result of the piping
connections shall be corrected as follows:
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 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.
 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.
5.5 Final Check for Static Equipment
1. For static equipment after all inspection and tests given in the vendor normal all
necessary connection and adjustment are complete. All trays and internals shall be
visually checked.
2. All trays and other internals shall be cleaned and checked to insure that all dirt, loose
scale, slag and any parts or tools are removed from inside of the vessels using vacuum
machine, cleaning sheets, or compressed air.
3. Manhole after man way decks when installed the vessel manholes shall be closed. This
shall be witnessed and signed by Client after final internal inspection.
4. All bolts and clamps on trays shall be torqued as required torque value.
5. Leak test shall be done on chimney trays after any required welding on chimney panels.

5.6 Final Check for Rotating Equipment

1. For rotating equipment after Hydrotest activity completed and reinstatement of all
piping spools. The parallelism of flanges discharge and suction shall be checked with
equipment nozzles.
2. Final alignment using dial indicators by reverse alignment method or face rim method
will be used. Coupling shall not be installed until after the no load test for the drivers is
completed.
3. Oiler cans and all lubrication system shall be checked to assure, no leak on all tubing.
4. All coupling guards should be in place to prevent any accident with the running parts.
5. All equipment shall be barricaded and provided with warning signs, when it’s
energized.

6 SAFETY
1. Job safety analysis attached.
2. All workers shall conduct orientation course.
3. Work at height full body harness shall be used with 100%Tie off.
4. Make sure access completely safe on scaffolding with green tag.
5. Hot work, A Gas/Oxygen level check through the use of gas detector shall be used prior
to any hot work (welding-gas cutting).
6. Confined space ventilation using air mover is required for any vessel prior to entry for
any internal activity.
7. 24V or 12V power lighting shall be used as required.
8. Working area shall be barricaded. (Crane operation area, erection or dismantling of
Scaffolding)
9. All warning signs shall be fixed in proper location to ensure personnel safety.
10. Rigging operation will be done under control of rigging superintendent all using rigging
study or lift plan as required for each lift.