PTTCHEM-SP-M-801 EQUIPMENT INSTALLATION

PTT CHEMICAL PUBLIC CO., LTD. BRANCH I-1: OLEFINS PLANT

STANDARD SPECIFICATION FOR

EQUIPMENT INSTALLATION DOCUMENT NO. PTTCHEM-SP-M-801

REV. ISSUED DATE

0

7 Dec 05

DESCRIPTION

First Issued

REV. TO

ADDED

MADE

CHECK

SHEET

SHEET

BY

BY Prathanwit

TOTAL PAGES

APPROVE

Chayan

14

(INCLUDED THIS PAGE)

PTTCHEM-SP-M-801

EQUIPMENT INSTALLATION

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SECTION

CONTENT

PAGE

1.

GENERAL

3

2.

GENERAL REQUIREMENTS

3

3.

COMMON REQUIREMENTS FOR INSTALLATION

4

4.

PARTICULAR REQUIREMENT FOR VESSEL AND

10

HEAT EXCHANGER

5.

PARTICULAR REQUIREMENTS FOR PUMPS AND

10

BLOWERS

6.

PARTICULAR REQUIREMENT FOR CENTRIFUGAL

11

COMPRESSORS AND STEAM TURBINES

7.

PARTICULAR REQUIREMENT FOR

12

RECIPROCATING COMPRESSOR, GAS TURBINE GENERATOR, WASTE HEAT BOILER, FIRED STEAM BOILER CRACKING HEATER, OLEFLEX HEATER

8.

LOADING OF CATALYST

12

9.

TRAY INSTALLATION

13

10.

EQUIPMENT INSTALLATION ON STEEL

13

STRUCTURE

14


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1.

GENERAL

1.1

Intent

This Engineering Specification covers the general requirements governing the installation of equipment.

1.2

Related Engineering Specification

The following engineering specification shall be as a part of this engineering specification.

PTTCHEM-SP-M-802

Inspection of equipment installation (to be submitted later on)

PTTCHEM-SP-P-631

Painting

2.

GENERAL REQUIREMENTS

2.1

Manufacturer's Installation Manual

For the equipment, of which manuals are provided by the Manufacturers, instruction in such manuals shall be given a preference over the Engineering Specification.

2.2

Precautions for Installation

2.2.1

The following items shall be considered for the selection of lifting method and the erection of lifting equipment.


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(1)

Size, weight and shape of the equipment to be installed, and the lifting points

(2)

Space of the location of installation

(3)

Space and ground condition at the place of erecting the lifting equipment

(4)

Buried objects such as underground piping and cables, and open trenched existing at the place where the lifting equipment is erected.

2.2.2

(5)

Condition of roads as to whether or not they can be used.

(6)

Existing lifting equipment, and whether or not it can be utilized.

(7)

Space for dismantling or taking-out of the lifting equipment

(8)

Performance and maintenance condition of the lifting equipment

Where equipment is roped for lifting, adequate pads shall be applied on the corners, finished surfaces, etc. of the equipment for preventing damage resulting form sling.

2.2.3

Construction equipment, machines, tools and measuring instruments to be used in the works shall be thoroughly inspected and tested prior to use.

2.2.4

Where the use of fire is prohibited, flame-free tools and devices and extinguisher shall be prepared.

2.2.5

When lifting up or lowering down the equipment by the use of a sling, due care shall be taken to its location and center of gravity in order to avoid unbalance of the equipment. And lifting points of the equipment, if specified by manufacturer, shall be complied with.

3.

COMMON REQUIREMENTS FOR INSTALLATION

3.1

Preparation of Foundation

Treatment for the surface of the foundation, such as chipping and fitting, shall be carried out in consideration of following points.

(1)

Remove foreign materials; specially oil and rust.

(2)

Chip the surface to give good adhesion and to avoid cracking, peeling off and etc. of grouting mortar.


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3.2

Liners and Shim Plate

3.2.1

In general, liners to be used shall be made of carbon steel, and shim plate to be used shall be made of anti-corrosive material.

However, in the case of corrosive environment, liners made of

anticorrosive material shall be used as instructed by PTTCHEM.

3.2.2

Liners shall be so arranged that the load of the equipment is uniformly and exactly distributed to the foundation within allowable load. And these liners shall be placed as near as possible to both side of each anchor blots. Maximum allowable load of liners contacting with the foundation concrete shall be 2

30 kg per 1 cm of the effective load area.

3.2.3

In case where only flat liners are used for alignment, these flat liners shall be piled in 3 layers or less at one point.

3.2.4

In case where wedge liners are used for alignment, gradient of the wedge liners shall be 1/30-1/60 and two wedge liners shall be put together in back to back to keep their top and bottom faces in parallel. And as base liner, flat liners having about 2 times the thickness of wedge liners, shall put under the wedge liners.

3.2.5

Shim plates placed on flat liners, shall be used for alignment of very small adjustment, and thickness of shim plate is maximum 1 mm.

3.2.6

Where the lines are used in multi-layers, they shall be intermittently welded each after completion of centering (or alignment) of the equipment.


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3.3

Setting

3.3.1

Prior to the installation, the following checks shall be made on the equipment :

(1)

Appearance of equipment, such as absence of damage and rust

(2)

Quantity and appearance of auxiliaries

(3)

Size of the anchor bolts, and damage and rust on the threaded parts, if anchor box type is applied.

3.3.2

(4)

Orientation marking

(5)

Marking of center of gravity

(6)

Lifting points

Oil and other foreign materials stuck on the surfaces of leges, bed, frame, etc. which will contact to grouting mortar shall be entirely removed.

3.3.3

Setting equipment on the foundation shall be executed in reference of Table-1 table as guidance.

3.3.4

Grouting

(1)

Before grouting, anchor bolts shall be cleaned from oil and also anchor boxes shall be cleaned from foreign materials.

(2)

For foundation of vertical equipments having skirt at bottom, drain pipe shall be provided inside of grouting.

(3)

The grouting mortar shall be poured into the gap between the equipment and foundation as reference of Table 1.

(4)

Mixing ratio of grouting mortar shall be as specified in Table-2, Mixing Ratio of Mortar (Reference).

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Table-1

Type of setting

(I)

Anchor Box Type

(II) Embedded in case with template or gauge plate

Part A Ordinary Non Shrink Mortar Mortar

Application

Small and light weight equipment horizontal type equipment such as vessel and heat exchanger , etc.

Steel Structure column Equipment such as tall tower and vertical type vessel, with have large uplift force

Part B Chipping

Part C Ordinary Non Shrink Mortar Mortar

o

o

o

o

o

-

Part D Ordinary Non Mortar Shrin k Morta r o

-

o

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Type of setting

(III) Sleeve type

Application

Large rotating machines installed on table top RC structure


o

Part B Chipping

o

Centrifugal Compressor

(IV) Manufacturer’s Standard

Note : (I) (ii) (iii)


according to Manufacturer’s instruction according to Manufacturer’s instruction

according to Manufacturer’s Instruction

Each equipment shall be installed in accordance with detail civil drawing Manufacturer’s installation manual shall be prior to table 1. Type of setting shall be decided by PTTCHEM. Symbol in above table x : Not applicable : Non-application o : Applicable blank : Not applicable in general

Part D Ordinary Non Mortar Shrink Mortar

o

x

o

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Type of setting


Application

(III) Sleeve type

Large rotating machines installed on table top RC structure

Part B Chipping

o


o

according to Manufacturer’s instruction according to Manufacturer’s instruction

Centrifugal Compressor

(IV) Manufacturer’s Standard

Note : (I) (ii) (iii)

Part D Ordinary Non Mortar Shrink Mortar

o

x

o

according to Manufacturer’s Instruction

Each equipment shall be installed in accordance with detail civil drawing Manufacturer’s installation manual shall be prior to table 1. Type of setting shall be decided by PTTCHEM. Symbol in above table x : Not applicable : Non-application o : Applicable blank : Not applicable in general

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Table-2

Mixing Ratio of Motar (Reference) Mixing Ratio (in weight)

Specification of Grouting

Non-

Ordinary

Shrink

Cement

Sand

Weight% Gravel

Cement

Curing

against

Time

Cement

Ordinary

Depth

up to 100

1

1

Cement

of Anchor

over 100

1

2

Anchor

Non-

Box (mm)

Bolts

Shrink

Grouting of

of water

3

40 -

7 days

50

or more

acc. to Manufacturer’s Instruction

Cement Grouting of

Frame of

Grouting thickness up to Ordinary

100 m/m

Cement

Grouting thickness over

1

2 40 - 50

1

2

100 m/m Equip.

Non-shrink Cement

7 days

to Manufacturer’s Instruction

3

or more

14

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Table-2

Mixing Ratio of Motar (Reference) Mixing Ratio (in weight)

Specification of Grouting

Non-

Ordinary

Shrink

Cement

Sand

Weight% Gravel

Cement

Curing

against

Time

Cement

Ordinary

Depth

up to 100

1

1

Cement

of Anchor

over 100

1

2

Anchor

Non-

Box (mm)

Bolts

Shrink

Grouting of

of water

3

40 -

7 days

50

or more


Cement Grouting of

Frame of

Grouting thickness up to Ordinary

100 m/m

Cement

Grouting thickness over

1

2

7 days 40 - 50

1

2

3

or more

100 m/m Equip.

Non-shrink Cement

Motor,

acc. to Manufacturer’s Instruction Non-shrink Cement


Pad

Remarks 1.

The above table shows, as reference, the standard of mixing ratio, water % against cement and curing time of mortar, which used for the grouting of anchor bolts, liners and frame of equipment.

2.

Standard of materials for making mortar shall be as shown below. (1)

Portland cement shall be used as "ordinary cement".

(2)

Sand with grain size of between 0.3 mm and 1.2 mm shall preferably be used.

(3)

Gravel with grain size of less than 10 mm shall be used, but, less than 5 mm shall not preferably be used.

(4)

Water to be used shall not contain detrimental substance such as oil, acid, alkali or salt.

3.

Mixing and pouring of ordinary cement shall be performed at ambient temperature of 5 degree C or over.


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4.

Type of non-shrink cement shall be selected depend upon service for use in reference of Manufacturer's recommendation and mixing procedure and pouring process shall be decided accordingly.

3.4

Precaution for Oxygen Service for the equipment handling oxygen, parts which may be exposed to oxygen shall be strictly checked for absence of oil.

4.

PARTICULAR REQUIREMENT FOR VESSEL AND HEAT EXCHANGER

4.1

Where the vessel having flat bottom is directly placed on the foundation, the vessel shall be installed without excessive concentrated force against bottom plate, and the sand, if used, shall be fully dried and filled on the foundation.

4.2

Where sliding plate is used, sliding surface of the equipments support shall be cleaned and if necessary plastered with anti-seizuring agent.

4.3

Anchor bolts at sliding side shall be once firmly tightened, loosen the nuts giving 1 to 2 mm of clearance, and then re-tightened with lock nuts leaving this clearance, after completion of the vessel and connection with pipings.

4.4

Centering of vertical vessel shall generally be carried out in consideration of climatic influence such as wind, direct sunbeams.

4.5

Centering shall be carried out by center marking and level marking scribed on the foundation.

4.6

Centering of the vessel for the level and perpendicularity shall be carried out against both direction intersecting at right angles on the same plane.

5.

PARTICULAR REQUIREMENTS FOR PUMPS AND BLOWERS

5.1

The requirements described herein apply only for pumps and blowers of general used. Hence, for large pumps, special type pumps, and blowers, Manufacturer's instruction shall be followed.


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5.2

Leveling shall normally be carried out on machined surface of the base for axial direction of shaft and right angle to the shaft.

5.3

Where adjustment between shaft and coupling is required for their fitting, the adjustment shall be carried out on the coupling, not on the shaft side.

5.4

On the alignment of the pump, end deflection and face deviation of the driving and driven shafts shall individually be measured.

5.5

After completion of alignment, it shall be confirmed that the shaft can be rotated smoothly by hand.

5.6

After connection with piping system, it shall be confirmed that the pump and blower are connected without excessive force, and alignment of the pump and blowers shall be re-checked. If the alignment is get out of order by connecting piping system, piping system shall be adjusted to the pump.

5.7

After confirming the direction of rotation of the driver, the shafts shall be coupled.

6.

PARTICULAR REQUIREMENT FOR CENTRIFUGAL COMPRESSORS AND STEAM TURBINES

6.1

The requirements described herein apply only for machine in general use and are additional to the Manufacturer's instruction which shall be preference of all.

6.2

Leveling shall be carried out on machined surface of the base plate for axial direction of shaft and right-angle to the shaft.

6.3

The alignment of the compressor shall be carried out on the basis of the finished surfaces which are as near as possible to the center of the shaft.

6.4

End deflection and face deviation of driving and driven shaft shall be individually measured at more than four equally divided points on periphery of the coupling.

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6.5

Hot alignment shall be performed in accordance with the figure given by Manufacturer and confirmed at start up period.

6.6

After connection with piping system, it shall be confirmed that the centrifugal compressor and steam turbine are connected without excessive force, and alignment of them shall be re-checked. If the alignment is get out of order by connecting piping system, piping system shall be adjusted to them.

7.

PARTICULAR

REQUIREMENT

FOR

RECIPROCATING

COMPRESSOR,

GAS

TURBINE

GENERATOR, WASTE HEAT BOILER, FIRED STEAM BOILER CRACKING HEATER, OLEFLEX HEATER

These equipments are so designed particularly in consideration of the service required.

Hence,

Manufacturer's instruction shall be strictly observed.

8.

LOADING OF CATALYST

8.1

Kinds and characteristic, of catalyst shall be observed throughout the execution of loading.

8.2

All foreign materials in the

reactors of vessels shall be thoroughly removed before loading the

catalyst. The removal of these materials may preferably be done by air or vacuum cleaning.

8.3

In general, it is desirable that the mechanical handling of the catalyst shall be minimized during catalyst loading.

8.4

If it is necessary for the personnel to enter the reactor during loading, dust mask must be provided and a small quantity of air shall be circulated through the reactor for safety.

8.5

Wooden supports shall be used to distribute the personnel's load uniformly on to the catalyst.

8.6

Careful inspection shall be performed to verify that no breakage of catalyst occurs when the first 5 to 10 percent of the catalyst is loaded.


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8.7

During catalyst loading, the top level of the catalyst shall be kept horizontal.

8.8

After completion of the loading all foreign materials shall be removed and all manholes shall be closed.

9.

TRAY INSTALLATION

9.1

Tray assembling and installing into the vessel shall be performed in accordance with Manufacturer's instruction.

9.2

Tray assembling work shall be proceeded as a rule from bottom stage to upward. However, in case of small diameter tower, it may be easy to proceed from top stage to downward.

9.3

Cleaning and putting-in-order work shall be done for each finished tray stage successively as the work progress. Closing of man-way shall be done after final confirmation of cleanliness and fit-up conditions.

9.4

Closing of manholes shall be done after closing of man-way, cleaning of the inside of manhole. Specification (brand name etc.) of gasket paste and anti-seizing agent for bolts and nuts shall be confirmed prior to use.

10.

EQUIPMENT INSTALLATION ON STEEL STRUCTURE

10.1

Equipments on steel structure shall be installed in accordance with Fig. 1 shown below, and civil detail drawing.


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10.2

Anchor bolts at sliding side shall be once firmly tightened, loosen the nuts giving 1 to 2 mm of clearance, and then re-tightened with lock nuts leaving this clearance, after completion of installation of equipments and piping with piping.

10.3

Centering shall be carried out by center marking and level marking scribed on the steel structure.

10.4

Centering of the equipments for the level and perpendicularity shall be carried out against both direction intersecting at right angle on the same plate.

PTTCHEM-SP-M-801 EQUIPMENT INSTALLATION

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