ONSHORE RECEIVING FACILITY (ORF) PROJECT
INSTALLATION PROCEDURE FOR PRESSURE VESSEL
PREPARED FOR
CLIENT CLIENT
EPCI CONTRACTOR
Job No. : QPCA00 Rev.
Date
Contract No. :
Doc. No.: Description
By
Chk.
App.
Rev : A Client Approval Sign
:
Date
:
INSTALLATION PROCEDURE FOR PRESSURE VESSEL
REVISION LOG REGISTER Revisions had been performed on following pages: No
Page
Date
Revision
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INSTALLATION PROCEDURE FOR PRESSURE VESSEL
TABLE OF CONTENTS REVISION LOG REGISTER ................................................................................................. 2 TABLE OF CONTENTS ........................................................................................................ 3 1. SCOPE ........................................................................................................................... 4 2. REFERENCES................................................................................................................ 4 3. SAFETY PRECAUTIONS................................................................................................ 4 4. PREPARATION AND PLANNING ................................................................................... 4 4.1 Planning ................................................................................................................. 4 4.2 Erection Equipment ................................................................................................ 5 4.3 Loading and Unloading ........................................................................................... 5 4.4 Preparation for Installation ...................................................................................... 5 4.5 Fondation ............................................................................................................... 5 5. INSTALLATION............................................................................................................... 6 5.1 Preparation of Shims .............................................................................................. 6 5.2 Installation of Equipment ........................................................................................ 6 5.3 Alignment ............................................................................................................... 6 5.3.1 General .......................................................................................................... 6 5.3.2 Plumbing ........................................................................................................ 6 5.3.3 Leveling ......................................................................................................... 6 5.4 Grouting ................................................................................................................. 7 5.5 Final Fixing of Anchor Bolts .................................................................................... 8 5.6 Installation of Accessories ...................................................................................... 8 6. INSPECTION .................................................................................................................. 8
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INSTALLATION PROCEDURE FOR PRESSURE VESSEL
1. SCOPE This procedure covers the requirements for installation, alignment and grouting works of, pressure vessel.
2. REFERENCE
The requirements contained in the latest editions or revisions of the following standards shall form integral part of the requirement of this procedure. o ANSI B30.5 Safety Code for Crawler, Locomotive and Truck cranes. o ANSI B30.9 Safety Standard for Slings. The requirements contained In Petronas Technical Standard. o PTS61.10.08.11Field Inspection Prior to Commissioning of Mechanical Equipment o PTS70.10.70.11The Preservation of Old and New Equipment and Piping Standing o PTS 30.48.00.31-P Protective Coatings and Lining The requirements in the following project documents shall also form integral part of the requirement of this procedure. o ITP o Quality Plan The requirements contained in the latest editions or revisions of the respective manufacturer’s instruction manual including relevant drawings (herein after called “Instruction manual”) shall form integral part of the requirement of this procedure.
3. SAFETY PRECAUTION
Isolate the job site area with warning tape in order to control entry of unauthorized persons into work area. Provide common safety equipment such as Fire Extinguishers, Fire Basket, PPE etc. at site in accordance with CLIENT Fire and Safety Regulations. Prior to start work, ensure that all relevant work permits have been obtained from CLIENT, as per contractual requirements. The Consortium shall ensure that all the lifting equipment, including man baskets, are certified in accordance with CLIENT Fire and Safety Regulations. Laborers working from the man baskets must wear an individual safety harness fastened to a sling attached to the main hook block of the crane. The certificate and license of the equipment operators shall be checked for its validity, prior to any rigging and lifting activities. Prior to start work, all pieces of construction equipment are to be inspected by the Consortium’s safety department to ensure that all the certificates are valid and are in accordance with CLIENT Fire Safety Regulations. All certificates and permits relevant to the particular job shall be kept at site for verification. No equipment shall be installed in high winds, heavy rain.
4. PREPARATION AND PLANNING 4.1
Planning
Prior to commencing the work, an installation plan shall be prepared by considering the following data, or site investigation:
Installation instruction by vendor, equipment data sheet, equipment layout etc. Shape, dimensions and material of construction shall be confirmed with nameplate of the equipment and if required, by actual measuring. Workspace around the installation area and any possible obstructions shall be identified. Installation sequence of the equipment will be in conjunction with rigging studies. Transportation route of equipment. List of erection equipment and tools for lifting. Transportation plan for erection of equipment such as heavy crane, special vehicles etc.
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INSTALLATION PROCEDURE FOR PRESSURE VESSEL
4.2
Erection Equipment
4.3
The Consortium shall ensure competency and suitability of the crane operator and signalman. Validity of the certificates and license of all erection equipment as well as the operators shall be confirmed in accordance with CLIENT Regulations, Governmental or other equipment authorities. A set of manufacturer’s lift table shall be placed conspicuously in the cab of the mobile crane and adhered to strictly. If required, timber mat and/or steel plate shall be provided for track or tires by considering soil bearing forces. All Chains shall be forged or electric welded steel link type of the correct size for the loads to be lifted. All Slings shall be inspected for any damage and suitability to withstand the maximum imposed load. The safety factor for wire rope slings of all grades shall be not less than five. All Fittings such as hooks, swivel hooks, shackles, cable clamps, turnbuckles etc. shall be of drop forged steels.
Loading and Unloading
Loading and Unloading shall be in accordance with Lifting Procedure
4.4
Preparation for Installation
4.5
The Consortium supervisor shall conduct a check for the following items; o Appearance of equipment for damage and rust free condition. o Orientation marking. o Marking of center of gravity. o Lifting points. A packing material or filling material for transportation shall be removed and disposed of correctly. All restraining clamps and attachments used for transportation and storing shall be kept until pre-commissioning. Temporary covers on all openings shall remain on the item until the related pipelines are to be connected. Oil and foreign matters stuck on the surface of legs, beds, frames etc, which will come in contact with grouting mortar shall be completely removed.
Fondation
Foundation shall be checked for the following items, before starting the installation; o Dimensions o Positions (center marking) and height (level marking). o Disorders in concrete such as cracks, abnormal concentration of aggregates, porous state, surface condition etc. o Dimensions and cleanliness of anchor box, if applicable. Surface of foundation shall be conditioned for proper seating and bonding of the grouting material with foundation. its surface shall be chipped around area of the seating of equipment. Foreign matters such as oil, grease, dirt, dust, loose concrete etc. shall be completely removed from the surface. Size and location of anchor bolts embedded in the concrete shall be checked against the drawings and inspect, for any damage or rust on the threaded parts. The threaded part of the anchor bolts shall be cleaned properly and greased or machine oil for smooth running of nuts over the threads. The following conditions shall be followed regarding all anchor bolts; o Tolerance for position shall be +1.5 mm o Projection shall be minimum 1.5 mm from the top surface of nut after installation o Miss aligned anchor bolts are not acceptable. o Pipe sleeves (if applicable) shall be approximately 50mm larger in diameter than anchor bolt, unless otherwise specified. Liners to be used, in general, shall be made of carbon steel, unless otherwise specified by manufacturer or process requirement. Liners shall be arranged so that the load of the equipment is uniformly distributed on the foundation. Liners shall be set so that the top levels of liners within + 1.5 mm of the specified installing height.
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INSTALLATION PROCEDURE FOR PRESSURE VESSEL
5. INSTALLATION 5.1
Preparation of Shims
Shims shall be made of carbon steel, brass or stainless steel. In general, shims shall be prepared by machining or grinding as indicated in Table-1 Table-1 Item
5.2
Length
Width
Thickness
(mm)
(mm)
(mm)
Material
Shim
100-450
50-200
0.05,0.1,0.2,0.3,0.5,1.0
Brass/ SS
Shim
100-450
50-200
1.5,2.0,3.2,4.5,9,12,19,25
Carbon Steel
Installation of Equipment
5.3
All equipment shall be lifted slightly to examine the underside for cleanliness and its level and the acceptability for installation. As a rule, shims shall be placed on liner plates fixed on the concrete foundation at near sides of the anchor bolts for leveling the equipment. During installation work, special care shall be taken so as not to damage anchor bolts and equipment. Equipment shall be lowered slowly and vertically. If Teflon sheet is not provided on the top of sliding plates, the sliding surface shall be cleaned and plastered with grease. Final adjustment between equipment base and linear plate shall be done, by using plate (shims). As a rule, welded lifting lugs used in the installation shall be left in place.
Alignment 5.3.1
General
All installed equipment shall be aligned for plumbing and level. Vertical vessels shall be aligned for plumbing and satisfy requirements in para. 5.3.2. Horizontal vessels and exchangers shall be aligned for leveling and satisfy requirements in para. 5.3.3. Hydraulic jack shall be used for lifting and fine adjustments.
5.3.2
Plumbing shall be checked by viewing from two directions 90 deg. apart with a theodolite.Checking of very tall equipment shall be done early in the morning. Out of plumb of the equipment shall not exceed 1.0 mm per 1.0 m subjected to a maximum of 25 mm for entire height, unless otherwise specified in the equipment specification. After alignment is finished and the lock nuts of the anchor bolts are tightened firmly, the shims shall be tack-welded to each other and shim plates should be set inside the outer edge of the equipment to avoid pinking and cracking of grout.
5.3.3
Plumbing
Leveling
The alignment for level shall be made using a spirit level or a theodolite at four points on the centerline marked on the equipment in the shop. The level shall be aligned in the direction of AB or CD and AC or BD at the centerline on the equipment. (Refer to Fig. 1)
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INSTALLATION PROCEDURE FOR PRESSURE VESSEL
A
B A
C BD
C
D
PLAN
ENDVIEW
Fig. 1 Leveling Points for Horizontal Equipment
The maximum tolerance shall be as shown in Table-2, Unless otherwise specified. Table-2
5.4
Points
Tolerance
A and B
5 mm per meter of length
C and D
5 mm per meter of length
A and C
5 mm max
B and D
5 mm max
After leveling is finished and the lock nuts of the anchor bolts are tightened firmly, the shims and wedges shall be tack-welded to each other, and shim plates should be set inside the outer edge of the equipment to avoid pinking and cracking of grout.
Grouting
Grouting shall be accomplished in accordance with the following requirements, unless otherwise specified.
The surface of the foundation shall be cleaned thoroughly of all traces of oil, grease, dirt, dust or any other foreign material to allow bonding. The top surface of the foundation shall be sprayed with fresh water prior to grouting. Portland cement mortar shall be used for grouting, unless otherwise specified by the supplier. The mixing method of the ingredients shall be as follows; o The cement to sand ratio shall be 1: 2 by volume and shall be mixed thoroughly when it is dry. o Water shall be added so that the mixture flows sluggishly. o Dry pack shall be prepared in the ratio of 1: 2(cement : sand) with only a little water. Non-Shrink Cement Mortar shall be used for load bearing portion as shown in Fig.2. The mixing method shall be in accordance with manufacturer’s instruction. The base plate shall be grouted as follows; o The space under base plate shall be packed with grout and compacted. o The grout shall cover all shims. After the grout has been poured fully, excess grout shall be trimmed away. The shims and wedges shall not be removed, unless otherwise specified.
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INSTALLATION PROCEDURE FOR PRESSURE VESSEL
Equipment
Dry-Pack
Dry-Pack Dry-Pack
Non Shrink Mortar Portland Cement
Figure2.Grouting Detail
5.5
Final Fixing of Anchor Bolts
5.6
After grouting has set and hardened, the nuts of the sliding and anchor bolts shall be loosened to allow for thermal expansion and re-tightened. The above requirement shall be applied to horizontal vessels.
Installation Of Accessories
Accessories such as platforms, staircases, ladders, that are part of the equipment , are to be installed according to the relevant drawings. Accessories shall be checked for quantity, size, and shape and for any damage or distortion prior to erection. Accessories shall, as a rule, be attached after the completion of curing of the grouting. These shall be attached in the sequence bottom to top. Special care shall be given to avoid distortion and stress on equipment or accessories due to thermal expansion and instructions in the vendor manual and drawings. Accessories that are not matching shall be modified to suit at site as directed by the Consortium supervisor. Auxiliary equipment piping and instrumentation are to be attached to the equipment in accordance with the manufacturer’s instruction manual. Special care shall be taken to avoid any damage to these accessories while handling.
6. INSPECTION Inspection shall be carried out in accordance with the following documents, and all the results of inspection shall be recorded in appropriate forms/ formats by QA/ QC Department of the Consortium.
Quality Plan ITP Page 8 of 8
