Procedure for Rotary Equipment -QCP35- Rev.0

PROCEDURE FOR INSTALLATION OF ROTARY EQUIPMENTS Document No.: QCP35

Company

: KUWAIT OIL COMPANY (KOC)

Project Title : Installation Of Multipoint Smokeless High Pressure Flare At Fourteen South And East Kuwait Gathering Centers.

Contract No. : KOC-13050638

Contractor

0

30-08-15

: MUSHRIF Trading & Contracting Company

Issued for Approval

QR

DE

QA/QCM

PM

PROCEDURE FOR INSTALLATION OF ROTARY EQUIPMENTS

Rev.

Date

Description

Prepared by

Reviewed by

Doc.: Project no.: Revision: Date: Page:

Reviewed by

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Approved by


REVISION LOG


QCP35 KOC-13050638 0 Aug. 2015 3 of 12


REV. NO

REV. DATE

REVISION PAGE

0

30-08-15

All


QCP35 KOC-13050638 0 Aug. 2015 4 of 12

REVISION DESCRIPTION Issued for approval.


INDEX

1.0

PURPOSE

2.0

SCOPE

3.0

REFERENCES

4.0

DEFINITIONS

5.0

ABBREVATIONS

6.0

PROCEDURE

7.0

6.1

General

6.2

Rotary equipment

6.3

Method of alignment

6.4

Grouting

6.5

Final Alignment check

6.6

Measuring & Testing Equipments Calibration

6.7

Personnel

6.8

Safety

ATTACHMENTS


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QCP35 KOC-13050638 0 Aug. 2015 6 of 12

1.0 PURPOSE The purpose of this procedure is to set the requirements for the installation and alignment of rotary equipments to meet the contractual specifications and requirements for works at KOC for the project “Installation Of Multipoint Smokeless High Pressure Flare At Fourteen South And East Kuwait Gathering Centers”.

2.0 SCOPE This procedure applies to the project “Installation Of Multipoint Smokeless High Pressure Flare At Fourteen South And East Kuwait Gathering Centers” for the installation and Alignment of rotary equipment’s in compliance with project specifications for works at KOC. This also covers foundation check, fixing of shims, bolting, grouting, inspection and Testing.

3.0 REFERENCES 3.1

015-CH-1001 - KOC Specification for Pressure Vessels

3.2

015-CH-1002 - KOC Specification for Light Duty Drums

3.3

KOC-MV-008 - KOC Specification for Air Cooled Heat Exchangers

3.4

PQP

- Project Quality Plan(PQP)

3.5

KOC-C -023

-

3.6

QCP24 - Procedure for Construction Works Site Survey.

3.7

QC ITP20

KOC Standard for Grouting for Bases – Materials & Workmanship

- ITP for Static Equipment Erection

4.0 DEFINITIONS 4.1

Company

4.2

Contractor -

4.3

Project

-

-

Kuwait Oil Company MUSHRIF Trading &Contracting Company

Installation Of Multipoint Smokeless High Pressure Flare At Fourteen



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South And East Kuwait Gathering Centers

5.0 ABBREVATIONS 5.1

KOC

-

Kuwait Oil Company.

5.2

QR

-

Quality Representative (QA / QC Engineer)

5.3

DE

-

5.4

QA/QCM -

QA/QC Manager

5.5

PM

-

Project Manager

5.6

U/G

-

Under Ground

5.7

HSE

-

Health, Safety & Environment

5.8

PQP

-

Project Quality Plan

5.9

IFC

5.10

ASTM -

-

Discipline Engineer

Issued for Construction American Society for Testing and Materials

6.0 PROCEDURE 6.1

General

6.1.1

On receipt of equipment such as pumps, blowers and compressors, QC Personnel shall carry out receipt inspection as per relevant Inspection and Test Plan (ITP).

6.1.2

Material Controller will be responsible for initiating warehouse requisition, receiving Material Issue report from Contractor and receiving all necessary documents like Packing list, Inspection Certificates related to individual equipments or Equipment



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packages. He shall verify the quantity as per the packing list to ensure the equipment/package of equipment items is complete.

6.1.3

6.1.4

6.1.5

Equipment shall be visually inspected by the Material controller and discipline supervisor as per the approved construction drawings or documents if any and for any visible damages, transportation damages etc. This shall extend to check the condition of the underside of base plates/structures which will come into contact with the grout. Coating damages if any shall be reported to the contractor before receipt. If any discrepancy is noticed, it shall be informed to Contractor and material shall not be received unless a specific written instruction is received from the Contractor. Preservation shall be carried out as per equipment manufacturer’s recommendation and contract specification. The equipment will be preserved as per the vendor preservation records and recommendations and documented by Material Controller in Attachment-6. Any templates supplied by the vendor for mounting bases for equipment shall be received from the Contractor and preserved in identified storage locations. Equipment on receipt shall be unloaded in a separate location or directly on the foundation. Equipment shall be covered properly to avoid from damages, water spillage, entry of foreign particle and dust. This is applicable to all rotary equipments. Records shall be maintained & updated regularly. QC personnel shall carry out receipt inspection as per Company approved Inspection and Test Plan (ITP). Records of inspection shall be documented as per Attachment -1 (As per Chapter 3 of API 686 Compliant Checklist).

6.1.6

Equipment protection, handling, lifting and installation shall be as per manufacturer’s installation procedure, approved techniques/drawings.

6.1.7

Prior to equipment installation, location, elevation of foundation, surface preparation of foundation and anchor bolt shall be inspected as per the approved project drawings. Packer plates (shims) shall be grouted on to foundations if required. Wherever templates are supplied by the manufacturer the anchor bolt position shall be verified with respect to template prior to start of installation.

6.1.8

Items that could be damaged during installation (e.g. sight glasses, gauges, thermo wells, earthing cables etc.) shall be removed and temporarily stored. All openings, bearing surfaces and threads shall be protected.

6.1.9

All lifting and tailing lugs shall be checked to ensure that the proposed shackles fit the holes and that the slings do not clash with any bolts of the equipment. All temporary attachments shall be removed before erection.

6.1.10

Alignment and its tolerance shall be as per approved project specification/ drawings and manufacturer’s instructions.

6.1.11

A preliminary alignment prior to grouting shall be carried out to incorporate any deflection or deformation of equipment skid base.

6.1.12

Connected piping shall be arranged and supported in such a manner that no strain is imposed on the equipment. Companion pipe and equipment flanges shall fit squarely



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and shall be parallel with the mating flange. Allowance for expansion shall be provided in the piping layout, for equipment which is to handle hot fluid. Flange connecting to the mating equipment flange shall be welded after final alignment. During welding of connected piping, machinery skid shall not be used for earth grounding. Flange Parallelism tolerances shall be as per Vendor documents

6.1.13

Each stage of the installation shall be inspected as per the approved Inspection and Test Plan (Doc. No.: JI-2003-000-CQU-ITP-076) to ensure that no deformations or errors are present in the completed phases of the work. Results of inspections shall be documented in relevant inspection reports as per Attachment-4. Records shall be maintained & Preservation deficiencies rectified as required

6.1.14

Preservation shall be carried out as per equipment manufacturer’s recommendation. Equipment Installation Report / Punch List Report for Rotary Equipment Installation (Attachment-6) shall be signed off to document correctness and completeness of the stage activity.

6.2 6.2.1

ROTARY EQUIPMENTS Pumps

6.2.1.1 Leveling (Factory mounted Pump and Driver on base Plate): i) Pump assemblies shall be installed at the locations and to the elevations as per the approved project drawings and manufacturer’s installation procedure. The coupling hubs of a pump and driver mounted on a base plate shall be disconnected prior to the placement of the unit on its foundation. ii) The base plate shall be supported on rectangular metal blocks / shims or on metal wedges having a small taper. The support pieces shall be placed close to the foundation bolts. On large units, small jacks made of cap screws and nuts may be used for leveling. When a “Pump Installation Manual” is provided by vendor, installation shall be carried out as per vendor’s recommendation. iii) In each case shims/metal blocks shall be placed directly under the base plate carrying the greatest weight and spaced close enough to give uniform support. Spacing between the shims and the grouting gap, between the base plate and the foundation shall be as per manufacturer’s recommendation. iv) The metal supports or wedges shall be adjusted until the shafts of the pump and driver are level. The coupling faces as well as the suction and discharge flanges of the pump shall be checked for horizontal and vertical level. The positions shall be corrected, if necessary by adjusting the supports or wedges under the base plate as required. vi) Vertical pumps with a separate sole or base plate shall be leveled and grouted prior to the installation of the pump. vii) The faces of the coupling hubs shall be spaced sufficiently apart to avoid contacting each other when the driver rotor is moved hard over towards the pump. Gap between the coupling hubs shall be as per manufacturer erection manual. viii) Two (2) dial gauges shall be installed on the equipment coupling to monitor the radial & axial relative position of half couplings. There should be no change on the dial



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gauge indication when the jack screws are released & the foundation bolts are tightened. However during the leveling procedure no alignment correction shall be done. Alignment checking shall serve only a measure of stress induced in the base plate by foundation bolts foundation The permissible amount of misalignment will vary with the type of pump and driver. The manufacturer’s recommendations shall be followed for permissible tolerance

METHOD OF ALIGNMENT

6.3

i) Alignment will be performed using laser or dial indicators with skilled and experienced technicians. If dial indicators are used, the sag or deflection of the indicator mounting brackets will be measured and accounted in the calculations. Either quick-fit/universal brackets or custom fabricated brackets will be used for the indicators. ii) Distance between shaft ends will be checked to verify the conformity to approved for construction drawings or vendor drawings. iii)Alignment shall first be checked by a straight edge, taper gauge or feeler gauges as accurately as possible using the procedure indicated above. iv)Set the dial to zero and mark with a chalk on the driver coupling hub at the point where the button rests. v)To check the top, bottom or sides, rotate both shafts together and by the same amount i.e., all readings on the dial shall be made with its button still resting at the chalk mark. vi)Secure the dial indicator to the pump hub of the coupling, with the indicator button resting on the driver coupling periphery whether or not the driver needs to be raised, lowered or moved to either side. After each movement, check to see that the coupling faces remain parallel to one another. Example: If the dial reading at the top is set at zero and the reading at the bottom or either side shows a plus or minus reading of 500 micrometers (0.020 in), the driver must be raised or lowered with the dial indicator button still in contact, by the use of suitable shims or moved to one side or the other by half of this reading.

6.4

GROUTING i) Grouting shall be carried out after the necessary corrective adjustments for angular and parallel alignment have been made. Foundation bolts shall be tightened evenly but not too firmly. The unit shall be grouted to the foundation with shims or wedges in place. Jack screws shall be loosened prior to tightening the foundation bolts. ii) Grouting and grout material shall be in accordance with TWI-110 (JI-2003-000-CQUQAP-011), the manufacturer’s recommendations and as specified in the equipment drawings. iii) A frame work shall be built around the base plate and the grout poured through the holes provided for that purpose. The grout shall completely fill the spaces under the base



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plate. iv) Allow approximately 72 hours for the grout to harden and set, then tighten the foundation bolts evenly and then torque the bolts wherever required. v) Grout shall be poured around the base plate, foundation bolt holes and the surrounding area. Grout shall be in accordance with the vendor's recommendation and construction drawings. Grout material shall be approved by the Company prior to use. Grouting thickness shall be as per approved drawing. vi) Equipment shall be checked for alignment, clearances and fit before and after grouting as per manufacturer’s recommendations and recorded in Attachments- 2 & 3.

6.5

FINAL ALIGNMENT CHECK i) After the grout has set & the foundation bolts have been properly tightened, the unit shall be checked again for final alignment. During final alignment check optical instruments shall be used. Before checking the alignment a soft foot check will be performed as per API 686 Chapter 7 Clause 5.4.4. Once the soft foot is checked & the required corrective action is taken (if required), the alignment shall be checked before & after the process piping are flanged to the equipment. A “Pipe Strain Measurement” shall be performed as per API 686 Chapter 6 Clause 4.8 & the results shall be recorded in Attachment-5 ii) The direction of rotation of the driver shall be checked to verify that it matches that of the pump. The corresponding rotation direction of the pump is usually indicated by a direction arrow on the pump casing. The coupling hubs can then be reconnected.

6.6

MEASURING AND TESTING EQUIPMENTS CALIBRATION i) Equipments (Dial gauges, Feeler gauges, Straight edges, Screw gauges, Vernier caliper, Spirit Levels and Torque wrenches) used for inspection, testing and measuring shall be calibrated.

6.7

PERSONNEL i) Personnel supervising the rotary equipment installation shall have documentary Evidence of suitable experience. Alignment shall be conducted by qualified millwrights and where applicable work shall be carried under manufacturer and/or vendor representatives’ supervision.

6.8

SAFETY i) The Project HSE Plan shall be complied to at all stages of construction. ii) Rigging plan & analysis for lifting and/or drawings shall be made prior to the installation of equipment. All slings, spreader bars, shackles and lifting equipment shall have valid test certificates. Job Safety Analysis and Risk Assessment for lifting heavy



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equipment shall be carried out prior to installation. iii) All safety aspects involved in the equipment installations as per KOC Fire and Safety Regulations shall be complied.

7.0

ATTACHMENTS Attachment -1

Rotary Equipment Receiving Inspection Report

Attachment -2

Rotary Equipment Installation Report

Attachment -3 Attachment -4

Rotary Equipment Foundation Pad Elevation and Plumb Check Report. Rotary Equipment Inspection Report

Attachment -5

Rotary Equipment Final Closeout Report

Attachment -6

Rotary Equipment Installation / Alignment Punch list Report.

Procedure for Rotary Equipment -QCP35- Rev.0

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