MS for Rotating Equipment-Pump

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NGHI SON REFINERY AND PETROCHEMICAL PROJECT

Document Title :METHOD STATEMENT FOR INSTALLATION OF PUMP

Contractor Doc. No:VV3160-001-C-*** REV – 0

CONTENTS

1.0 Scope 2

2.0 Reference 2

3.0 General 2

4.0 Job site receiving & Inspection 2

5.0 Pump foundation preparation 3

6.0 Pump skid installation 4

7.0 Base plate leveling 5

8.0 Pump skid grouting 6

9.0 Installation of pump and motor on the baseplate 8

10.0 Pre-Alignment check 8

11.0 Motor solo run test 9

12.0 Pipe strain measurement 10

13.0 Piping hydro test 10

14.0 Final alignment check & Inspection. 11

15.0 Summary of hold points & acceptance criteria 11

16.0 Proposed inspection schedule 13

17.0 Attachments 14

18.0 Installation flowchart 16

19.0 Diagrams of baseplates 17

WEC ENGINEERS & CONSTRTORS PTE LTD

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1.0 Scope

1.1 This document covers the method details and requirements for erection / installation of rotating equipment. (Pump) at Nghi son refinery and petrochemical complex – Vietnam.

2.0 Reference

API 686 - Recommended Practices for Machinery Installation and Installation Design

API 610 - Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and Gas Industry Services

S-000 1635-003V-0 for Pumps - Installation and Checkout

S-000-1320-1001VA for Grouting for Machinery

S-000 1670-0004V for Piping Erection, Testing, Flushing & Cleaning

Pump Vendor Installation, Operation & Maintenance (IOM) Manual

3.0 General

3.1 The Work shall be performed in accordance with project specification and the drawings concerned. Any conflict or irregularity found between specification and the drawings shall be informed to client’s in-charge persons.

3.2 The Work shall be performed by WEC under the supervision of Client supervisor/engineer’s or his authorized representatives.

3.3 For the specialized equipment installation shall be closely supervision by the Vendor representative.

4.0 Job site receiving & Inspection

4-1. Inspection of Skid and Machinery:

a) Visual inspection for physical damage or contamination.

b) Check items against delivery list, and tag all loose items against pump

identification number.

c) Verify baseplate dimensions e.g. Anchor bolts and leveling jackscrews locations.


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d) Ensure weatherproof covers provided. Carry out any preservative and lubrication as required.

4-2. Verify baseplate type for leveling method:

a) Verify baseplate supplied with or without leveling jackscrews, if baseplate comes, with leveling jackscrews - will have a jackscrew next to all the anchor bolts.

b) Without leveling jackscrews - will only have a single hole for anchor bolts.

c) If baseplate has leveling jackscrews - level and grout with jackscrews

(removed after grouting) only.

d) If baseplate comes without leveling jackscrews - level and grout with shims and

shim pads only. If without leveling jackscrews - baseplate do not conform to API

686 Chp 5 - 2.6.5& 3.8.4. Client to be informed.

4-3. Trial Alignment & Leveling of base plate:

a) Temporarily level the baseplate measuring on the suction or discharge nozzle. For

baseplate with leveling jackscrews - use the leveling jackscrew with a disc pad

underneath For baseplate without leveling jackscrews - use the wedges or shim

packs

b) Conduct trial alignment to verify pump and motor can be aligned to specificationIf unable to align, investigate and report cause.

c) If alignment is achievable, remove pump and motor to a temporary stand.

d) Trial level the baseplate again but measuring from the motor and pump machined pads. If unable to level, investigate and report cause. Check for base plate bending, warping or twisting.

5.0 Pump Foundation Preparation

a) Areas that will be covered by grout shall be prepared by chipping away the laitance with a chipping hammer. At least 25mm will be removed during the chipping process to ensure enough clearance (up to 50mm) between the concrete and the bottom of the baseplate.


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b) All corners of the foundation where the grout extends will be chipped off at least

50 mm with a minimum of 45° chamfer to provide a shear plane at the grout-to-

concrete interface to prevent de-lamination.

c) Foundation must be thoroughly swept and air blown free of dust with clean, dry,

oil-free after the chipping or roughening process is completed.

d) Ensure foundation is free of structural cracks.

e) Cover with clean polyethylene sheets for weather protection and to avoid for any

contamination by oil, dirt or water when work is not in progress.

6.0 Pump Skid Installation

6-1 preparation for lifting of pump skid:

a) Verify and double check all reference points and markings are positively identified i.e. Orientation, Reference Bench Mark & Elevation

b) Ensure all anchor bolts are in place, correct type of sleeve, size and length according to drawing issued for construction. Ensure it is clean and dry and sleeve has filled with non-bonding moldable material to prevent water accumulation. This sleeve is meant to ensure proper bolt elongation during tightening of the anchor bolt.

c) Clean the machined base plate surface free from any dirt (preservation coating).

6-2. Setting of support pads for leveling

DEVICES: SETTING OF JACKSCREW LEVELING PADS:

a) Prepare pieces of stainless steel levelling disc pads with diameter 50 mm x 12mm (t) in size. Levelling pads must be of round corners, no sharp edges and clean or free of dirt, oil, rust, scale and burrs.

b) Baseplates should be provided with vertical levelling screws. Shims and wegdes should not be used since they create hardspots that interfere with the grout ability to provide uniform base support. They may also allow ingress of moisture with the resultant corrosion and grout spalling.

SETTING OF SHIM PADS:

c) Shims pads will be used only if the baseplate is supplied without the vertical levelling screws. And only with the approval of the client. As this practice contravenes API 686 recommended practice.

d) Ensure each location of levelling shim pads has enough distance from the anchor bolts as not to obstruct the insertion soft moldable material in the anchor bolt


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sleeve pockets prior grouting. Or the filling of grout in the sleeve pockets if so designed or preferred by client.

e) Set down the the leveling screw pads or shim pads according the to the type baseplate to be installed.

6-3. Lifting of pump skid in position:

a) For rigging and lifting execution of pump assembly, please refer to METHOD STATEMENT FOR LIFTING OF PUMP SKID.

b) Ensure pump skid is installed in accordance to the construction drawings; refer to the PUMP GENERAL ASSEMBLY & FOUNDATION DRAWING.

7.0 Base Plate Leveling

7-1. Preparation for leveling:

a) Verify and confirm that straight edge and precision machinist level are calibrated with a valid certificate of calibration.

b) Confirm the pump machined base plate elevation is in the correct position based on the pump nozzle as a point of reference.

c) Verify the jackscrew levelling pads or shim pads are completely done according to the required location and elevation and for shim pads - cured enough to hold for leveling application.

d) Ensure jackscrews are coated with paste wax to prevent grout adherence. Care must be taken to prevent wax from contacting the concrete foundation or metal surface that will be in contact with the grout.

e) Ensure the pump skid is isolated, unconnected to any piping and in strain free condition.

f) Set up weather shelter for the whole pump skid area.Avoid direct sunlight on the foundation and baseplate (maintain 18-32 degC)

Note: 1. Only jackscrews will use for levelling, shims & wedges are not allowed to use.2. Liquid waxes and oil are not permitted to use to prevent grout adherence.

7-2. Leveling of base plates (Pump & Motor):

a) Locate the skid high end and use it as a reference point when levelling the rest of the baseplate.

b) Start at the high end of the machined pads of the baseplate surface and place the precision machinist level across ends (transversely) and across the middle (longitudinally) using straight edge. Continue leveling until the baseplate is level in crosswise and longitudinal direction by adjusting the leveling jack screws and snug the anchor bolt nut to hold the base plate in place.


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c) Check level repeatability by reversing precision machinist level by reversing 180°. d)

d) Repeat the same steps (item b & c) when leveling pump and motor base plates.

e) Record down the final reading using the Baseplate Level & Elevation Report Report and call for inspection and acceptance.

f) Criteria for Base Plate Levelness < 0.20 mm/m (HOLD POINT) - API 610 Pumps 0.002 inch / ft

Criteria for Base Plate Levelness < 0.40 mm/m (HOLD POINT) - General Purpose or 0.005 inch / ft ASME Pumps

Note:In case tightening of anchor bolts upset the skid level (out of level) > adjust leveling jackscrews until baseplate is level in both direction at place where level is out. Again, tighten anchor bolts and verify level in both directions. Continue these steps until all anchor bolts are completely tightened and all base plates are completely leveled.

8.0 Pump skid grouting (By Civil group)

8-1. Grouting material & precautions:

a) Grout Material Safety Data Sheets (MSDS) is approved by Client and available at site and associated hazards made known to all grouting personnel.

b) Safety requirements or PPE (i.e. protective gloves, dust masks, goggles, etc) as per MSDS must be available at site and should be worn during grouting process.

c) Grouting material descriptions, properties, packaging, mixing instructions and personnel.

8-2. Grouting preparation / checklist:

a) Ensure jack bolt/screw(s) are coated with paste wax or grease to prevent grout adherence. Care must be taken to prevent wax from contacting the concrete foundation or metal surface that will be in contact with the grout.

b) Any miscellaneous mounting plate holes (e.g. coupling guard mounting holes) are to be plugged to prevent grout entry. All plugs to be wax coated to prevent grout adherence.

c) Verify all anchor bolt nuts are snug tight prior to grout application to ensure that it will not float out of position. Exposed anchor bolt threads/projections must be protected with duct tape.


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d) Confirm the area between top of anchor bolt sleeves and the bottom of mounting plates (skid) shall be packed with soft moldable material

e) Ensure grout forms materials is sturdy and sealed to withstand liquid head and forces during grouting.

f) Prepare & install expansion joints strip or Flexcell Boards (12 mm thk) by glueing into position in the form works where required.

g) Grout forms should have a 25 mm, 45 deg chamfer strips at all vertical corners and at the horizontal surface of the grout.

h) Prior to grout mixing, ensure sufficient quantity of grout material is on hand including clean tools, equipment, and safety PPE.

8-3. Grouting work:

a) Grouting must be completed in a single operation without interruptions. Grout should be mixed in a clean, slow sped (15-20 rpm) portable mixer. For small pours, grout can be mixed in a clean wheelbarrow with a mortar hoe.

b) The resin and hardener are to be mixed at 200 - 250 rpm as per manufacturer's specified time period before introducing aggregate. There should be no entrained air in the mixture.

c) Start pour from one end of the forms and fill the cavity completely while advancing toward the other end. This will help prevent air entrapment. Do not vibrate the grout to help it flow as this tends to separate the aggregate from the resin binder. Limited use of push tools may be used to distribute the grout in long strokes rather than short jabs. Violent ramming is not permitted.

d) Check the grout used against the estimated baseplate cavity volume, as a method to check against insufficient filling and possible air pockets

e) Check for grout leaks, which is not self sealing and can results in voids.f) Check that all grout holes and vent holes are filled with grout.g) Machinery installer will be onsite to verify the level readings before, during and

on completion of grouting.

8-4. Post grouting work:

a) Confirm grout is completely cured and sufficient hardened (practically 3 days) and remove the jackscrews and grout form works. Grout is considered to be cured if a nail cannot be driven into it.

b) Jackscrew holes shall be filled-up with silicone sealant (not grout) or short cap screws that do not to extend below the threaded holes in the baseplate.


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c) Each anchor bolt are lubricated and torque (refer to API 686 Chapter 5 Appendix A if vendor info not available).

d) All anchor bolts should have full penetration of the bolt nut with 2 to 2 1/2 threads protruding above the nut top.

e) After the grout has cured, the quality of grouting will be checked by tapping around the top deck plate of the skid.

f) A solid thud sound indicates a good grout area and a drum like hollow drum like sound indicates a void portion which requires repairing.

g) Acceptance Criteria for checking voids is a solid thud sound. (HOLD POINT)h) Paint the top surface of the grout with compatible paint non-skid protective

coating for oil and weather resistant.

Note:In case voids or drum like sound is noted, mark the portion and repair according to grouting vendor’s recommendation. (See attached – Method of repair for voids on baseplate.)

9.0 Installation of pump and motor on the baseplate:

a) Clean the pump and motor mounting pads on the baseplate with grout's manufacturer recommended grout solvent.

b) Clean the underside of the motor and pump feet as well with a anti-corrosion solvent before mounting.

c) For rigging and lifting execution of pump assembly, please refer to METHOD STATEMENT FOR LIFTING OF PUMP SKID

d) Install hold down bolts for pump and motor and snug tight.

10.0 Pre-Alignment check

a) Ensure there is no piping hook up on the pump nozzles or no load strain on the equipment. Install coupling, disengage mech seal locking tabs and remove any packing or blockage material that interferes with shaft rotation during alignment.

b) Provide lubrication for the bearings during rotation.c) Use the pump as reference when checking alignment. No shims are allowed to be

installed under the pump.d) Verify and confirm the distance between shaft ends (DBSE) with a micrometer

and coupling manufacturer’s recommendation. Take note of motor magnetic center if applicable.


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e) Prepare lifting equipment or hydraulic jack to elevate or move the motor assembly to safely install shims, if jack bolts are not provided.

f) The maximum allowable number of shims under equipment support foot is five (5).The minimum height per shim stack is 3mm and up to a maximum of 12mm. Only one 3 mm or thicker shim is allowed per foot. And shims thinner than 0.05 mm should not be used.

g) Use torque wrench to tighten the hold down bolts equally. Use either vendor's recommended values or API 686 - Chapter 7 Appendix E.

h) Set up the Laser Alignment Equipment.i) Measure Motor Soft Foot and then Shaft Angularity (Face) and Offset (Rim),

adjust accordingly to alignment specification. For soft foot measurement, dial indicator can also be used.

j) After getting the final pre-alignment reading of shafts offset and angularity and soft foot record the reading in the Pump Alignment Report and call for inspection

k) Acceptance Criteria for Shaft Face & Rim Alignment = < 0.05mm (HOLD POINT)

l) Acceptance Criteria for Soft Foot = < 0.05mm at each foot (HOLD POINT)m) Sign off the Pump Alignment Report (for Pre-Alignment) for acceptance.

11.0 Motor solo run test (By electrical group)

a) Confirm the coupling is disconnected from the motor & pump shaft.

b) Ensure Lock tag is removed and replace with No Load Test Tag.

c) Perform Megger check.

d) Provide proper barricade and signboard at the field site.

e) Check and record the motor test data.

f) Conduct motor rotation check

g) Proceed with motor solo run test. Appointed client’s personnel to give the go ahead to energize the power.

h) Record the required reading every 30 minutes (refer to inspection form)

i) Criteria for Bearing Temp = < 60°C & Bearing Vibration = < 2.5mm/s rms(HOLD POINT)


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j) Sign off the Motor Solo Run Test Report for acceptance.

k) After Motor Solo Run Test, must place the tag again for the act of other work interception on the motor.

12.0 Pipe strain measurement

12.1 Pump nozzle and mating flange alignment check

a) Install pump suction and discharge lines to the pump skid.b) Check flange pipe flange holes area correctly lined up with the pump nozzle bolt

holes (suction and discharge) to ensure and permit bolt insertions without applying any external force.

c) Acceptance Criteria for Bolt Hole Off Center = Max 1.5mm Offset - (HOLD POINT)

d) Check and verify pump and piping flange faces (suction & discharge) parallel.

e) Acceptance Criteria for Flange Face Parallelism: (HOLD POINT)Flanges O.D. < 250 mm, Gap Diff Less Than 0.250 mmFlanges of Other O.D. = 0.001 mm / mm of Flange OD, Gap Diff up to 0.750 mm

f) Check the flange face separation or gap between the piping flange nozzle flange face and pump face (suction & discharge) by using filler gauge. Reading will be taken at least 90° apart on the raised face of the flange.

g) Criteria for Flange Face Separation = ±1.5mm plus Gasket thickness - (HOLD POINT)

h) Record the reading using the Pipe Stress Check Form and call for inspection. (HOLD POINT)

12.2 Pipe stress check.

a) Set the dial indicators on the opposite machine to measure the coupling hub for vertical and horizontal movements as the pipe flange bolts are tightened using torque wrench.

b) Bolt-up the suction spool flange (larger flange) first to the pump nozzle completely. Snug tight bolts in sequence (10% of total torque value), then set to


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30% of total torque and tighten. If dial indicators movement is within the allowable tolerance, proceed to full tightening to 100% of the final total torque.

c) Apply the same method to discharge spool.

d) Record the reading using the Final Pump Alignment Inspection Form and call for inspection.

e) Criteria for Shaft Movement in either Vertical or Horizontal directions = < 0.05mm (HOLD POINT)

f) Record the reading using the Pump Final Alignment Report and call for inspection (HOLD POINT) for acceptance.

Note:

1. Pipe stress shall be checked while all piping connections are connected including the Lube Oil, Cooling Water and all auxiliary piping.

2. If flange face gap / clearance and bolt holes were out of alignment based on the acceptance criteria, adjustment can be done by on the pipe supports and repeat again the same sequence. If adjustment still cannot be done, pipe spools to be removed for rectification.

13.0 Piping Hydro test (By Piping group)

a) Piping hydrotest shall not be done through any type of machinery including vertical and horizontal pumps. Separate hydrotest blinds shall be installed or the inlet and outlet piping spools shall be removed to isolate the machinery during hydrotest.

b) Conduct piping hydrotest as per requirement S-000 1670-0004V, Piping Erection, Testing, Flushing & Cleaning.

14.0 Final alignment check & Inspection

14-1. Final alignment check list.

a) Suction & discharge lines connected to equipment nozzles were hydrotested and water is entirely drain out from the system.

b) Suction line strainer is installed and witnessed by Client.c) All temporary supports such as chain blocks, wedges, etc and test blinds were

completely removed and designed pipe supports are correctly installed.


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d) Correct bolts & nuts and gaskets are in place free from any damage.e) Ensure spring supports set at cold load setting, no clearance in between or no

bottomed or topped out.f) All piping connections to the unit must be disconnected and free from any stress

or movement.g) Verify pipe flange bolt holes should be lined up with pump nozzle bolt holes,

piping and pump nozzle flange faces are parallel and flange face separation within gasket spacing are within tolerable to ensure alignment.

h) Spring hanger and spring support stops or gag must be in place and in cold position to prevent any spring function during the piping alignment check. Adjusting of spring tension of spring hangers / supports to achieve piping alignment is not allowed.

14-2. DBSE (Distance between shaft ends) Check

a) Check the actual distance between shaft end (DBSE) using internal micrometer and record the reading. (as per coupling drawing)

b) Confirm the coupling dimension.c) After getting the distance between shaft end and the coupling length, record the

readings using the Pump Alignment Report form and call for inspection.d) Acceptance Criteria for DBSE (HOLD POINT)Flexible Element Coupling = ±0.25mm (Unless a closer tolerance is specified by mfgr)

Gear or Elastometric Coupling = ±0.75mm (Unless a closer tolerance is specified by mfgr)

Spacer Coupling = Spacer free length used to set the spacer gap length.

Motor Magnetic should be located when setting the axial alignment.

14-3. Final shaft alignment / & Soft foot check

a) Set the Laser Alignment Equipment and check the final shaft face and rim alignment.

b) Any horizontal or vertical adjustment on the movable equipment will be made depending on the laser beam reading prior to achieve the acceptance criteria. Concurrently softfoot checking will be done accordingly.

c) After getting the final alignment reading of shafts offset and angulariy including soft foot, record the reading using the Pump Final Alignment Report form and call for inspection.

d) Acceptance Criteria for Shaft Face & Rim Final Alignment = < 0.05 mm (HOLD POINT)

e) For Soft foot checking, Dial Indicator will be used.


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f) Acceptance Criteria for Soft Foot = < 0.05mm at each foot (HOLD POINT)g) Record the reading using the Pump Alignment Report and call for inspection

(HOLD POINT).h) Install the coupling guard

15.0 Summary of hold points & acceptance criteria:

# Base Plate Levelness < 0.20 mm/m (HOLD POINT) - API 610 Pumps# Base Plate Levelness < 0.40 mm/m (HOLD POINT) - General Purpose or

ASME/ANSI Pumps

# Elevation : Elevation +/- 5.0 mm

# Expansion Joints : Placed at 1.4 to 2.8 m intervals

# Skid Grouting Check: Solid Thud Sound

# Motor Solo Run Test: Bearing Temp = <60°C Vibration =<2.5mm/s

# DBSE Tolerances: Flexible Element Couplings - +/- 0.25mm

Spacer Couplig: Spacer free length used to set the spacer gap length

Gear or Elastometeric Coupling : +/- 0.75mm

Coupling Runout Radial & Face = <0.05mm T.I.R.

# Piping Alignment : Bolt Hole Offset = Max. 1.5mm

Flanges O.D. < 250 mm, Gap Diff Less Than 0.250 mmFlanges of Other O.D. = 0.001 mm / mm of Flange OD,

Gap Diff up to 0.750 mm Flange Face Gap = ± 1.5mm plus Gasket Thickness Pipe Stress Check in Vertical & Horizontal = <0.05mm


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# Shaft Alignment: Face & Rim Alignment : Face (Angularity) Not More Than 0.03 degreeFace (Angularity) Equivalent to 0.05 mm / 100 mm of Face DiameterRim (Offset) Not More Than 0.02 mm

Reverse Rim Alignment :0.50 mm / meter (distance between indicators) at both indicator locationsEquivalent to 0.50 mm / 1000 mmEquivalent to 0.05mm / 100 mmPump & Motor Soft Foot Check = <0.05mm

16.0 Proposed inspection schedule:

Base Plate Levelness Check - TBA Pump Skid Grouting Check - TBA Pre-alignment of Pump and Motor -TBA Motor Solo Run Test -TBA Piping Hydro Test -TBA Pipe Stress / Flange Parallelism Check -TBA Final Alignment of Shaft Angularity & Off Set Check -TBA


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17.0 Attachments:

1 - Method Statement for Lifting of Pump Skid

2 - Pump Gen. Assembly & Foundation Drawing

3 - Grouting Material MSDS and Instructions - By Civil Group

4 - Method of Repair for Voids on Baseplate - By Civil Group

5 - Inspection Forms: Baseplate Level & Elevation Report,Piping Alignment (Pipe Stress / Flange Parallelism) Data ReportAlignment Report

6 - API 686 - Chapter 5 Appendix A - Anchor Bolt Torque Table

7 - API 686 - Chapter 7 Appendix E - Hold Down Bolts Torque

8 - Flowchart of Pump Installation Process


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18.0 Installation flowchart


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19.0 Diagrams of baseplates


Date post:	21-Dec-2015
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