MS for Rotary Equipment

PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Package A1: OLEFINS PLANT Rev.A METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 Method Statement For Rotary Equipment Installation SUBCONTRACT DOCUMENT REVIEW Long Son Petrochemicals Co., Ltd REVISE AND RESUBMIT PROJ PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM TỔ HỢP HÓA DẦU MIỀN NAM VIỆT NAM TO BE ISSUED AS FINAL PROVIDED COMMENTS ARE INCORPORATED CLIENT: Long Son Petrochemicals Co., Ltd NO COMMENT – FINAL ISSUE SUBCONTRACT No 036909C-1000-CS-13000011 FOR INFORMATION ONLY (INTERNAL USE) U.O.: TPSK Consortium ITEM: Maurizio Liburdi 2020.08.20 10:50:26 DATE: +07'00' BY: A REV 06/08/2020 DATE MOHD SAIFUL 2020.08.12 15:08:42 +08'00' ISSUE FOR APPROVAL REV.STATUS H.N.TIN PREPARED BY T.V.NHAT CHECKED BY H.V.DUC APPROVED BY P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 DOCUMENT INFORMATION The following required information is minimum requirement which need to be updated each time the document is changed Creation by Review Frequency File Name List of Qualified Approvers Locations of Controlled Copies  Master Document  Copied Document (E-file) Management of Changes Related Documents : LILAMA Corporation : When new revision issue : MS for Static Equipment Installation : Project Manager : ☐CV ☐CO ☒CM ☐CE ☐EE ☐EM ☐ES ☐FT ☐HR ☐IE ☐IF ☐IT ☐MR ☐MS ☐PE ☐PL ☐PM ☐QM ☐CV ☐CO ☒CM ☐CE ☐EE ☐EM ☐ES ☐FT ☐HR ☐IE ☐IF ☐IT ☐MR ☐MS ☐PE ☐PL ☐PM ☒QM : ☐ Internal (MOC No.) : ☐ External (Project Correspondence No.) : ☐ New Issue Document Number ☐DC ☐FF ☒MP ☐PC ☒DC ☐FF ☒MP ☐PC Document Title P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 INDEX PURPOSE AND SCOPE OF WORK ABBREVIATION REFERENCE AND SPECIFICATIONS SITE ORGANIZATION CHART MOBILIZATION MANPOWER & EQUIPMENT GENERAL EQUIPMENT INSTALLATION 10 ASSEMBLY OF ACCESSORIES 17 INSPECTION AND TESTING 17 10 QUALITY CONTROL 17 11 PRESERVATION METHOD 17 P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 REVISION LOG Rev A Revised Detail Date (dd/mm/yyyy) 06/08/2020 Item All Page All Article All Description Issue for Review P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 PURPOSE AND SCOPE OF WORK 1.1 PURPOSE This method statement is to establish the requirements for installation of static equipment for Long Son Petrochemical (LSP) meeting the requirement of the project related Technical specifications and Standards to ensure the quality of the work 1.2 SCOPE OF WORK The scope of work: static equipment installation such as tower, vessel, heat exchanger & the other facilities etc … which below than 40 tons within Lilama scope of work (2E, 2D & 0S area) as plot plant below P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 - METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 ABBREVIATION - Rev.A Package A1: OLEFINS PLANT OWNER : CONTRACTOR : SUBCONTRACTOR : Long Son Petrochemicals Company Limited TPSK Consortium LILAMA Corporation REFERENCE AND SPECIFICATIONS / Tài liệu tham khảo tiêu chuẩn - OL1-2M92 -0001-A : Technical spectification for mechanical erection - 036909C-1000-MS-6893-0052_A : Job spectification for mechanical inspection - AXC8-007: Construction Specification for Equipment Installation SITE ORGANIZATION CHART  PROJECT ORGANIZATION CHART – TPSK Construction Manager Mr Kris Choi Email : kris.choi@sk.com Tel :0917381669 Safety Manager Mr YOGARAJAH QA/QC Manager MR Marco Carosi Mail : Mail : marco.carosi@technipfmc.com Tel : 093 3703384 Mech/STLSTR Manager MR Astin Choi yogarajah.thurairajah@tec hnipfmc.com Tel : 0933703326 Mail : hoony1757@sk.com Tel : 0933703408 P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 MOBILIZATION MANPOWER & EQUIPMENT  Mobilization Manpower  Mobilization Equipment P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 GENERAL 6.1 Supplier’s Erection Manual - All equipment shall be erected according to the supplier’s instruction manuals for installation, alignment, tolerances, tightening sequences, torque limits, lifting method and other details of a technical nature Lifting plan, JSA, risk assessment - When the approved Vendor's installation manual specifies the tolerance, the tolerance specified in the manual shall supersede to the tolerance specified in this specification 6.1 Cleaning 6.1.2 Every precaution shall be taken to prevent foreign matters such as sand, soil, clay and insulation materials, from entering the equipment during all phases of the installation work 6.1.3 All equipment nozzles prior to connection to piping systems shall be covered with proper methods to prevent foreign materials from entering into the equipment 6.1.4 Cleaning of the equipment shall be done in accordance with the supplier's instructions 6.2 Lubrication 6.2.2 All the necessary lubrication to the equipment (bearing, sliding parts, etc.) shall be done in accordance with supplier's instructions All the machined surfaces shall be protected with grease where required 6.2.3 All bolts connection used throughout the size for all applications are to have suitable antisize applied to the threads 6.3 Protection of Facilities 6.3.2 Concrete floors and other concrete surfaces shall be protected from grouting, scratching, straining and other damage Damaged section shall be repaired, removed and replaced 6.3.3 Floor grating and stair threads shall be protected against damage from heavy loads, movement of equipment and material, flame cutting, and welding, etc 6.3.4 Glass components, such as gauges or other fragile components shall be protected during the construction period with plywood enclosures or other means satisfactorily Gauges etc should be installed after the installation of the equipment is complete 6.3.5 Machine finished surfaces, polished external surfaces, or other bare metal surfaces which are not to be painted, such as machinery shafts and coupling, shall be provided with temporary protection during storage 6.4 Anchor Bolt and Embedded Material Installation 6.4.2 If required, field engineer will be made templates to install the anchor bolt 6.4.3 Prior to installation of any equipment there shall be a formal “hand-over” inspection of the civil works from the civil works contractor to the erection contractor 6.4.4 The location for anchor bolt and embedded material shall be designated on the X and Y P a g e | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 coordinates by survey team 6.4.5 Based on the appointed coordinates, install the respective anchor bolt template as per each foundation At this time, proper support shall be installed to avoid from un-necessary movements 6.4.6 The installed anchor bolts shall be inspected the location and elevation after alignment and fixed them on designated location as follows tolerance 6.4.7 The installed embedded materials shall be inspected the location and elevation after fixed them on designated location as per the relative drawings with ± 5mm tolerances or the supplier’s requirements 6.4.8 Before concrete pouring, the thread part of anchor bolts shall be wrapped with vinyl tape to prevent them from exposure with possible contaminants 6.4.9 After concrete pouring and curing, field engineer shall be re-inspected its final location 6.5 Alignment Alignment pump will be follow by step as per para 7.5 6.6 Welding / Hàn Welding as tape and plump a part of the installation of the equipment shall be done according to the supplier's drawing instructions and the related project welding procedure 6.7 Expansion Anchor Installation of expansion anchor shall be performed in accordance with vendor instruction if require EQUIPMENT INSTALLATION 7.1 Execution of work The sequence of constructing for Static Equipment will be in compliance with the chart as following: 7.1 Material handling and lifting Material received from TPSK warehouse or Vendor P a g e 10 | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Rev.A Contract No : LSP – CA – 136 Material handling and lifting requirement for equipment accordance with project documentation Liftting and transportation for equipment 7.2 Foundation work / Cơng tác móng bê tơng Foundations shall be checked before installation of equipment or materials for the following items     Curing period of foundation concrete Dimensions Position (center marking) and height (level marking) Size of anchor bolts, and damage or rust of threaded parts  Dimension and cleanliness of anchor boxes, if anchor box type is applied Center line marking and level marking of foundation or structural steel shall be checked prior to commencement of works Major dimensions and position of anchor bolts or anchor pockets shall be checked Center and alignment of anchor bolts shall be within the following tolerance: ITEM TOLERANCE Level ±3 mm Position ±3 mm Treatment for the surface of the foundation, such as chipping and fitting, shall be carried out in consideration of following points:  Remove foreign materials especially oil and rust  Chipping the surface to remove laitance, to give good adhesion and to avoidcracking, peeling off, etc., of grouting mortar P a g e 11 | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136  Chipping the surface by small tool or hand tool only Heavy pneumatic or electrical tool is prohibited for protecting concrete foundation cracking When the equipment is installed on structural steel, the contact surface of structural steel to equipment base plate shall be checked and confirmed free from foreign materials In case that it fouls on welded joint of structural steel, the structure member shall be replaced or position of welded joint shall be relocated 7.3 Installation of Liners or Leveling Pad Plate  In general, liners to be used shall be made of carbon steel, and shim plates shall be made of anti-corrosive material Material of liners shall be ASTM A36 or equivalent  Liners shall be provided on both sides of anchor bolt basically  In general, the spacing between liners shall not exceed 500mm If the spacing exceeds 500mm, an additional liner shall be added between the liners  The liner plate position shall be decided considering uniform load to the foundation The liner plates shall be generally placed as near as practicable to each anchor bolt In case the anchor bolts are apart each other, additional liners shall be properly employed among them  Maximum Allowable Stress of liners shall be 60kg/cm2 If this is exceeded, either the width or number of liners or both shall be increased The allowable stress shall be calculated in accordance with the following equation Sa = W/NLB Where, Sa: Allowable stress of liners (kg/cm2) W: Equipment erection weight (kg) N: Number of liners L: Width of base plate of equipment (cm) B: Width of liner (cm) Note: In general, one set of liners shall consist of pieces of taper liners and one piece of straight liners 0.3t using only straight liners is permissible, if possible  The Liners shall be protruded minimum 10mm out of the width of the equipment’s base plate (inside and outside of base plate)  Thickness of liners shall be minimum 10mm  The area to be grout shall be extended beyond the base plate minimum 50mm (inside and outside of base plate)  Thickness of the grout shall be minimum 30mm  The following liner plates made of carbon steel shall be generally used: P a g e 12 | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 DIMENSION (MM) APPLICATION Length x Width x Thickness 150 x 70 x t Small size equipment 200 x 100 x t Medium size equipment 300 x 100 x t Heavy size equipment  The surface of liners shall be entirely cleaned from oil and the like prior to the installation  When placing of liners both sides of anchor bolts is not possible due to limited space between anchor bolts, a liner shall be placed at the center of neighboring anchor bolts  Where the liners are used in multi-layers, they shall be tack welded to each other after completion of alignment of the equipment  Shim plates placed on flat liners for alignment of very small adjustment shall be less than mm thickness for one shim plate  When the equipment is installed on structural steel, elevation of top surface of structural steel shall be adjusted using liners or shim plates, if required 7.4 Equipment installation - Prior to the erection of the equipment, the following points shall be checked and confirmed: + Distinct marking for alignment on the equipment and foundation + Orientation marking on the equipment and foundation + The top of foundations shall take into consideration the grouting height as indicated on equipment of foundation drawing + Cleaning of the bottom of equipment base plate + Complete cleanliness from foreign matters on the chipped foundation + Proper cleanliness of anchor bolt / nut + Setting of sliding plate for horizontal equipment if applicable - In case where weld type washers are to be welder to the base plate after completion of the alignment inspection, it shall be confirm before welding that the anchor bolts are properly tightened, then washers shall be welded according to the drawings - All flanges shall be protected from rust and damage by placing suitable flange corrosion protection media in accordance with specification “Equipment Protection during construction” over the raised face portion and P a g e 13 | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Package A1: OLEFINS PLANT Rev.A METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 held in position with a temporary blind - In case equipment to be installed on Steel Structure, after equipment is placed on steel structure, if there is any gap between the bottom face of equipment base plate and the surface of steel structure with the anchor nuts loose, the gap shall be filled by inserting appropriate thick liners In the case, liners shall be welded into a single body with the structure - Installation and alignment of pump shall generally be carried out in the order as follows: + Place pump with base on the liners and set anchor bolts + Align provisionally the pump base + Fix the anchor bolts by pouring mortar into anchor pockets + Set permanent liners as near as to and both sides of each anchor bolt, after the mortar has cured + Remove temporary liners + Tighten anchor bolts + Align the pump and driver and tighten hold-down bolts + Grout the base plate + Connect piping systems + Check the final' alignment of the pump and driver, couple the shafts between pump and drive - Coupling alignment + The first coupling alignment has to be performed prior to installing the pipe in order to be able to correctly interpret possible changes in the alignment duringpipe installation And final inspection alignment after complete conection pipe + The alignment of the pump shall be carried out on the basis of the finishedmetal surfaces being as near as possible to the center of the shaft + Parallel deviation and angular deviation of the driving and driven shafts shall be individually measured + Where dial gauge is fixed on arm with a magnetic base, the following precautions shall be taken for decreasing errors caused by change of measure points: 1) Fix firmly 2) Shorten the arm length as much as possible P a g e 14 | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A 3) Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 Use small type dial gauge (light weight) 4) Put measuring point of the dial gauge at right-angle to the shaft, pointing to the center of the shaft + When the off-set figures are specified by the Vendor, the alignment shall be performed incorporating the off-set into the tolerance + After completion of alignment, it shall be confirmed that the shaft can be rotate smoothly by hand 7.5 Alignment Equipment shall be aligned within the following tolerances and the results shall be recorded according to ITP Unless otherwise specified, alignment shall be performed using a lifting device with either liners or shim plates used, as necessary Alignment of the pump base shall be carried out as follows, unless otherwise specified: - Tolerance shall be as in the following table: + Elevation of finished surface of base plate shall be measured on the basis of the level marking on the foundation + Position of the pump center, marked on the base frame, shall be measured on the basis of the center marking of the foundation + For measuring of the Perpendicularity or level, the finished surface of the base frame shall be the basis - Alignment of the shafts shall be carried out within the tolerance as following, unless otherwise specified: + Tolerance for parallel deflection of shafts shall not exceed 0.03 mm + Tolerance for angular deflection of shafts shall not exceed 0.03 mm - Method of the alignment is as follows: + Fix two dial indicators on the shaft 2, so that one of their tips comes in contact with the circumference of shaft 1, another with the face of shaft The two contact points on shaft shall be as near as possible to each other, see Fig.1 P a g e 15 | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 + Turn shaft fully once, and check fluctuation in tip contact + Set the scales of two dial indicators to zero at the top point of shaft + Turn shaft slowly through 360°, and read indications of the two dial indicators at every 90° - Distance between the couplings shall be confirmed to meet the dimension specified in the drawings, after the shafts are set to the base lines 7.6 Shim Plates In case the alignment is carried out without taper liners, shim plates may be used between the pad plates and the base plate Materials for shim plates shall be made of stainless steel and the width and length of the shim plates shall be the same as the liners The number of the shim used on any hold down bolt shall be minimized width utilizing of suitable thickness of shims 7.7 Grouting Before grouting, Concrete foundation should be fully cured at least days prior to surface preparation Soak with water minimum 12 hours prior to grouting and remove water to thin film For epoxy grout, the surface shall be completely dry In case drain pipe, oil exhaust pipe, etc are buried in the grouting, necessary countermeasures shall be taken into consideration not to clog up the pipes The non-shrink cement shall be poured into the gap between equipment and foundation Grout mortar shall be poured not to form any air pocket Vent tubes shall be provided to prevent air pocket forming, when required The extent of application, mixing ratio, etc for use of non-shrink cement or epoxy grout material shall be in accordance with the Vendor's installation manual Before grouting, anchor bolts shall be cleaned from oil, where in contact with grout, and also anchor pockets shall be cleaned from water and foreign materials Anchor bolts threaded portion shall be protected with a sleeve or temporary tape rapping prior to grouting P a g e 16 | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 ASSEMBLY OF ACCESSORIES / Lắp đặt phụ kiện 8.1 Assembly work of platforms, staircases, etc shall be carried out in acccordance with the following: - Prior to the assembly work, the accessories shall be checked for quantity, damage, deformation, etc in accordance with the relevant drawings and/or parts list - With regard to the assembly work of the platforms, it shall be started from the brackets installation The final tightening of bolts and nuts shall be carried out after the complete adjustment 8.2 Handling of attached auxiliary equipment piping as well as instrumentation shall be as follows: - Where such apparatus are to be attached to equipment, care shall be taken to avoid damaging it or the equipment and flange face in the course of assembling and installation - Attached piping and instruments shall be installed as per Vendor's instructions INSPECTION AND TESTING All concerned inspection & testing shall be performed in accordance with Inspection & Testing Plan and recorded the related inspection report 10 QUALITY CONTROL All inspection items, forms and instruction are described in the “Quality Control Plan for Site Activities” and quality control shall be carried out thoroughly in accordance with Quality Control Plan 11 PRESERVATION METHOD When subcontractors receive equipment and accessories from TPSK warehouse for installation work Subcontractors have to check to ensure that equipment and accessories are in good condition And also protected against rusting/ deterioration and accumulate dust Equipment are transported to site if equipment not install immediately, theywill put on the leveled area with good drainage and use timber or wooden bar to isolate equipment from ground All nozzles, dial gauges and P a g e 17 | 18 PETROCHEMICAL COMPLEX IN SOUTH OF VIETNAM Long Son Petrochemicals Co., Ltd Doc.No.: OL1-2D31-001076 Rev.A Package A1: OLEFINS PLANT METHOD STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 connected flanges have been covered, machined surface has been greased and covered After installation, subcontractors have to inspectand maintain equipment periodically follow Manufacturer’s or Vendor’s recommendation P a g e 18 | 18 ... and transportation for equipment 7.2 Foundation work / Công tác móng bê tơng Foundations shall be checked before installation of equipment or materials for the following items     Curing period... issue : MS for Static Equipment Installation : Project Manager : ☐CV ☐CO ☒CM ☐CE ☐EE ☐EM ☐ES ☐FT ☐HR ☐IE ☐IF ☐IT ☐MR ? ?MS ☐PE ☐PL ☐PM ☐QM ☐CV ☐CO ☒CM ☐CE ☐EE ☐EM ☐ES ☐FT ☐HR ☐IE ☐IF ☐IT ☐MR ? ?MS ☐PE... STATEMENT FOR ROTARY EQUIPMENT INSTALLATION Contract No : LSP – CA – 136 PURPOSE AND SCOPE OF WORK 1.1 PURPOSE This method statement is to establish the requirements for installation of static equipment