KALTIM – 5 PROJECT

2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 1 of 15

OWNER :: PT. PUPUK KALTIM

CONTRACTOR : PT. INTI KARYA PERSADA TEHNIK –

TOYO ENGINEERING CORPORATION

PROJECT TITLE : KALTIM – 5 PROJECT

PROJECT LOCATION : BONTANG, EAST KALIMANTAN, INDONESIA

PROJECT NO. : 10107 / BA096300 / 11-018-01

REV. DATE DESCRIPTION PREP’D BY CHK’D BY APPROVED BY

0A 12/02/2011 FOR INQUIRY AST PGH/DS US

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 2 of 15

REVISION CONTROL SHEET

REV. NO. DATE DESCRIPTION

0 12/02/2011 For Inquiry

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 3 of 15

TABLE OF CONTENT

Page ........................................................................................... Error! Bookmark not defined.

1. GENERAL ...................................................................................................................... 4
2. REFERENCE DOCUMENT ............................................................................................ 4
3. EQUIPMENT CHECKING, IDENTIFICATION & PROTECTION ..................................... 4
3.1. Item to be checked...............................................................................................4
3.2. Preservation activity........................................................................................... 5
4. PRESETTING………………………………………………………………………………….. .. 5
4.1. Foundation Check............................................................................................... 5
4.2. Chipping Foundation.......................................................................................... 6
4.3. Cleaning Foundation........................................................................................... 6
4.4. Liners and Shim Plates....................................................................................... 6
5. EQUIPMENT INSTALL & SETTING ............................................................................... 9
5.1. Rigging and Transportation Study.................................................................... 9
5.2. Equipment Lifting................................................................................................ 9
5.3. Alignment.............................................................................................................10
5.4. Grouting.............................................................................................................. 12
5.5. Install Platform & Ladder.................................................................................. 14
5.6. Internal Cleaning............................................................................................... 14
5.7. Internal Part Installation................................................................................... 15
5.8. Install Davit........................................................................................................ 15
6. FINALIZATION ............................................................................................................. 15
7. INSPECTION ................................................................................................................ 15
7.1. Inspection Plan................................................................................................. . 15

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 4 of 15

1. GENERAL

This procedure consists of general mechanical work procedure for static equipment
installation for KALTIM - 5 PROJECT in Bontang, East Kalimantan as specified in cover
sheet.

Within the content of this procedure, the following definitions are used:

“OWNER” means PT. PUPUK KALTIM

“CONTRACTOR” means PT INTI KARYA PERSADA TEHNIK

“SUBCONTRACTOR” refers to the party, which perform the duties specified by the
“CONTRACTOR” for completing the “Work”.

“STATIC EQUIPMENT" means Column, Vertical and Horizontal Vessel, Shell and Tube
Heat Exchanger, Plate and Frame Heat Exchanger, Air Fin Cooler, and Shop
Fabricated Tanks. Unless otherwise listed, shall refer to typical function of the aforesaid
equipment

2. REFERENCE DOCUMENT

Reference documents shall be used as apart of this procedure are:

2.1. Project Specification

2.2. Vendor Instruction Manual including relevant drawings (hereinafter called “Technical
Data Book”).
2.3. DP-CON-MEC-001 (Field Work Matrix & Quality Plan).
2.4. DP-CON-MEC-II-006 (Static Equipment Installation Work Flow)

Should there be any conflict between the information supplied in the documents,
subcontractor shall notify IKPT, and obtain clarification on the points in question and IKPT
shall obtain CLIENT approval.

3. EQUIPMENT CHECKING, IDENTIFICATION & PROTECTION

Equipment or material have just arrive on site shall be checked for some considering items;

3.1. Item to be checked

Check actual equipment and/or material's arrived dimension, weight, quantity and
specification compare to packing list and engineering / vendor document.

Check quality of equipment and / or material's for damage or loose.

Check whether shop fabrication, transportation protection and preservation for
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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 5 of 15

equipment are in well done condition.

3.2. Preservation activity

Equipment and/or material's protection and preservation shall be done before
installation until release for commissioning. These activities shall include, but not limited
to:

To protect any particle get inside nozzle, covering nozzle with temporary blind.

Allocate and secure all fragile and loose instrument materials.

Allocate and secure sight glass or level glass to protect from broke and loss.

Secure area or barricade if needed.

Protect equipment or materials from weather by waterproof cover material.

Check that inert gas purged equipment (Nitrogen) still has the required pressure
applied if any. Report failures to CONTRACTOR for corrective action. The
equipment shall remain sealed unless otherwise instructed by CONTRACTOR.

4. PRESETTING

Presetting Work consists of some activities as bellows:

4.1. Foundation Check

The following condition of the concrete foundation shall be checked against the relevant
drawings:

4.1.1 Concrete Foundation

The following condition of the concrete foundation or structural steel shall be
checked against the relevant drawings:

a) Whether centreline is marked.

b) Accuracy of height and whether elevation lines are marked.

c) Dimension.

The top of the concrete foundation shall lower than the finished height by the
grout thickness indicated on the foundation drawings.

Flatness and level shall be checked at the points where pad and/or liners are
to be installed.

4.1.2 Anchor Bolts

The following condition of the anchor bolts embedded in the foundation shall
be checked the drawings:

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 6 of 15

a) Position
Tolerance shall be +1.5 mm from the dimension indicated on the related
equipment drawings, unless otherwise specified.

b) Projection
The projection of the bolts above the foundation surface shall be of
proper length relative to the final level of the foundation finish.

c) Condition of Bolts
Threaded parts shall be completely coated with grease or machine oil
allowing the nut to be unscrewed smoothly.

If discrepancy with drawing occurs, report to CONTRACTOR immediately for

further action

4.2. Chipping Foundation

The foundation surface shall be chipped and roughened.

Chipping is to make the surface of top concrete become rough by power tools/hand
tools.

Rough surface is required to allow grouting material evenly bonding to foundation, in
order to have good adhesion, to avoid cracking and peeling off.

Chipping depth minimum 25mm, or until aggregate appearance.

4.3. Cleaning Foundation

After chipping completed, clean the foundation surface by water and then use air
compressor to remove the weak upper layer of the concrete, damaged concrete,
any oil-soaked concrete, any loose material and also to get dry surface.
The concrete surface shall be soaked with clean water for 24 hours, unless the
grout manufacture specifies otherwise, before grouting commences.

When the equipment is installed on the structural steel, the contact surface of
structural steel to the equipment base plate shall be checked and confirmed free
from foreign materials. If it fouls on the welded joint of structural steel, welding
reinforcement shall be ground off flush.

4.4. Liners and Shim Plates

4.4.1. In general, liners and shim plate to be used might be made of JIS G 3101
SS400 or ASTM A36 when embedded on the grouting, unless otherwise

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 7 of 15

specified. However, shim plates made of brass shall not be used for ammonia
or acid service equipment, unit or area.
4.4.2. Dimension of liners shall be as per table 4.4.2.

Thickness of liner 12 mm
Width of liner 75 mm
Length of Liner 150 mm or 20 to 40 mm longer than width of
base plate of equipment.
Gradient of Wedge Liner 1/30 – 1/40

4.4.3. Liners shall be arranged that the load of the equipment is uniformly and exactly
distribute to the foundation. Liners shall be placed as near as possible to and
both side of each anchor bolt. See fig. 4.4.3.

4.4.4. The allowable stress on liner contact are on the concrete shall be 40 kgf/cm2
(392N/cm2). The common practice load calculation shall be the following
formula:

W
A≡
N .L.B

Where:
A = Stress (kgf/cm2) or (N/cm2)
N = Number of Liner
L = Length of liner (cm)
B = Width of liner (cm)
W = Erection load of equipment (kgf) or (N).

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 8 of 15

4.4.5. 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 centre of neigh
boring anchor bolts.
4.4.6. Distance between liners shall be maximum of 600mm for static equipment.
4.4.7. Total number of shim shall be minimized, and in case where only flat liners are
used for alignment, no more than maximum of 5 pieces be used in any stack.
4.4.8. Shim plates placed on flat liner for alignment of small adjustment shall less than
1 mm thickness of one shim plate.
4.4.9. Where liners are used in multi layers, they shall be tack welded to each other
after completion of alignment of equipment.
4.4.10. Surface of straight liner need no machining. Gradient surface of wedge liner
shall be finished smoothly by machining. All corners of liner shall be rounded.
4.4.11. Wedge liners shall be set as per fig. 4.4.11.

4.4.12. When the equipment is installed on structural steel, elevation of top surface of
structural steel shall be adjusted using liner or shim plate, if required.
4.4.13. In case of anchor box type foundation, temporary liner shall be placed near to
anchor boxes. After grouting of anchor boxes and curing, permanent liners shall
be placed as near as possible to anchor bolts and temporary liners shall be
removed.
4.4.14. Liners material shall be JIS G 3101 SS400 or ASTM A36, unless otherwise
specified.

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 9 of 15

5. EQUIPMENT INSTALL & SETTING

5.1. Rigging and Transportation Study

All equipment as far as practical should be erected as received with a minimum of

re-handling.

Equipment base plate shall be checked against the foundation bolt circle, bolt size,
and projection as soon as the vessel received at site.

Ensure the north orientation has been marked on the equipment at the correct
orientation in order to avoid any deviation between the nozzle orientation and piping
arrangement.

Use proper method for lifting equipment during erection. For reference, please refer
to General Rigging Procedure.

Check and identify equipment lifting facilities.

Check access road from temporary storage yard or warehouse.

Check lifting crane position and ground condition.

Check lifting apparatus ie, shackle, sling, spreader beam condition.

Check lifting equipment and transporter condition.

5.2. Equipment Lifting

Confirm that foundation work have been finished and verified.

Secure lifting/working area by barricade.

For the transportation, lifting, installation, assembling, etc. of the equipment is made
of stainless steel (including stainless steel lined/cladded equipment), the use of
galvanized and/or zinc coated/painted tools and tackle such as, but not limited to
wire sling, stay wire rope, scaffolding, protection wore-net, and it’s stay wire, etc. is
prohibited to contact directly the surface (either outside or inside) of the equipment.

Outside surface of stainless steel equipment shall be washed by fresh water at site
before installation, when the equipment was ocean transportation in bare condition.

Cables and slings are bearing only on the intended lift points and are not
transmitting any loads onto auxiliary piping, instruments, chain guards, and so forth.

Confirm cables & slings are not touching to equipment surfaces directly (apply
proper protection between cables/slings & part surface).

Lift point for individual machinery pieces are not used for lifting machinery skids or
packages.

For base plate or skid mounted machinery, only use lift points on the base plate or
skid.

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 10 of 15

Keep other subcontractor and plant personnel from working under the lift and keep
them safe distance away until the machinery is secured in place on its foundation or
structure.

Timber or pallet are shall be used for laydown (no direct ground contact) on transfer
lifting point.

Equipment orientation compliance to related drawing.

Base plate/skid properly seat on pad.

After the lifted equipment seat on the designated base, the sling shall not
dismounted before the equipment secured properly with it’s mounting bolts.

5.3. Alignment

a. General

All installed equipment shall be aligned for plumbness and/or levels. Towers and
Vertical Vessels shall be aligned for its plumbness and satisfy the requirement.
Horizontal Vessels and Heat Exchangers shall be aligned for its levels and satisfy
the requirement.

b. Plumbness

• Plumbness shall be checked by viewing from two directions 900 apart with a
transit, and from top to bottom of one orientation shall be performed on three (3)
points, The check of plumbness of very tall (>40m) equipment shall be done
early in the morning.

Figure 5.3.b

NORTH
00

315
0

45 0 TOP

0
270 90
0

MIDLE

225 0
135
0
BOTTOM
0
180

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 11 of 15

Out of plumb of any equipment installed shall not exceed 1.0 mm per 1 m of
height or total 30 mm to entire height, whichever is smaller, unless otherwise
specified by manufacturer job specification.

After alignment is finished the lock nuts of the anchor bolts are to be tightened
firmly.

c. Leveling

The leveling shall be made using a spirit level instrument or a transit at four
points based on the center line marked in the equipment in the shop. The level
shall be aligned in the direction of AB or CD and AC or BD at centerline on the
equipment.

Out of level of any equipment installed shall not exceed 1.0 mm per 1 m of long,
unless otherwise specified by manufacturer job specification.

After leveling is finished the lock nuts of the anchor bolts shall be tightened
firmly.

Fig. 5.3.c

d. Loosening Slide Anchor Bolts.

After grouting and connecting of piping to nozzle on equipment have finished,
the nuts of the sliding and anchor bolts shall be loosened to allow for thermal
expansion.

The above requirement shall be applied to horizontal vessel, shell and tube heat
exchanger.

For some equipment, the teflon sliding plates shall be installed between the
bearing plate attached to equipment and equipment base plate in accordance
with manufacturer’s instruction.
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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 12 of 15

5.4. Grouting

a. Grouting Material

Grouting material to be used is Non Shrink Grout unless otherwise specified by

manufacturer.

b. Grouting Preparation

Check that the foundation surface has been chipped and roughened.

To Provide 1800 a part of ½”drain line on the water trap grouting area prior
pouring.

Check that the foundation surface have been blown by air compressor at which it
make clear from any loose material and also get dry surface.

When the equipment is sitting on top of lining plate and the top of grouting
elevation was set, formwork can be started.

Ensure Formwork is tight and waxed. Formwork is sufficiently high to
accommodate head of grout (typically, the elevation to the top of the grout
extends half of the thickness of the soleplate).

Formwork has been sealed to the foundation to prevent leaks (Pour grout
material between foundation-formwork gaps).

The concrete shall be cleaned from pounding water, dirt, grease and other
foreign material.

Ensure the cleanliness at the foundation surface, and then soak that surface with
water prior to pour the grout.

Fig. 5.4.b

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 13 of 15

c. Grout Mixing and Application

The grout mixing shall be performed using concrete mixer or portable mixer.

Make sure to meet the correct mixing ratio between grout material and water in
accordance with manufacturer instruction.

The flow able grout shall be applied and the mixing water content shall follow the
recommendation from the grout manufacturer.

The grout shall be poured from one side (while the vent hole kept in open) until
the whole area required to be grouted is filled and sure there will be no hollow
still remain.

Create vent hole on base plate to flow grouting materials (if needed).

The forming shall be sealed to avoid material grouting flow out.

Precaution for weather prior grouting conduct, provide temporary shelter to keep
the uncured grout being exposed d to rain (during rains weather).

The performance test shall follow to applicable code and standard, which is
specified on the manufacture data.
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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

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d. Curing

After grouting is completed, all foundation and metal surfaces are within the
temperature range of grout material (vendor's recommendation). Add some
water on the grout surface to make it wet or cover by wet gunnysack as
necessary, and let it dry naturally.

Curing period applied shall follow grout Vendor recommendation.

e. Finishing Work

Formwork removed after curing times have been passed, and make sure
grouting surface are smooth, flat and no crack.

Anchor bolts tightened to recommend tightening torque.

Grouting touch up to get finishing surface.

5.5. Install Platform & Ladder

Platforms and Ladders could be mounted, either before or after the installation of the
equipment. However, if these are mounted before installation it shall be confirmed
that those platforms will not affect the erection work activity of equipment itself.

For vertical towers and vessels subject to expansion/contraction, platforms and
ladders shall not be fixed to structural steel. When fixed to structural steel in
accordance with drawing, slot holes of platforms, ladders or nuts shall be confirmed.

Welding slag of platform and ladder shall be completely removed by hammer and
cleaned by mechanical brush.

When handrail is assembled by welding at site, the weld shall be finished flash by
grinding.

Fire blanket shall be provided to protect the painted equipment and platform/ladder
from the spark welding. But, this protection shall not be limited due to others
installed equipment, such electrical, instruments, cables, etc.

Smooth movement and correct position of safety gate (bar) shall be checked and
repaired if required.

Any defect on galvanized platform/ladder/grating, shall be touch up by zinc rich
paint.

Any damage on the painted platform/ladder/equipment shall be re-paired as per
project specification.

5.6. Internal Cleaning

Internal cleaning shall be conducted for ensure there is no debris, dust and rust or other
foreign material left inside equipment.

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 KALTIM – 5 PROJECT
2500 MTPD AMMONIA & 3500 MTPD UREA PLANT

GENERAL PROCEDURE OF Doc. No. : K5-00-C9-CR-001-I

STATIC EQUIPMENT INSTALLATION Job No : 10107 / BA096300 / 11-018-01

Rev. : 0 Page No. : 15 of 15

5.7. Internal Part Installation

Internal parts installation for column/vessel such as trays, internal pipe, packing shall
refers to the procedure, vendor general arrangement drawing and specification.

After completed installation of internal parts, perform internal cleaning, inspection
and manway closure for pressure vessels and columns.

Thorough inspection shall conduct for following items; completeness of internal
parts, dimension of internal parts and clearance, fastened internal parts level and
flatness, tightening torque, water leakage and cleanliness.

5.8. Install Davit

Davit shall be mounted in accordance with drawings.

After mounting of davits, its free movement shall be checked.

6. FINALIZATION
• Inspect for Manhole Gasket against Vendor drawing and specification.
• Close Manhole and Tightening Bolt by Torque wrench as per procedure.

7. INSPECTION

7.1. Inspection Plan

Matrix of Inspection plan is as follow:

NO INSPECTION ITEM S/C CONTRA CLIENT

CTOR
1. Foundation check M W R

2. Chipping and padding M W R

3. Plumbness / levelling M W W

4. Finish Grouting M W R

6. Internal Installation, M W W
Cleaning and boxing up
7 Platform and ladder M W R

Remark:
M = Perform work R = Review
W = Witness

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