Hassan Allam Construction HAC

Quality Management System

Quality Department

Page 1 of 11
Method statement

PROJECT NAME

METHOD STATEMENT FOR

STATIC AND ROTATING EQUIPMENT
INSTALLATION
MS-XXXXX

Rev. Issue Date Prepared by Prepared by Reviewed by Approved by

Technical Office Project Quality
Site Manager Project Manager
Manager Manager

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

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Method statement

Document Revision History

Revision Date Summary of Changes / Details of Issue

TABLE OF CONTENT

1.0 SCOPE.............................................................................................................................................3
2.0 REFERENCES...............................................................................................................................3
3.0 RESPONSIBILITIES.....................................................................................................................3
4.0 RESOURCES..................................................................................................................................4
5.0 EXECUTION METHODOLOGY................................................................................................4
6.0 HSE REQUIREMENTS..............................................................................................................10

7.0 ATTACHMENTS.......................................................................................................11

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

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Method statement

1.0 Scope
This procedure applies to the following but not limited to the items of Equipment listed below.

- Compressor

- Pumps

- Columns

- Vessels/Tanks

- Heaters

- Heat Exchangers

- Air Coolers

- Mixer

- Filters

- Turbines

- Other Static and Rotating Equipment

This procedure shall be understood as guide line where Uhde specification and manufacturer
recommendation, whichever is more stringer, shall take precedence to this procedure.

2.0 References

- Project HSE Plan

- Vendor Documents

- UN9252-01 Part 1: Erection, Vessels, Machinery, Internal

- UN 9253-02 Erection of above ground piping

- UN 9281-02 Part 1: Concrete and reinforced concrete

- HAC-CM-G0O-DC-00028: Material Control Procedure

- API RP 686: Recommended Practices for Machinery Installation and Design.

3.0 Responsibilities

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

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Method statement

3.1 Construction Manager Responsible for all activities.

3.2 HSE Manager Responsible for Safety matters and safety monitoring.

3.3 Equipment Superintendent: Responsible and present during contractor activities under this
method statement.

3.4 Equipment Supervisor: Responsible for the execution of the work under the monitoring of the
Equipment Superintendent.

3.5 Rigging Supervisor: Responsible for all lifting operations and ensures that all lift tackle is fully
tested and approved.

3.6 Q Coordinator. Responsible for all the quality of the work.

3.7 Q Equipment Inspector Responsible for the inspection, monitor and review records in quality
matters to minimize rework and repair works_

3.8 Safety Officers Safety officer required for oversee monitoring of safety during the activities and
will.

4.0 Resources

4.1 Manpower

4.2 Material

4.3 Equipment and Tools

5.0 Execution Methodology

5.1 Equipment Off-loading & handling

- Equipment / Materials shall be off-loaded into the designated storage area or to their final field
location for site inspection for the storage of the equipment, UN 9250-01 "warehousing" shall
apply.

- Vendor data sheets and the relevant IMO/ (Installation Manual and Operating Instruction) shall
be referred for details of any special requirement including precautions to be taken during off-
loading and subsequent handling.

- Off-loading, field receiving inspection and subsequent handling shall be carried out under
directions of the Equipment Supervisor by the Rigging Supervisors and trained
Riggers/Operator

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

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Method statement

- Every effort shall be made to minimize the handling of static equipment prior to installation by
providing adequately sized lay down areas at each site location and considering the delivery
dates against the actual schedule of installation.

- Equipment shall be lifted following the requirement given in the H&S Field Manual.

- Only Vendor approved lifting points shall be used and ensure that the lifting slings are bearing
only the lifting points themselves and not an auxiliary piping and instruments, etc., during all
lifts.

- Upon receipt of equipment Material Controller and store personnel shall carry out inspection for
any missing and damages during transit_ The Material Controller and QC Inspector will report
Overages / Shortages / Damages or non-conformity as per Material Control QCP,

- The equipment orientation upon installation shall be in accordance with the reference drawing.
Dumpy level or water hose shall be used for checking elevation and Total Station shall be used
for checking verticality.

5.2 Preparation of Equipment Foundation

- Foundations to be prepared as per relevant drawings and specification. The Equipment

Supervisor

- QC Inspector check’s location, elevation and orientation of anchor bolts, as per drawings.
Levelling pads reference lines of elevation and axis shall also be checked and clearly marked by
permanent paint marker on foundations prior to installation of vessels by the Surveyor_

- For the dimensional tolerance of foundation and structure, the Data contained in UN 9281-02
Part 1 shall apply for the Dimension tolerance of steel structure the data contained in UN 9281-
03-part 1 section 7 shall apply.

- Specific vendor instructions shall be followed. QC Inspector shall record the details before
releasing the foundation for equipment installation.

- QC will review chipping for grouting and shim levelling, prior to release the foundation for
installation.

- No equipment can be installed on the foundation without the release note duly approved by the
Contractor and the Company.

5.3 Equipment Installation

- Prior to the equipment being installed, the Equipment Supervisor shall re-check levelling plates
I shims. The equipment shall be placed close enough to final elevation for shimming to proceed.

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

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Method statement

The shims shall be evenly spaced under the support ring or skirt and as close as practicable to
the anchor bolts.

- Before installation of equipment a visual check is carried out to ensure that, there are no
damages during transportation to site location. The Equipment Supervisor carries out the visual
check and in case of any damage during transportation from project store to site location,
reporting and handling of damage shall be executed in accordance with Material Control QCP.

- All equipment to be installed at correct orientation and elevations in accordance with applicable
drawings, equipment data sheet and vendor instructions.

- Particular attention shall be given to placement of slings to reduce rubbing against surfaces,
contact pads, nozzle bending, spreader bars used where required, etc_

- Equipment shall be lifted using suitable Cranes including a specific heavy lift plan.

- Shipped loose items (i.e., bolts, gaskets, miscellaneous items, etc.) shall be installed in
accordance with the approved drawings.

- Equipment to be handled using manufacturers recommended lifting points and approved

procedure.

- Items that maybe damaged during installation such as sight glasses, gauges, davits, thermowells,
earthing cables etc., shall be removed and temporarily stored in warehouse. All openings
bearing surfaces and threads shall be protected.

- Equipment that requires dust protection, non-exposure to dust, direct sunrays and moisture shall
be covered and store in closed warehouse. Follow the vendor's storing recommendation.

- Prior to installation of the vessel temporarily seal off all surfaces, cover up and protect including
all projecting parts from damage, dirt and dust excessive humidity and other that cause
deterioration.

- Lined equipment or equipment made of plastic shall be protected against impact, knocks and
abrupt temperature changes. At temperature of <10°C this equipment shall be installed with
special care.

- Equipment with a rubber lining having a hardness >75 Shore D shall not be installed when the
ambient temperature is <0°C.

- Cover, Caps, and preservation agents as well as protective covering for machined or bare
surface shall not be removed until immediately prior to assembling the equipment or prior
piping and instrument tie-ins

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

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Method statement

- All joints shall have bolts installed with the boils on same side. If bolted are removable, the
thread shall be treated with a suitable lubricant.

- In case of bolts exposed to high temperature of > 250°C heat resistant lubricants shall be used

5.4 Alignment

5.4.1 Static Equipment’s Alignment

- When the equipment has been finally set, the Equipment Supervisor with QC Inspector shall
check for alignment, orientation, elevation and verticality in accordance to specification

- Shims of at least 100mm x 50mm shall be used for aligning. If approved by the site
management, sectional steel may be used for aligning of vessel and light steel structure if
grouting is specified for space between support and unfinished foundation 10% of supporting
area shall be provided with shims

- After levelling is completed and the lock nuts of anchor bolts are tightened firmly, any excess
shims shall be removed.

- Any equipment designed for expansion shall remain free to slide as designed with locked double
nuts on sliding end base plate, but allowing movement.

- Equipment bases shall be grouted per UN 9281-02 Part 1, Inclusive of injected/forced grouting
if necessary to ensure cavities are filled. Attachment shall be made after grout has cured,

- Access ways shall be opened for inspections and to install internal components required by the
manufacturer for operation of equipment (i.e. Tray, Anchor, Electrodes, Catalyst, Filler
Elements, Media etc.) where applicable refractory and linings shall be installed and cured per
manufacturer's instruction.

- Internals of equipment shall be thoroughly cleaned before being placed on operation. Equipment
shall be boxed-up once all parties concerned are satisfied those internal components are installed
correctly and cleanliness is acceptable.

5.4.1.1 Vessel Internals

- Installation work requiring welding or cutting shall not be carried out unless specified in the
applicable drawings and if welding or cutting is unavoidable, approval of UHDE shall be
obtained before proceeding the work. No welding shall be performed on PVVHT equipment
without approval of UHDE.

- When installing internal parts, all bolts and clamps shall be tightened firmly to required torque
using a calibrated torque wrench or equipment tool.

- Access to inspections shall be observed. All trays and other internals 1.e,
Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018
 Hassan Allam Construction HAC
Quality Management System
Quality Department

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Method statement

- packings, gaskets, demisters, etc. shall be thoroughly cleaned and checked, to ensure that all
dirt, loose rust scales, slag, etc., are removed from inside the vessel and that all required
hardware’s are installed. All manways for entry to vessels shall be protected against internals
being loaded in and out.

- After all internal materials required in the specifications were installed and all necessary
corrections and adjustments are complete, all trays and other internals shall be physically
checked by Q Inspector and UHDE as required.

- All vessels internal cleanliness, internals and tray installation shall be jointly inspected as
scheduled by Q Equipment Inspector, UHDE, Vendor, Commissioning and Licensor
representatives as required. A joint inspection is necessary to minimize use of labour, gaskets
and bolting materials and tools. In areas where access is confined, each tray section shall be
checked by all parties for acceptance prior to installation of next tray.

- Tray manways shall be closed after all internals inspection, tests of trays and other internals and
the internal cleanliness have been accepted by UHDE, Vendor, Commissioning and Licensor
representatives as required. Tray manway closures shall be physically checked by QC and
UHDE Representative and documented in respective equipment forms. Request for Final
Closures of vessel shall be raised by HAC Equipment Engineer using an RFI and relevant
equipment forms.

5.4.1.2 Vessel Manholes Closure

- Vessels without internal trays shall be internally cleaned and inspected prior to manholes
closure.

- Vessels with internal trays, packings, etc., shall have their tray manways closed and accepted
prior to manholes closure.

- In all vessels for closure, Equipment Engineer shall raise a request for Final Closure
Authorization with the approval of UHDE, Vendor, Commissioning and Licensor as required.
Vessel’s internals shall again be finally checked as to cleanliness, correct bolts, nuts & gaskets,
correct internals installation etc., Final closing authorization will be documented in respective
equipment form.

5.4.2 Rotating Equipment’s Alignment

5.4.2.1 Pumps

- Pump assembly shall be installed at the location & to the elevations as per drawing &
manufacture installation procedure

- Coupling hubs of a pump & driver mounted on a base plate shall be disconnected prior to the
placement of the unit on its foundation
Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018
 Hassan Allam Construction HAC
Quality Management System
Quality Department

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Method statement

- The base plate shall be supported on rectangular metal blocks/shims or metal wedges having
small taper

- Support pieces shall be paced close to the foundation bolts, on large units’ small jacks made of
cap screws ant nut may be used for levelling.

- Metal supports or wedges shall be adjusted until the shafts of the pump & driver are level,
coupling faces as well as the suction & discharge flange of the pump shall be checked for
horizontal & vertical level any correction needs to be done by adjust wedges under the base
plate

- Vertical pumps with separate sole or base plate shall be levelled & grouted prior to the
installation of the pump

- 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 manufacture erection manual, for checking the approximate alignment of a
coupling a straight edge, taper gauge or a set of feeler gauges or required

- Check for angular alignment shall be made by inserting the taper gauge or feeler gauges at four
points between the coupling faces at 90 deg. Intervals around the coupling, unit to be in angular
alignment when the measurements show that the coupling faces are the same distance apart at all
points

- A check for parallel alignment shall be made by placing straight edge across both coupling at
the top, bottom & at both sides

- In case of machines with simple coupling and speed 51500 rpm the axial Deviation checked
with feeler gage shall not exceed 0.1 mm.

- In case of machines with special or multi- part and speed of >1500 rpm the axial and radial
alignment shall be by means of a test device (with dial gages) the measuring accuracy of dial
gages shall be 0.01 mm.

- If the permissible deviation as indicated by the motor manufacturer are contradictory to the data
of the machine manufacturer, the machine manufacturer's data shall govern.

- The unit will be in parallel alignment when the straight edge rest evenly on the coupling rim tall
position, parallel to the axis of the shafts

- Allowance may be necessary for temperature changes & for coupling hubs that are not the same
diameter

- The permissible amount of misalignment will vary with the type of pump & driver, the
manufacture recommendations shall be followed for permissible tolerance
Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018
 Hassan Allam Construction HAC
Quality Management System
Quality Department

Page 10 of 11
Method statement

- Dial indicator could be used as alternative method for accurately aligning the coupling hubs
after check by straight edge, taper gauge or feeler gauge.

- In case of the pump & the driver not at the same base, pump adjust first level & alignment then
driver adjust to the same level & position then coupling alignment adjust like before mentioned

- When the units are lined up cold, it may be necessary to make an allowance for the vertical rise
of the driver and/or pump caused by heating. Manufacturer's recommendations shall be
followed.

- The pads provided on the base plate for the driver shall be marked with chalk to facilitate
marking the location of the hold-down bolt-holes. The driver snail shall be placed on the base
plate by adjusting the positions of the driver and by placing shims as required under the driver
feet so that the distance between the coupling halves is in accordance with the dimensions
indicated on the outline elevation, of the complete unit,

- The alignment of pump and driver coupling halves shall then be checked and corrected. The
circumference of the hold down bolt-holes in the driver feet shall be scribe on the base plate
pads. The scriber shall be removed and the size of hold-down bolts shall be determined. Drilling
and tapping for hold-down bolts shall be carried out. The driver on the base plate shall be
replaced, the bolt shall be inserted, and the driver shall be aligned before tightening.

- Grouting shall be carried out after necessary corrective adjustments for angular & parallel
alignment have been made

6.0 HSE Requirements

All individual tasks mentioned in this method statement will be subject to individual USA, and toolbox
talks at site before work commences on a daily base, Supervisor shall fully explain and discuss the task
ahead including lifting technique, pre-planning, details of lifting procedure, safety aspects and individual
responsibilities.
No refuelling whilst equipment is running.
All lifting tackle will be tested and certified before use.
All personnel will have undergone the applicable safety training and wear appropriate PPE, i.e., safety
helmet, steel toed safety boots, safety glasses and coveralls as the minimum requirement and gloves and
high visibility vests where necessary.
No lifts by a single crane are allowed where the load exceeds the 85% of the cranes rated lift capacity.
Inspect the rigging prior to the lift.
Use sling softener in between the sling and any sharp corners of the load. Use taglines to control the load
and keep workers away from the load.

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018

 Hassan Allam Construction HAC
Quality Management System
Quality Department

Page 11 of 11
Method statement

Measure the radius by a measuring tape and place markers with paint in the ground, do not step it off or
use pace value or use the boom angle indicator as basis of measurement. Boom angle indicator should
only be used as reference.
Watch for boom draw down as the crane takes the load.
Use caution when the lifting operation includes swinging with load, especially 180 degrees. Ensure that
tag line(s) are used for guidance purposes
Instruct the operator to leave the house swing brake open and/or lock off during lifting in order the load
block of the crane is allowed to move towards the centre of gravity of the load and to avoid side loading.
Do not make any lift in winds that exceed the manufacturer's recommendation.
Special circumstances will be considered by the Rigging Engineer and the Site Manager on a case-to-
case basis to determine if a lift needs to be elevated to a higher level of Design and/or approval.

7.0 Attachments

Document Ref#. HAC-xxxx-xxxx - Rev. 01- Issued Date. 01/01/2018