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DOC.

NO: HDOL/ETP/6249/JP/MECH-REE-001/Rev-00

JOB PROCEDURE FOR


ROTARY EQUIPMENT
ERECTION
Name of Work
Owner
Consultant
Contractor
Job No

: Effluent Treatment Plant.


: ONGC Mangalore Petrochemicals Limited.
: TOYO Engineering India Limited.
: M/s Hindustan Dorr-Oliver Limited.
: 6249

Procedure No. HDOL/ETP/6249/JP/MECH-REE-001/Rev-00

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ABBREVIATIONS:
AFC

Approved for Construction

BM

Bench Mark

CI

Cast Iron

GI

Galvanized Iron

IBR

Indian Boiler Regulation

Id

Identification

IQI

Image Quality Indicator

MS

Mild Steel

MT

Magnetic Particle Testing

NDT

Non Destructive Testing

OMC

Optimum Moisture Content

PQR

Procedure Qualification Record

PT

Penetrant Testing

PWHT

Post Weld Heat Treatment

RF

Reinforcement

SPT

Standard Penetration Test

U/G

Under Ground

WPS

Welding Procedure Specification

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DOC. NO: HDOL/ETP/6249/JP/MECH-REE-001/Rev-00

CONTENTS

1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 TERMS & DEFINITIONS
5.0 RESPONSIBILITIES
6.0 METHODOLOGY
7.0 HEALTH, SAFETY & ENVIRONMENT
8.0 QUALITY ASSURANCE & QUALITY CONTROL
9.0 DOCUMENTATION

1.0 PURPOSE

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APPROVED
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DOC. NO: HDOL/ETP/6249/JP/MECH-REE-001/Rev-00

The purpose of this procedure is to


- Bring clear views and guide line for supervision of Rotary Equipment erection/Installation.
- Bring uniformity for supervising the job.
- Minimize avoidable errors.

2.0 SCOPE
To define and establish procedures for on site handling, movement and installation of rotating equipment.

3.0 REFERENCE DOCUMENT


i) Piping Isometric drawings.
ii) STANDARD : API-610, API 674
iii ) PMC SPEC:

4.0 TERMS & DEFINITIONS

For the purpose of this document the term:


1. Shall, indicate a mandatory requirement and should indicate a
recommended practice.
2. All terms used in the development of this procedure are defined in
the above reference documents.
3. QA/QC shall mean Quality Assurance & Quality Control.
4. ITP shall mean Inspection & Test Plan.
5. PM shall mean Project Manager.

5.0 RESPONSIBILITY

Following are the responsibilities and reporting structure of personnel involved in the scope of the procedure:

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Resident Construction Manager

Shall report to the Project Manager.


Shall be overall responsible for management of the project.

Shall report to the Resident


Construction Manager.
Shall be responsible for compliance of this procedure.
Shall provide all necessary resources to implement this
procedure.
Shall periodically audit the compliance of the procedure.

QA/QC Manager
Construction Manager

Store In charge
-

6.0

Shall report to the Resident Construction Manager.


Shall be responsible for control, supervision and direction
for implementation and execution of construction plans.
Shall develop construction schedules, Procedures and
prepare progress and accomplishment reports.
Shall report to the Resident Construction Manager.
Shall be responsible for handling, storage and issuance of
construction materials.

METHODOLOGY :
GENERAL :
Foundation shall be completed and checked for correctness and levelness as per drawings and specifications.
Prior to installation, foundation shall be clean with correct anchor bolt holes location, centerlines marked,
elevations and levels established for correctness. Shimming and wedging shall be carried out as per drawings

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DOC. NO: HDOL/ETP/6249/JP/MECH-REE-001/Rev-00

and specification. As required, perform on site installation of the various equipments as per approved
construction drawings and specification and instruction by a manufacturer/vendor representative.

ROTATING EQUIPMENT INSTALLATION:


1. Prior to installation, inspection for equipment acceptance to be carried out. Equipment installation includes
loading, hauling, unloading, inspection, lifting, shimming, aligning, placing and securing in its final position.
2. Remove all temporary supports, bracing or other foreign objects that were installed in the equipment or
machinery to prevent damage during shipment, storage and erection, and repair any damage sustained. This
may need vendor assistance.
3. Before positioning the equipment, it shall be checked against the drawings to verify the pipe installation of
flanges, nozzles, junction boxes, coupling and other items that require external connection.
4. HDOL to prepare lifting and rigging plan for all heavy lifts taking into consideration location and other
activities such as equipment insulation, structural platform and ladder, instrumentation, piping erection and
other work which can possibly be accomplished prior to final erection of equipment, saving scaffolding and
basket work.
5. The foundation and anchor bolts preparation shall be completed and checked by PMC/OWNER inspector
prior to installation of equipment.
6. Prepare foundation surface, install equipment, and level the equipment as per approved drawings and
specification.
7. Inspect and check the work during the construction stage, and perform such non-operational tests as are
necessary to assure the integrity of the installation in accordance with the issued for construction drawings,
specification and vendor instruction.
8. Conduct all operational tightness tests.
9. Qualified craftsman with experience in installing rotating equipment will be assigned at site during the
erection, installation, commissioning and start-up period with vendor assistance as required for all special
equipment.

INSTALLATION OF PUMP AND OTHER ROTARY EQUIPMENT:


Rotary machines and equipment, such as pump, blower, agitator, etc will be installed in the ETP Project.
The installation methods are as follows:
1. For pump installation, alignment of axle centers between driving machine (motor or turbine) and pump is of
essential importance. When connecting driving machine to pump, axial line of pump shall be taken as
reference for alignment; when there is intermediate equipment installed between driving machine and
pump, axial line of intermediate equipment shall be taken as reference for alignment. Generally, three (3)
gauges will be adopted for alignment at the same time.
2. In general, liner and shims will be used for installation. And according to the type of base plate, flat liner
and shims, wedge or small jacks will be used to facilitate the adjustment.

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DOC. NO: HDOL/ETP/6249/JP/MECH-REE-001/Rev-00

3. Non-shrinkage cement mortar will be used for grouting work. Foundation of pump and machine will be
grouted in two lines. After initial alignment, primary grouting will done for anchor bolt holes. When the
mortar reaches certain strength, precise alignment will be performed, then secondary grouting work may be
carried out.
4. The parallelism and concentricity between flanges of piping to be connected with pump and inlet/outlet
flanges of pump shall meet requirements stated in relevant specification. And during connection, no undue
stress will be imposed on pump body. After final alignment, dial indicator will be applied when connecting
piping flange to pump flange.
5. Rotate pumps by hand to ascertain that they turn freely. Align pump with driver after coupling installation;
ensure that the axial and radial deviations, and axial clearance are within the approved tolerance.
6. Disconnect the coupling, check motor for rotation, run-in uncoupled and check bearing. After motor no load
test, re-couple pump to motor.
7. Installed proper lubricants(fuel, coolant) prior to commissioning after review with PMC
8. Installed strainers in the suction piping to prevent foreign objects from entering the pump during
commissioning and initial operating period.
9. Test run of pump will be performed after successful test run of each auxiliary equipment.
10. Check the general compatibility of the pumps with respect to any cavitations problem, discharge head,
excessive vibration, excessive noise etc. which may hint at abnormal operation of pump.
11. Test run of pump shall be done with working medium.
12. For installation of dryer, suitable gradient shall be guaranteed in compliance with requirements specified in
vendors technical document. First base plate shall be installed and aligned to certain gradient, Then
cylindrical shell will be installed and bearings and other screw conveyor will be inspected and adjusted, and
then expansion joint flexible coupling and outlet hopper will be installed. Finally motor will be installed.
During installation, axial center of motor shall be precisely aligned.

13. For installation of agitator, technical specification and codes by PMC shall be strictly followed, especially
the agitator of reactor, perpendicularity requirement of its center axle is very strict, so after positioning of
reactor, not only the perpendicularity of housing shall be carefully measured, but also leval of top
flange(connected with agitator flange) shall be precisely adjusted, to assure the perpendicularity of center
axle of agitator.
14. Activities relevant to tolerances for agitator horizontal/vertical alignment shall be performed according to
the technical specification provided by PMC. Any misalignment of relevant vessels must by adjusted
accordingly.
7.0 SAFETY
During fabrication and erection adequate safety measures shall be taken as per the safety norms/Standard.

All workers shall must wear appropriate PPEs like safety helmets, safety shoes, safety belts, goggles, gloves
etc.
Suitable scaffoldings shall be provided to workmen for all works that cannot be safely done from the ground.
Ensure electrical systems and equipments including tools & tackles used during construction phase properly
selected, installed, used and maintained as per the Standard.

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DOC. NO: HDOL/ETP/6249/JP/MECH-REE-001/Rev-00

8.0

Fire extinguishers and insulating mats shall be provided at power distribution area.

QUALITY ASSURANCE & QUALITY CONTROL


Quality Assurance & Quality control of ERECTION work shall be as per Quality Plan .All quality
records as appended to this procedure shall be maintained for all activities.

9.0

DOCUMENTATION AND RECORDS


All records pertaining to execution of the job as per ITP No. HDOL/ETP/6249/JP/MECH-TANK-001/REV-0,
to be maintained by the contractor as the work progress & till its completion and then handed over
to customer through TEIL along-with an electronic copy of the same.

Notes : In case of any conflict between the requirement of this procedure and TEIL specification , the letter shall govern.

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