HALFAYA PROJECT SURFACE FACILITY

PHASE FOUR
PROVISION OF EPCC FOR
CPF2 TRANSFER PUMP STATION

DETAIL DESIGN DOC. NO.: HFY4-5030-MEC-PD-0002 REV.: A PAGE 1 OF 9

HFY-CON/F&C1058-1081

Static Equipment Installation Procedure

An Sun Chen
A Issued for Approval 30.01.2022 Ji Renzhu
Shaoheng Shuochang Jianjun

REV. DESCRIPTION DATE PREP’D CHK’D REV’D APP’D

 Static Equipment Installation Procedure

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REVISION DESCRIPTION SHEET

Rev. Page Para. Reason for Revision
A 9 All Issued for Approval

Hold No. Page Para. Reason for Hold

 Static Equipment Installation Procedure

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CONTENT

1.0 SCOPE......................................................................................................................................4

2.0 REFERENCES AND APPLICABLE CODES.....................................................................4

3.0 QUANTITY OF EQUIPMENT................................................................................................ 4

4.0 INSTALLATION AND CONSTRUCTION MEASURES....................................................5

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1.0 SCOPE
This procedure shall be applied to CPF2 TRANSFER PUMP STATION project, including
installation and construction of 1st stage separator and basket filter.

2.0 REFERENCES AND APPLICABLE CODES

2.1 Specifications and Codes

HFY-GEN-GEN-SPC-0001_B Specification for Quality Assurance

HFY-GEN-GEN-SPC-0005_A Specification for Protection of Goods during Shipment

HFY-GEN-GEN-SPC-0007_B Specification for Worksite Storage and Equipment

Protection

HFY-GEN-CIV-SPC-0008_A Specification for Steel Work

HFY-GEN-MEC-SPC-0002_B Specification for Welded Pressure Vessel

HFY-GEN-MEC-SPC-0005_B specification for Packaged Equipment

2.2 Reference Documents

Approved for Construction Engineering Drawings

Related Piping, Electrical and Instrumentation Drawings
Manufacturer Installation and Maintenance Manual

3.0 QUANTITY OF EQUIPMENT

Main Equipment List：

Sr. No Equipment Name Qty

1 1st Stage Separator 2
2 Basket Filter 3
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4.0 INSTALLATION AND CONSTRUCTION MEASURES

4.1 CONSTRUCTION PREPARATION

4.1.1 Tools and Equipment

·Cranes
·Trailer
·Rigging tools
·Hand tools
·Levelling and alignment instruments
·Theodolite
·Spreader beam (if required)
·Scaffolding
4.1.2 Rigging Study
Rigging Study for heavy equipment shall be prepared and get approval from
client.
· An overall plan of the equipment erection shall be prepared before the
commencement of the installation to execute the lifting equipment.

· The plan shall identify the crane capacities for various equipment, keeping in view the
plot plan of the work area, the equipment weights, dimensions and type.
· For all Heavy and Critical Lifting the rigging studies shall be issued for client approval.
4.1.3 Transportation Study
The following important points are to be considered:
· Get equipment arrival schedule from manufacturer to organize resources and to make a
sequence of erection.
· transportation route shall be surveyed and marked before transport of the equipment and
maintain properly for transportation.
· Transport and lift will not commence unless the visibility of the route is cleared. Fog,
sandstorms, excessive rains or other reasons shall be cleared first before commencing
transport activities.
· Heavy equipment shall be off-loaded as close as possible to the foundation, if site
condition is acceptable for off-loading.
· Off-loading crane & lifting gears shall be selected considering the weight of the
equipment leaving sufficient safety margin.
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· While engaging lifting gear, care must be taken to avoid damage to the equipment. A
spreader bar or a lifting beam may be needed for this operation.
· Proper rigging of the equipment should be done to have equal loads on the lifting
slings. Chain blocks may be used to achieve the levelling for unequal shapes.
4.1.4 Checking and Preparation of Foundations
· Prior to installation of static equipment, survey the foundation & make dimensional
checks to ascertain the correctness of equipment drawing.
· Chip the surface of the foundation, and set shim plate on the mortar/grout material. The
mortar pad height shall be adjusted to attain grouting clearance.
· Check the dimension & condition of the foundation/ anchor bolts. In case the threads
appear to be rusted or damaged, thread shall be cleaned and a thread runner shall be
used for their smooth working.
· The arrangement of foundation/ anchor bolts shall be checked to comply with layout of
the equipment drawing (latest revision). Foundation bolts shall be installed according to
Project Drawings.
4.1.5 Checking of equipment before installation
Equipment shall be checked thoroughly as per 4.2.
4.1.6 Crane Accesses
· For smooth Lifting operation make sure that the crane accesses ways are clear.
· Crane access shall be clear of unauthorized personnel and unnecessary materials.
Make sure that there is nothing between crane & crane access way and lifting equipment &
equipment erection place.
· Bearing capacity and of soil and compaction condition at crane set position shall be
checked prior to installation of equipment.
4.1.7 Barricading
Make sure barricading shall be provided around crane, lifting accesses and lifting place
before equipment erection.
4.2 OPEN PACKAGE INSPECTION

· Equipment shall be checked thoroughly for any damage after transportation.

·After inspection, unloading shall be done as per position defined on the lift study
drawings. It should be as near as possible to the foundations.
·Prior to installation work, the static equipment shall be checked for the following points:
a. Cleanliness of the equipment. All loose material shall be removed.
b. Erection position shall be marked with reference to critical nozzle.
c. Center of gravity shall be marked for proper engagement of lifting gear.
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d. Inspect the condition of slings and lifting gears and certificates of conformity.
e. For installation of internal of equipment, a separate procedure shall be used
f. Secure erection work permit prior to lifting of the equipment.

4.3 FOUNDATION ACCEPTANCE

Foundation acceptance certificate will be obtained as per QA/QC requirement.

4.4 EQUIPMENT INSTALLATION

A working group comprising of a rigging supervisor, a lift supervisor, a lifting equipment

operator, riggers and a HSE supervisor shall carry out equipment erection. The
responsibilities of each personnel of the working group shall be clearly defined. The
operator shall be in possession of the necessary licenses.
4.4.1 THE SHIM PLATES OF EQUIPMENT INSTALLATION & PRIMARY GROUTING
·Shim plates will be provided to prepare a levelled surface to install equipment. It is also
important to adjust anchor bolt threaded length sufficient to bolting and tighten after
installation and before secondary grouting.
·After shim plates installation and level inspection by QC Engineer primary grouting will
be performed and non-shrink grouting material will be used.
4.4.2 EQUIPMENT PLACEMENT
· Unpacking of machinery/equipment shall be done in the presence of the client’s
representative.
·Main crane and the tailing crane shall be rigged into the correct position as per rigging
study. Safety exclusion zones shall be marked with high visibility warning tape will be
established and maintained during rigging, lifting operations and de-rigging of equipment
into which no unauthorized personnel will be permitted.
·Lifting will only be permitted when the specified conditions of weather and visibility are
achieved. Lifting will generally commence as soon as possible in the day to maximize
daylight hours available.
·Dimensional checks for the lift radius, the tail swing radius and super lift radius to be
verified after crane set-up. Lifting tackle will be inspected as per rigging study.
·Make sure that the signal man is clearly visible to the crane operator.
·Ensure that the proper tools are available and are used for the proper installation of
static equipment.
·Using the rigging study the heavy lifts shall be planned and executed.
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4.4.2.1 Installation of Horizontal Equipment

·The crane to be used will be mobilized to the site, set-up and rigged in the correct
location as per equipment manufacturers manual and rigging studies. Safety exclusion
zones will be established and maintained during rigging, lifting operations and de-rigging.
·Dimensional checks for the lift radius and the tail swing radius to be verified after crane
set-up. The lifting tackle will be inspected and then be attached to the crane hooks as per
rigging study.
·Weather conditions will be closely monitored prior to and during all lifting operations.
· The boom tip will be positioned directly over the center of gravity of the equipment.
·The crane will lift until all the lifting slings are tight. The load will be monitored using the
safe load indicator (SLI) equipment and checked by the lifting supervisor that it is as
predicted.
·The crane will continuously lift until the equipment’s required height is achieved. The
crane will be turnned in accordance with an approved rigging study until the equipment is
over the foundation.
· Equipment will then be checked for orientation and lowered to its final position on the
foundation. Once it is secure, lifting tackle will be released from the top lifting points.
· The protection on equipment nozzles shall not be removed without client’s consent.
· Care shall be taken during the erection of equipment to avoid damage to the bolts and
bolt threading.
· All the equipment installed shall be levelled and plumbed in correct position.

4.4.3 ALIGNMENT
·Alignment of equipment shall be done after erection of equipment.
·Alignment shall be done with the help of qualified surveyor and manpower.
· Alignment of equipment shall be as per project specification and approved for
construction drawings.
·Alignment shall be inspected and approved by PMC.
4.4.4 SECONDARY GROUTING OF FOUNDATION
·Prior to grouting, loose concrete or dust shall be removed, preferably by compressed
air. Anchor bolt sleeves shall be cleaned out to allow the ingress of grout into the sleeve.
·Only non-shrink grout shall be used for base plate, skid or equipment grouting.
·The grouting shall be applied after saturating foundation with water and cleaning all
foreign material. The mixing ratio of epoxy grouting material shall be in accordance with
the manufacturer’s specifications.
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·Pouring of the grout material into a gap between bed of the equipment and foundation
shall be sufficiently remained to ensure no voids
·Anchor bolts shall be set so that a few threads come out from the nut after tightening.
·For grout curing should follow client specification.
· After reaching to the sufficient hardness of the grout, all anchor bolts should be
tightened completely and uniformly.
4.4.4 SECONDARY GROUTING OF FOUNDATION
·Bolt tightening of equipment shall be done after inspection of alignment.
·Bolt tightening of equipment shall be as per vendor recommendation and approved for
construction drawings.
·Alignment shall be rechecked & approved by PMC QA/QC after final tightening of
equipment as per project specification and approved for construction drawings.