STATIC EQUIPMENT INSTALLATION

STANDARD OPERATING PROCEDURE

FOR
STATIC EQUIPMENT INSTALLATION

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 STATIC EQUIPMENT INSTALLATION

Approval History

ORIGINATOR CHECKED BY APPROVED BY

NAME DATE NAME DATE NAME DATE SIGNATURE

Vijaianand Rajaram Dinesh Singh Eugene Eybers

15/04/20 15/04/20 15/04/20
QA/QC Manager Project Manager Operations Manager

Revision History

REVISION DATE DESCRIPTION OF CHANGE

0 15/04/20 Initial Issue

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TABLE OF CONTENTS
1. GENERAL ............................................................................................... 4
1.1. PURPOSE ................................................................................................... 4
1.2. SCOPE ...................................................................................................... 4
1.3. ABBREVIATIONS ........................................................................................... 4
1.4. REFERENCES ............................................................................................... 4
2. SAFETY ................................................................................................. 5
3. RESPONSIBILITIES ..................................................................................... 5
3.1. CONSTRUCTION MANAGER ............................................................................... 5
3.2. SUPERVISOR ............................................................................................... 5
3.3. QA/QC INSPECTOR ........................................................................................ 5
3.4. HSE ADVISOR............................................................................................... 5
4. PROCESS ................................................................................................ 6
4.1. GENERAL ................................................................................................... 6
4.2. INSTALLATION PREPARATION ........................................................................... 6
4.3. LIFTING & HANDLING ..................................................................................... 6
4.4. EQUIPMENT SETTING & ALIGNMENT .................................................................... 7
4.5. GROUTING ................................................................................................. 7
4.6. TORQUING ................................................................................................. 8
4.7. INTERNAL INSTALLATION ................................................................................ 8
5. APPENDICES ............................................................................................ 8

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 STATIC EQUIPMENT INSTALLATION

1.GENERAL
1.1. PURPOSE
The purpose of this Procedure is to describe the technical process and the attendant Safety and
Environmental constraints to be employed while executing Static Equipment installation in according
with relevant Codes of practice.

A safe and secure working environment will be provided at all times for the personnel as it details
the general requirements, resources, quality requirements & safety requirements.

1.2. SCOPE
Sets out the method to be used by The Oman Construction Co LLC (TOCO) to carry out Static
Equipment installation in accordance with relevant codes of practice.

1.3. ABBREVIATIONS

ABBREVIATION DEFINITION
PPE Personal Protective Equipment

QHSE Quality, Health Safety and Environmental

ITP Inspection and Test Plan

RFI Request for Inspection

PPE Personnel Protective Equipment

Vessels, heat exchangers, drums, tanks or any other
EQUIPMENT
static equipment

1.4. REFERENCES

NUMBER NAME
L_(TOC)_MNL_001_R0 QHSE Manual
Standard Operating Procedure for Flange Bolting and
O_(TOC)_SOP_014_R0
Torquing
Recommended practice for machinery installation and
API-686
installation design
Vendor Equipment Manual & Schematic drawings /
-------------------
Assembly drawings

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2.SAFETY
 Activities shall be carried out in accordance with QHSE Manual.

 All personnel shall attend the Project Safety Induction and issued with a valid ID badge.

 Site personnel shall adhere to the site safety policies at all times with emphasis on wearing the
correct PPE and equipment relative to the type of operation being performed.

 All personnel, including third parties shall be safety inducted prior to entry on site. Visitors shall be
accompanied by a person in possession of a valid safety induction identity card.

 Safety precautions shall be of paramount importance to prevent any danger to the public and any
operations carried out adjacent to public access or thoroughfare shall be closely monitored by the
Project Safety Advisor.

 Risk assessment shall be constantly monitored for changes in conditions.

 Prior to commencement of work every day the supervisor/ Foremen shall check all equipment against
the safety check list.

3.RESPONSIBILITIES
3.1. CONSTRUCTION MANAGER
 Overall responsibility for installation activity.

3.2. SUPERVISOR
 Ensure all installation personnel comply with the Health and Safety requirements, Determine
and identify tools, equipment and qualified personnel for installation.

3.3. QA/QC INSPECTOR

 Verify work to conformance to specification and procedures.

 Verification of Drawing & Orientation.

 Shall carry out visual inspection of equipment to check weld quality, coating damages, proper
bolting, cleanliness etc.

3.4. HSE ADVISOR

 Assure necessary precautions are taken to ensure the health and safety of all personnel.

 Ensure adequate PPE, certified lifting equipment, first aid etc. are available at site.

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4.PROCESS
4.1. GENERAL
 The Material Controller shall inspect the physical conditions of equipment upon arrival at the
jobsite before and after unloading. The equipment shall be accompanied with vendor’s
certificate, equipment drawing, packing list and recommendation for handling and installation.

 The Construction Manager shall determine the sequence of installation.

 Pre-installation activities like installation of internals, welding, internal coating, bolting, nozzle
alignment etc. shall be determined and carried out as per the manufacturer instruction manual.

 The Construction Manager shall ensure that all required permits, lifting equipment, tools,
drawings, packing lists etc. are available together with TPI certificates for all lifting equipment.

 Equipment shall be installed in correct position in accordance with manufacturer’s drawings and
the anchor bolts shall be fastened. Thereafter all flange closures shall be removed, including
the blind flange. Finally all piping, equipment and blind flanges shall be connected.

4.2. INSTALLATION PREPARATION

 The Construction Manager shall check the equipment, dimensional size, nozzle orientation,
service, type, etc. prior to installation.

 Prior to installation of the static equipment, the foundation shall be completed by civil
discipline and handed over for equipment installation. The foundation shall be correctly marked
with elevation, centerlines; other benchmarks and comply with the design requirements/
drawings. The QC Inspector shall check the dimensions, lines and levels of the equipment
foundation and anchor bolt position and projections against the applicable drawings prior to
commencing erection of the equipment.

 All dimensions and positions of anchor bolts or anchor pockets shall be checked. Centre and
alignment of anchor bolts shall be within the tolerance.

 Upon acceptance of foundation, the surface shall be roughened with chipping; the leveling pad
plate shall be placed on both sides of the anchor bolts or on the locations as per the drawings or
technical specifications. The leveling pad plate and shim plates shall conform to
ASTM standard. The leveling pad plate shall be set in level and have good contact with the
foundation surface. Each group of leveling pad plate shall not exceed four pieces, which shall
be pressed tightly and checked by hitting with hand hammer. After the alignment of the
equipment, the leveling pad plate shall be tack welded.

4.3. LIFTING & HANDLING

 All lifts shall be carried out as per HSE procedure for Lifting Operations, Equipment and
Accessories’.

 Hoist equipment and lifting gears suitable for the weight of the equipment shall be made
available with valid certificates.

 The equipment shall be lifted by means of suitable slings, and handled in such a way as to avoid
any damage.

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4.4. EQUIPMENT SETTING & ALIGNMENT

 The Equipment shall be set and aligned at the proper positions, elevations, levelness and
perpendicularity with reference to the bench marks, centerlines, elevations marked on the
foundation and in accordance with the manufacturer’s drawings. The alignment and setting of
the equipment shall be measured and adjusted to achieve the bench marks on the equipment.
If the height of the vertical equipment exceeds over 20 meters, the measurement and
adjustment of the perpendicularity of equipment shall be addressed adequately to counter the
strong wind velocity. For horizontal vessels in the event of thermal expansion, a tolerance of
elevation shall be allowed.

 The Alignment of vertical equipment shall be checked using a level, theodolite, or a plummet on
two longitudinal area 90 deg. Apart with two transits, and the alignment of horizontal
equipment shall be achieved with ‘spirit level. Leveling plates and shims will be used for
equipment alignment. The maximum out of tolerance on verticality shall be 1:1000 or as
specified in Client specifications. The levelness for horizontal vessels shall not be out of
tolerance of L/1000, radial tolerance of 2D/1000, where L stands for the distance between the
two saddle supports, D for the external diameter of the vessel.

 When leveling the equipment, wedges or Leveling pad plates shall be used for adjustment
instead of loosening or tightening the anchor nuts, or imposing external force.

 If equipment is installed with anchor bolt pockets, the equipment shall be subject to preliminary
alignment and leveling by placing temporary shims, then grouting anchor bolts, when the grout
strength reaches 75% of its design strength, the final alignment and leveling shall be achieved by
setting shims at the both sides of anchor bolts.

 The anchor bolt pockets and foundation surface shall be fully filled with grout, the grout shall
be a grade higher than foundation concrete and be rammed firmly and completely.

4.5. GROUTING
 The grouting material shall be as specified in Client technical specification requirements.

 Prior to the grouting application, the anchor bolts shall be cleaned from oil, where in contact
with grout, and anchor pockets shall be clean from water and foreign materials. The foundation
surface shall be chipped and cleaned. Water shall be sprayed onto concrete for soaking, before
grouting.

 For foundation of vertical equipment having skirt at bottom, adequate number of drain pipes
shall be provided inside of grouting.

 Grouting of one area shall be completed without interruption. The grouting shall be applied
under the equipment bases, anchor holes and ejected portion of the lines.

 Mixing ratio of grouting mortar shall be as specified in Standards of mixing Ratio of Mortar.

 The grout shall be placed in between the base plate and the foundation top and rammed in and
tempered sufficiently with an iron bar to eliminate any air pockets.

 Upon completion of grouting, the grout mortar shall be adequately cured for at least three days.
The bolting shall carried out upon achieving 75% compression strength of the grout inside the
anchor holes. The surface of grouting shall be finished by smoothening using a steel trowel.

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4.6. TORQUING
 The torqueing of the flange cover assembly shall be carried out as per approved Bolt Tensioning
& Torqueing Procedure O_(TOC)_SOP_014.

4.7. INTERNAL INSTALLATION

 The internal installation and sequence shall be carried out in accordance with the
manufacturer’s instructions. The installation shall be carried after acceptance of hydrostatic
test and flushing.

 The internal surfaces of the equipment shall be thoroughly cleaned and free of oil, grease,
slags, rust or burrs, and all internals shall be properly arranged and labeled to facilitate
installation.

 The required supply and discharge pipes shall be connected. Protective covering and plugs shall
be removed at the moment of installation.

 De-aerate and drain the equipment prior to operation.

5.APPENDICES

ITEM DESCRIPTION FORM NUMBER

Insulation report (if applicable) O_(TOC)_FRM_021_R0

Grouting Inspection report O_(TOC)_FRM_048_R0

Flange Tightening report O_(TOC)_FRM_104_R0

Turbine Installation / Leveling Record O_(TOC)_FRM_107_R0

Manufacturer installation manual ------

Schematic drawings ------

Equipment Alignment report (to be Established) ------

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