QUALITY PROCEDURE FOR

INSTALLATION OF ROTATING EQUIPMENT

Document Title
QUALITY PROCEDURE FOR
INSTALLATION OF ROTATING EQUIPMENT
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

TABLE OF CONTENTS

1.0  Scope ................................................................................................................... 3 

2.0  Purpose ............................................................................................................... 3
3.0  Referances .......................................................................................................... 3
4.0  Definitions and Abbreviations .......................................................................... 3
5.0  Safety ................................................................................................................... 3
6.0 Responsibilities ................................................................................................... 3
7.0  Testing and Measuring Equipments ................................................................ 4
8.0  Procedure............................................................................................................ 4
9.0  Inspection and Test Status .............................................................................. 12
10.0  Attachments...................................................................................................... 12
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

1.0 SCOPE

This Quality Control Procedure defines the general requirements for the control of site installation,
erection and inspection activities for rotating equipment. In case instruction/s for site
storage/handling/installation/erection of equipment is/are specified by vendor/manufacturer, such instruction/s
shall supersede the requirements of this procedure.

2.0 PURPOSE

The purpose of this procedure is to provide general requirements for the installation of rotating equipment in
the project scope in order to ensure that all units and their auxiliary equipment/s and components are erected,
installed and inspected in accordance with Project Specification.

3.0 REFERENCES
PP13-00-Y-QPT-GAM-016: Inspection and Test Plan for Static and Rotating Equipment Installation

4.0 DEFINITIONS and ABBREVIATIONS

Company : Saudi Electric Company (SEC)

Contractor : Worley Parsons (WP)

Sub-Contractor : GAMA Power Systems Arabia LTD

Contract : PP13 Combine Cycle Power Plant Project

QCP : Quality Control Procedure

ITP : Inspection and Test Plan

QA/QC : Quality Assurance / Quality Control

5.0 SAFETY
All works shall be carried out in accordance with manufacturer(s) instructions and project safety requirements.
Personal Protective Equipment (PPE) shall be worn at all times.
Personnel involved in working at heights shall undergo necessary training.
Scaffoldings erected for facilitating the activities shall be safe, securely erected & tagged and shall not be
removed until completion of the inspection activities.

6.0 RESPONSIBILITIES
The Equipment Engineer in-charge shall be responsible for the following:-
To ensure that project health and safety requirements are met particularly within the area of responsibility.
To ensure construction is carried out to meet the required Project Specifications and vendor instructions.
To control site supervisors to follow quality requirements throughout the work as per this procedure (QCP)
and relevant Inspection and Test Plans (ITP).
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

To notify QC when portions of the work are ready for inspection, as identified in the ITPs.
Ensure that notification time to QC is sufficient to meet the agreed project procedure notification time.
Responsible for preservation and maintenance.

Quality Control Inspectors (Equipment) shall be responsible for, but shall not be limited to the following:
Ensure that inspections are performed and recorded as per project specifications.
Ensure that inspections are carried out and documented as per ITP.
Coordinating with other QC Disciplines, as necessary.
Ensuring that notification times to Contractor and Company are upheld as per Project Procedure.
Report any non-conformance to the QC Engineer and seek advice on path forward.

Storekeeper
Storekeeper shall be responsible for ensuring that all materials are stored safely in a dry and well ventilated
area that and all manufacturers’ storage recommendations are followed. Level gauges, level indicators,
capillary tubes, trims and other loose items supplied by vendor shall be securely stored and handed over to
responsible personnel for installation as and when required. He shall maintain a list of tools and equipments
that the technicians generally require for their daily activities and ensure that the Equipment Engineer is kept
informed of shortages and damages if any.

7.0 TESTING & MEASURING EQUIPMENTS

The inspection and measuring tools and equipments shall be calibrated and stickers shall clearly indicate
therein the date of expiry. Certificates shall also be available and produced upon demand.

8.0 PROCEDURE

8.1 Preservation
All rotating equipments are required to have their preservation periodically reviewed and implemented as
identified within the equipment preservation schedule, project specifications and/or vendor/manufacturer’s
instructions. Nozzle flanges shall not be left open to air and shall be blinded with metallic or wooden blinds
until they are connected to piping.
8.2 General
All equipment and auxiliary materials received at site shall be inspected in accordance with project procedures
and vendor instructions. Preservation will be in accordance with the relevant procedure and vendor
guidelines. Unless it is considered necessary, vendor installed preservation shall not be removed.
Equipment shall be off-loaded from the transportation, using the Vendor recommended lifting points and
approved techniques (equipment erection including heavy lift).
All loose items not immediately required for installation shall be identified and tagged as per P&ID and
retained in the stores.
All equipment shall be unpacked in the presence of Contractor or vendor/manufacturer representative with
photographic evidence and all spare parts tools etc, shall be repacked, clearly marked and stored accordingly
if necessary.
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

Fragile parts, such as level oilers, capillary tubes, small piping, small valves, etc., loosely supplied shall be
removed after being match marked, and stored. The parts shall be clearly identified by use of tags relating to
the relevant P&ID’s with the equipment numbers clearly marked. Tags shall be attached with wire to the parts.
Machined surfaces shall be checked and rust-preventatives applied as necessary.
The equipment shall not be placed directly on the earth (soil or mud), after removing from packing box,
without using adequate wooden blocks.
Free issue material: Free issue material/equipment shall only be checked visually for damages if any and for
correct quantities. Any discrepancies or damages (non-conformances) shall be informed to the Contractor.
The Contractor and Vendor (as applicable) are required to be present should any protective covers have to be
removed. After inspection by the Contractor and vendor as applicable, the protective covers & preservation
will have to be reinstated. If any obvious damage to the material has occurred, an OSD Report shall be raised
showing damaged parts as necessary.
8.3 Installation
Before installation, all locations, elevations and orientations of the equipment foundations and support
structures shall be checked and verified in accordance with installation drawings and specifications.
All equipment concrete foundations and support structures shall be respectively released by QC Civil and
Structural Inspectors prior to the erection of equipment. This release is controlled and documented in the
applicable civil and steel structure ITPs.
For critical rotating equipments like heavy compressors, etc an anchor bolt template shall be considered prior
to concreting of foundation and placement of bolts on the foundations. It is also necessary for the equipment
inspector to ensure before the concrete is poured that the required tolerances (including vendor tolerances)
are adhered to.
Confirm anchor bolts are plumb, and projection is as per drawing requirements.
Reference lines of levels and/or axis shall be marked / identified on the foundations. Before installation of
equipment, chipping shall be done on all the required surfaces of the foundations in preparation for grouting
and there shall be no remains of curing agents or other substances which hamper grout cure.
Shim plates shall be installed preferably by the equipment group or certainly with consultation with them and
as per the required lay-out and on either side of each anchor bolt. The number of shim plates, size and lay out
is decided based upon the size and weight of the equipment load the shim plates are required to carry. It is
essential that shim plates be fixed to the foundation surface using the same grout material that the foundation
will be eventually grouted with. It is recommended that the top of elevation of the installed shim plate is 1-2
millimeters lower than the required value. This will facilitate the alignment process to a great degree.
The elevation difference between top of concrete and top of shim plate shall allow for at least 1” (25.4mm) of
grout under the base plate or more if it is so required. In the case of epoxy grouting, the contact areas of
anchor bolts shall be wrapped with waterproof tape. It must be ensured that shim plate grout is cured prior to
loading the foundation.
The bottom of the base plate shall be cleaned by suitable means to remove mud, oil or grease prior to
installation. It shall also be ensured that the mating surface of the shim plate is rust free and free of any
grease or oil.
Once it is confirmed that the foundation as a whole is ready to receive the equipment, it shall be installed in
accordance with manufacturer’s installation manual, approved method statement and in accordance with
project specifications as applicable.
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

8.3.1 Levelling
1) Below recommendations shall be followed before commencing levelling of equipment that:
The height of the bottom surface of the equipment or base plate is within the specified project elevation and
centerline tolerances at a minimum of four locations that are diametrically opposite.
Orientation, elevation and levelness of installed equipment shall be documented in equipment ITP records.
2) Unless otherwise specified, levelling of rotating equipment shall be carried out with a calibrated machinist
level on the machined surfaces of the driver base plate and on the machined surfaces of the equipment
pedestals (or, if that is not possible, on the surface of the suction flange or discharge flange of the vertical
nozzles on the top of the equipment).
The levelling shall be measured in the direction of the shaft and at right angles to the shaft. Adjustments shall
be made by removing and inserting liners and wedges. Jack bolts shall be used when specified.
3) Base plate maximum out-of-level tolerance shall be 0.20 mm/m for API pumps and 0.40 mm/m for ASME
pumps, unless otherwise specified by project specification.
4) Liners, wedges and jack screws are standard erection aids for use during base plate/skid levelling
operations. Final choice depends upon site requirements and vendor installation manual.
5) At levelling inspection, it shall be confirmed that all anchor bolts of equipment are tightened to 80% of full
torque, depending on foundation design (not applicable for Box out)
6) Final tightening shall be carried out only after grouting and subsequent curing time has been completed.
7) After the locknuts on the anchor bolts are firmly fastened, the liners and wedges shall be tack-welded
together and excess shall be cut off by grinding and cleaned properly.
8) Recommended sizes for liners and wedges based on general industrial practices are shown below. These
dimensions may be modified as necessary for each application.

Item Length Width Thickness Taper

Liners 50-100 mm 50-75 mm 1,6.2.3,3.2,4.5,6,9,12,16

& 19 mm -

Wedges 50-100 mm 50-75 mm 6,9,12,19 & 25 mm 4-5°

9) Liners and wedges shall be located on both sides of and placed close to each anchor bolt. Where the
distance between the anchor bolts is larger than 80 cm for rotating equipment, then extra liners and wedges
shall be placed between the anchor bolts to prevent the base plate from bending.
10) When jacking screws are used for levelling equipment it is not necessary to remove them after grouting. It
is however required that the jacking screws be backed off two turns and the hold down bolts be re-torqued to
the correct value after the grout has adequately cured.
11) All driver base plates shall be provided with necessary jacking guides to facilitate alignment.
8.3.2 Preliminary Alignment
Prior to grouting of rotating equipment base plates/skids, the preliminary shafts alignment of the equipment
shall be carried out. If preliminary alignment requirements are met, then the base plates/skid shall be released
for grouting.
8.3.3 Axial Spacing (Clearance Between shaft Ends/Coupling Ends):
For flexible-element couplings, axial spacing between the shafts ends (DBSE) or coupling ends (DBCE) as
shown on the relevant drawing or vendor manual shall be measured using a thickness gauge, calipers, inside
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

micrometer and shall be accordingly maintained within + 0.25mm unless otherwise specified by
vendor/manufacturer requirements. Inside micrometer shall be used wherever applicable.
For spacer couplings, the coupling spacer free length shall be measured and used when setting the spacer
gap length.
For gear and elastomeric couplings in equipment trains, the spacer gap length shall be maintained within a
tolerance of + 0.75mm unless a closer tolerance is specified.
Expected shaft thermal growth, relative shaft movement, magnetic center and spacer gap length relative to
position of active thrust bearing shall be considered as applicable and as indicated by vendor manual.
8.3.4 Shim Recommendations:
Shims less than 0.100” (2.5 mm) thick shall be stainless steel. Shims thicker than 0.100” (2.5 mm) may be
carbon steel. The number of shims used under any one hold down bolt shall not be more than five. Mixing of
carbon steel and stainless steel shims is not allowed. All shims used shall be machined. The shims shall be
full bearing and straddle the hold down bolts. When shims are used directly under channel or “H” beam sub-
bases, the shims shall cover the entire width of the channel or “H” beam.
The use of tapered shims, laminated shims, brass & aluminium shims and shims thinner than 0.05 mm is not
permitted. Shims are generally supplied by vendor. If shims must be made at site, they shall be patterned
from the vendor’s shim or the support foot.
The movable machine shall have a minimum of three millimeters of 300 series stainless steel shims under
each support foot. The maximum shims stack height shall not exceed 12 mm. Only one three millimeters or
more shim is allowed per mounting foot.
An adequate assortment of stainless steel shim thicknesses are to be available to allow the number of shims
used at each location to be minimized.
8.3.5 Bolts and Bolts Clearance:
Undercutting of hold down bolts for alignment is not permitted. Lock washers are not permitted at machinery
hold down bolts.
If special washers are not provided by vendor or if standard washers yield when the hold down bolts are
torqued to the required value, thick ground washers shall be used.
8.3.6 Soft Foot:
All hold down bolts shall first be tightened using vendor specified criteria and measurement shall be taken as
each bolt is loosened. The hold down bolt shall be re-tightened before proceeding to the next foot. The
maximum tolerance for soft foot is 0.05 mm measured with a dial indicator placed on each foot. Soft foot
measurement check shall be carried out at each foot and not at the coupling shaft unless the situation
warrants it and in which case, it must be permitted by the designated authority.
8.3.7 Alignment Fixtures and Tools:
The alignment fixtures and brackets shall be suitable to each specific coupling apparatus and shall be
accordingly tagged. Suitable brackets need to be fabricated for operating temperature alignment. Use of
magnetic alignment fixtures is not permitted.
The maximum allowable sag for dial indicator brackets/fixtures used for alignment is ≤ 0.8 millimeters per
meter of span.
To ensure that all indicator readings (from top to bottom of shaft or from bottom to top position) are correctly
taken, the bracket sag present in the fixture must be determined before starting the alignment process. The
following steps must be taken to determine sag of any given bracket set up:
a) Mount the set up on a pipe length and allow the dial indicator to ride on the pipe itself
b) Set the indicator at “0” on top
c) Roll the pipe until the indicator is at the bottom of the pipe
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

d) The delta reading is algebraically subtracted from the reading obtained at the bottom position
In the example shown below, the bracket sag checked out at 0.05 mm. This reading will always be negative.
Further, it should be remembered that:
Bracket sag need not be considered for the horizontal or side to side readings
Bracket sag shall be checked for each DBSE (Distance Between Shaft End), recorded and taken into
consideration during shaft alignment process

Reading set at 0

Reading: -0.05 mm

8.3.8 Ambient Off-set:

This shall be pre-determined from vendor manual/instructions if applicable and implemented accordingly
during the coupling alignment process. It shall also be recorded in the inspection record.
8.3.9 Methods of Coupling Alignment:

Reverse Rim Alignment:

The dial gauges shall be mounted on the periphery of the coupling hubs of both the driver and the driven
equipment and the needles touched to the flange rims of the coupling hubs. The shafts shall be rotated at the
same time and in the direction of rotation simultaneously. The measuring points shall be at four points at 90
degree intervals.
The equipment shall be turned by hand whenever possible and strap wrenches may be used as required.
Pipe wrenches are not permitted.
For readings to be considered valid, the readings and zero shall repeat within 0.02 millimeters. The algebraic
sum of the horizontal and vertical plane readings shall be within 0.05 millimeters.
Alignment reading must be graphed if required & recorded in the corresponding inspection check list.
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

Rim and Face Alignment:

The parallelism of the end surface of the equipment coupling hub, and the offset values at the periphery of the
hub shall be measured respectively with dial gauges with readings taken at four points at 90 deg intervals. In
general, three dial gauges shall be mounted from the driver equipment’s hub to read on that of the driven hub,
one to read the periphery and two diametrically opposed to read facially. Both shafts shall be rotated
simultaneously unless it is not possible and in the direction of rotation and the readings recorded.
The equipment shall be turned by hand whenever possible and strap wrenches may be used as required.
Pipe wrenches are not permitted.
Rim readings shall be taken with a dial indicator and when made to a stationary hub or shaft it shall be
confirmed that the machined surface of the stationary machine is concentric to the centerline of rotation.
Face readings shall be taken with a dial indicator as well unless there is insufficient space.
Rim and Face Alignment is recommended when the coupling hub or shaft end flange diameter is greater than
the spacing between indicators or when one of the train elements cannot be turned.
Laser Alignment:
Laser alignment (non-dial-indicator-based alignment) shall be carried out if specified by user (Company). Only
trained personnel shall carry out this operation. It shall be ensured that the temperature of the brackets shall
equalize with that of the surroundings before the alignment operation commences. All requirements related to
safety and to electrically operated instruments shall be complied with.
Alignment Tolerances:
The alignment tolerances shall be in accordance with table below.
Final alignment readings shall not exceed the manufacturer’s recommendations or project specifications
whichever is more stringent or as applicable.

Tolerances Remarks

0.05 mm TIR at both indicator Unless a closer tolerance is specified by

Reverse Rim
locations manufacturer

0.05 mm angularity & at centre Unless a closer tolerance is specified by

Rim & Face
of coupling manufacturer

DBSE/DBCE
+ 0.25 mm when machine’s Unless a closer tolerance is specified by
(flexible element
rotating elements are in the manufacturer
& spacer
axial operational position.
couplings)

DBSE/DBCE + 0.75 mm when machine’s

Unless a closer tolerance is specified by
(elastomeric rotating elements are in the
manufacturer
coupling) axial operational position.

8.4 Installation of Driver at Site:

When a Driver is to be mounted onto a common base plate at site, the following steps shall be taken:
1) The base plate shall be levelled and the holding down bolts tightened to 80% torque.
2) The driver shall be put onto its base plate and aligned to the driven equipment.
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

3) The centers of the hold-down bolt holes shall be marked on the driver mounting pads.
4) The driver shall then be removed and bolt holes drilled and tapped on the mounting pads.
5) The driver shall be installed and aligned to the driven equipment.
6) The base plate shall be grouted in accordance with requirements.
When the equipment base plates are separated, the alignment and grouting shall first be carried out on the
main equipment base plate. Equipment on other base plate(s) shall then be levelled and aligned to the main
equipment skid.
The alignment of rotating equipment shall be carried out by inserting or removing shims under the saddles or
legs of driver and speed changer if applicable, until the centerlines of the equipments come within the
specified tolerances. In case of large equipments, these alignments will take place early in the mornings and
at the same time and same ambient temperature, simultaneously.
8.5 Grouting
Grouting shall proceed as per requirements of applicable ITP after preliminary alignment described above is
completed and accepted by QC inspector. Considering the importance of grouting in relation to rotating
equipments, a few points are mentioned here.
Preparation
The grouting of base plates shall be undertaken after completion and acceptance of the leveling, preliminary
alignment and release by the QC Equipment Inspector.
The top surface of the foundation shall be cleaned by blowing with compressed air. All foreign matter such as
grease, oil or other contamination shall be removed by suitable means.
For epoxy resin grout, the surface is required to be completely dry before application.
When applying cementitious grout, the foundation surface shall be thoroughly wetted with fresh water for 24
hours prior to placement of the grout mortar.
Water on the foundation and in the anchor bolt sleeves shall be removed by compressed air blowing, or other
means, immediately before grouting.
Foreign matter on the foundation surface shall be removed.

Materials
Materials for grouting shall be in accordance with the requirements of the applicable project specifications
unless otherwise noted.
Grout Procedure
The procedure for grouting shall be in accordance with the following and the applicable project specification.
1) Anchor bolt sleeves shall be filled with grout unless otherwise specified on the design drawings.
2) The grouting of the base plates shall be carried out as follows:
a) Formwork/shuttering shall be installed around the concrete foundation local to the area to be grouted.
b) The grouting materials shall be mixed and prepared in accordance with manufacturer’s instructions and
then poured through the grouting points up to the bottom face of the base plates. If the wedges and liners are
required to be buried, they shall be completely covered with grout.
c) If the removal of wedges and liners is specified, then block out systems, foams, plastics, board, etc, around
the wedges and liners shall be installed prior to grouting. Otherwise, the grout shall be removed around the
liners to facilitate the removal of wedges and liners after hardening.
d) After hardening of the grout, the cavity of the base plates shall be filled with grouting/concrete fill materials
in accordance with the referenced procedure and specification.
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

3) After complete hardening of the grouting, visual inspection shall be performed to confirm that it is free from
cracks and a hammer tap test on the surface of the equipment base plate shall be done to check for voids. All
voids shall be eliminated by filling with epoxy resin applied under pressure.

Curing
Grouting shall be cured as per project specification and grout manufacturer’s recommendations.
Post Curing
The following operations shall be performed after the grouting has cured:
Levelling screws shall be removed or “backed off” two turns.
Wedges and liners shall be removed from under reciprocating machinery and from under major centrifugal
machinery when recommended by the equipment manufacturer.
The space left by the removal of wedges and liners shall be dry packed with grout.
8.6 Solo-Run
Motors shall be uncoupled prior to solo run test. Coupling shall be secured and guarded if installed. Motors
shall be mechanically released by Equipment Engineer in accordance with the ITP to verify grout, lubrication
and bolting acceptance prior to motor solo run test. Solo run shall be conducted by Pre-commissioning Group
after accomplishing the safety lock-out/tag-out requirements. Dowelling to be performed wherever required
after final alignment is achieved.
8.7 Final Alignment
Once the preliminary alignment is completed, base plate skid is grouted and it is ascertained that grout is
cured, final alignment of rotating equipment may commence.
During final alignment, coupling alignment readings are taken first without piping connected (pipe-off) and next
with piping connected (pipe-on) to suction and delivery flanges. Flange parallelism and off-set on machinery
flanges shall be in accordance with API RP 686 requirements or as specified by project specifications.
Permanent pipe supports in accordance with project drawings shall be in correct position and secured
properly with the bolts fully tightened. Temporary supports shall be removed or loosened enough so that they
do not lend an influence to the alignment process.
8.7.1 Final Cold Alignment after Grouting and Connecting Piping:
1) Prior to the commencement of final cold alignment, grouting is required to be completed 100%. Additionally
all anchor bolts/nuts are also required to be tightened 100%.
2) All machine components shall be tested for soft foot in accordance with specification / vendor requirements
(refer details above).
3) Shims to be verified as detailed above.
4) After installation of the piping has been completed, the piping alignment to equipment can commence,
taking into account flange parallelism and off-set tolerances, etc. This data shall be recorded in the inspection
record.
5) Final alignment pipe-off shall be checked while considering ambient offset requirements. Spring
Hanger/Support Stop shall be in place (cold position). If final alignment pipe-off readings are satisfactory shaft
deflection due to pipe stress shall be checked. The maximum shaft movement in either the vertical or
horizontal directions after the flange is tightened shall be in accordance with API RP 686 or project
specifications. If the shaft movement is more than the specified value, the piping flange shall be loosened
from the machinery and corrections made to the piping or supports. After the piping has been corrected,
piping alignment shall be rechecked for acceptance.
 QUALITY CONTROL PROCEDURE
INSTALLATION of ROTATING EQUIPMENTS
Power Systems

6) Final alignment pipe-on (flanges fully tightened/torqued) shall be checked and recorded after acceptance of
shaft deflection values. Confirmation shall be obtained that connecting piping has been hydro tested and
properly cleaned to ensure that no sand, dust or other foreign matters enters the interior of the rotating
machinery.
7) Any piping misalignment found during the inspection is required to be rectified. The rectification shall be
carried out without disturbing the equipment alignment.
8) Final alignment pipe-on (flanges fully tightened/torqued) shall be checked and recorded after acceptance of
shaft deflection values.
9) For turbine driven equipment, final cold alignment shall be carried out with a specified offset after the piping
alignment for both the turbine and the driven equipment has been completed. Steam piping to turbine shall be
cleaned by steam blowing operations as per specification and vendor acceptance criteria shall be met prior to
connections to turbine flanges.
10) All inspection and installation data shall be recorded as per ITP requirements. After installation of the
rotating equipment, the auxiliary piping, oilers, and other accessories shall be installed in accordance with
project drawings and vendor manual.
8.7.2 Operating Temperature (Thermal) Alignment
When operating temperature alignment is required, alignment checks shall be carried out with the equipment
in operation. The procedure and tolerances shall be mutually confirmed based upon vendor
instructions/requirements and applicable specifications.
8.8 Installation of Agitators/Mixers on Drums (Pressure Vessels)
The machined surface of the mounting flange shall be thoroughly cleaned and levelness achieved within the
required tolerance by using a machinist level. The unit must be aligned as per vendor requirements and if a
blade clearance is prescribed, it must be verified and recorded. The levelness of the mounting flange shall be
ensured before the base-plates/saddles of the pressure vessel are grouted to the foundation.
8.9 Installation of Vertical Pumps on Drums (Pressure Vessels)
The machined surface of the mounting flange shall be thoroughly cleaned and levelness achieved within the
required tolerance by using a machinist level. Coupling alignment and DBSE/DBCE shall meet vendor
requirements and shall be verified and recorded accordingly. The levelness of the mounting flange shall be
ensured before the base-plates/saddles of the pressure vessel are grouted to the foundation.

9.0 INSPECTION & TEST STATUS

The inspection and test status shall be defined and controlled by the applicable Inspection & Test Plan (ITP)
and the respective Inspection Check List. Inspection activities shall be recorded progressively by QCI.

10.0 ATTACHMENTS
PP13-00-Y-QPT-GAM-016: Inspection and Test Plan for Static and Rotating Equipment Installation
 1 of 6

SEC PP13
INSPECTION and TEST PLAN (ITP)
STATIC & ROTATING EQUIPMENT INSTALLATION
PROJECT: SEC PP13 Project
INSPECTION AND TEST PLAN (ITP)
CLIENT: SEC/WP
Discipline: Mechanical DOCUMENT Rev: 0
PP13-00-Y-QPT-GAM-016
Location: PP13 Dhurma Saudi Arabia NUMBER Date: 13.02.2016

INSPECTION
TEST / INSPECTION POINTS
Item Activity Description Reference Document Report Reference
REQUIREMENT GAMA
WP/
No. SUBCONT GAMA
RACTOR SEC

1 MATERIAL

PP13-00-Y-LNA-GAM-001-FR001, PP13-
1.1 Material Approval 100% Physical Check Purchase order H W R 00-Y-LNA-GAM-002-FR001

PP13-00-Y-LNA-GAM-001-FR001, PP13-
1.2 Material delivery and inspection 100% Physical Check Vendor specification H W R 00-Y-LNA-GAM-002-FR001

PP13-00-Y-LNA-GAM-001-FR001, PP13-
1.3 Material handling and storage 100% Physical Check Vendor specification H W R 00-Y-LNA-GAM-002-FR001

2 DOCUMENT REVIEW

2.1 Review of technical documentation 100% Review IFC drawings H R R Equipment installation checlist

Calibration procedure PP13-00-Y-QNQ-GAM-

2.2 Calibration records 100% Review 018
H R R Calibration records

2.3 Preservation control 100% Visual / Review Preservation procedure H W R Preservation reports

3 BEFORE INSTALLATION

3.1 Conduct site survey of civil foundations Survey Civil drawings H W R Survey reports

3.2 Check chipping and brushing of foundation surface and padding inspection 100% Visual Civil drawings H W W Equipment installation checlist
 2 of 6

SEC PP13
INSPECTION and TEST PLAN (ITP)
STATIC & ROTATING EQUIPMENT INSTALLATION
PROJECT: SEC PP13 Project
INSPECTION AND TEST PLAN (ITP)
CLIENT: SEC/WP
Discipline: Mechanical DOCUMENT Rev: 0
PP13-00-Y-QPT-GAM-016
Location: PP13 Dhurma Saudi Arabia NUMBER Date: 13.02.2016

INSPECTION
TEST / INSPECTION POINTS
Item Activity Description Reference Document Report Reference
REQUIREMENT GAMA
WP/
No. SUBCONT GAMA
RACTOR SEC

4 STATIC EQUIPMENT INSTALLATION

4.1 HORIZONTAL EQUIPMENTS

4.1.1 Positioning inspection of the equipment and orientation check 100% Dimensional Approved drawings H W R Equipment installation checlist

4.1.2 Alignment and levelling inspection of the equipment Survey Approved drawings H W W Equipment installation checlist

4.1.3 Internal Inspection if necessary (Cleaning, tray, final closure and torqueing) 100% Visual / Review Vendor requirements H W R Equipment installation checlist

4.1.4 Final tightening of the anchor bolts with calibrated wrench 100% Control Vendor requirements H W R PP13-00-Y-QDF-GAM-044

4.1.5 Conduct grouting activity Test Approved drawings H W R 3rp party report

4.1.6 Flange face verification (Cleaning, gasket type, bolting) 100% Visual / Review Vendor requirements H W R Equipment installation checlist

4.2 VERTICAL EQUIPMENTS

4.2.1 Positioning inspection of the equipment and orientation check 100% Dimensional Approved drawings H W R Equipment installation checlist

4.2.2 Alignment and levelling inspection of the equipment Survey Approved drawings H W W Survey report

4.2.3 Check verticality of the equipment Survey Approved drawings H W W Survey report

4.2.4 Internal Inspection if necessary (Cleaning, tray, final closure and torqueing) 100% Visual / Review Vendor requirements H W R Equipment installation checlist

4.2.5 Final tightening of the anchor bolts with calibrated wrench 100% Control Vendor requirements H W R PP13-00-Y-QDF-GAM-044
 3 of 6

SEC PP13
INSPECTION and TEST PLAN (ITP)
STATIC & ROTATING EQUIPMENT INSTALLATION
PROJECT: SEC PP13 Project
INSPECTION AND TEST PLAN (ITP)
CLIENT: SEC/WP
Discipline: Mechanical DOCUMENT Rev: 0
PP13-00-Y-QPT-GAM-016
Location: PP13 Dhurma Saudi Arabia NUMBER Date: 13.02.2016

INSPECTION
TEST / INSPECTION POINTS
Item Activity Description Reference Document Report Reference
REQUIREMENT GAMA
WP/
No. SUBCONT GAMA
RACTOR SEC

4.2.6 Conduct grouting activity Test Approved drawings H W R 3rp party report

4.2.7 Flange face verification (Cleaning, gasket type, bolting) 100% Visual / Review Vendor requirements H W R Equipment installation checlist

5 ROTATING EQUIPMENT

5.1 Positioning inspection of the equipment and orientation check 100% Dimensional Approved drawings H W R Equipment installation checlist

5.2 Alignment and levelling inspection of the equipment Survey Approved drawings H W W Survey report

Approved drawings, Vendor requirements, API

5.3 Shaft, coupling preliminary alignment (Reverse or Face & Rim Method) 100% Dimensional 686
H W W Equipment installation checlist

5.4 Conduct grouting activity Test Approved drawings H W R 3rp party report

5.5 Final tightening of the anchor bolts with calibrated wrench 100% Control Vendor requirements H W R PP13-00-Y-QDF-GAM-044

5.6 Shaft, coupling final alignment (DBSE, Run out, soft foot chek) 100% Dimensional Vendor requirements, API 686 H W W Equipment installation checlist

Approved drawings, Vendor requirements, API

5.7 Check that pipe (Suction, discharge) connections are free from stress 100% Visual 688
H W R Equipment installation checlist

5.8 Final flange bolt torquing 100% Control Vendor requirements H W R PP13-00-Y-QDF-GAM-044
 4 of 6

SEC PP13
INSPECTION and TEST PLAN (ITP)
STATIC & ROTATING EQUIPMENT INSTALLATION
PROJECT: SEC PP13 Project
INSPECTION AND TEST PLAN (ITP)
CLIENT: SEC/WP
Discipline: Mechanical DOCUMENT Rev: 0
PP13-00-Y-QPT-GAM-016
Location: PP13 Dhurma Saudi Arabia NUMBER Date: 13.02.2016

INSPECTION
TEST / INSPECTION POINTS
Item Activity Description Reference Document Report Reference
REQUIREMENT GAMA
WP/
No. SUBCONT GAMA
RACTOR SEC

6 INSTALLATION of COMPRESSOR & BLOWER & FAN

6.1 Positioning inspection of the equipment and orientation check 100% Dimensional Approved drawings H W R Equipment installation checlist

6.2 Alignment and levelling inspection of the equipment Survey Approved drawings H W W Survey report

6.3 Shaft, coupling preliminary alignment (Reverse or Face & Rim Method) 100% Dimensional Vendor requirements H W W Equipment installation checlist

6.4 Conduct grouting activity Test Approved drawings H W R 3rp party report

6.5 Flange face verification (Cleaning, gasket type, bolting) 100% Visual / Review Vendor requirements H W R Equipment installation checlist

6.6 Final tightening of the anchor bolts with calibrated wrench 100% Control Vendor requirements H W R PP13-00-Y-QDF-GAM-044

6.7 Shaft, coupling final alignment (DBSE, Run out, soft foot chek) 100% Dimensional Vendor requirements, API 686 H W W Equipment installation checlist

Approved drawings, Vendor requirements, API

6.8 Check that pipe (Suction, discharge) connections are free from stress 100% Visual 688
H W R Equipment installation checlist

6.9 Final flange bolt torquing 100% Control Vendor requirements H W R PP13-00-Y-QDF-GAM-044

6.10 Installation of coupling spacers & coupling guards 100% Visual Approved drawings H W R Equipment installation checlist

6.11 Blower & Fan alignment (if applicable) 100% Dimensional Vendor requirements H W R Equipment installation checlist
 5 of 6

SEC PP13
INSPECTION and TEST PLAN (ITP)
STATIC & ROTATING EQUIPMENT INSTALLATION
PROJECT: SEC PP13 Project
INSPECTION AND TEST PLAN (ITP)
CLIENT: SEC/WP
Discipline: Mechanical DOCUMENT Rev: 0
PP13-00-Y-QPT-GAM-016
Location: PP13 Dhurma Saudi Arabia NUMBER Date: 13.02.2016

INSPECTION
TEST / INSPECTION POINTS
Item Activity Description Reference Document Report Reference
REQUIREMENT GAMA
WP/
No. SUBCONT GAMA
RACTOR SEC

7 INSTALLATION of PUMP

7.1 Positioning inspection of the equipment and orientation check 100% Dimensional Approved drawings H W R Equipment installation checlist

7.2 Alignment and levelling inspection of the equipment Survey Approved drawings, API 686 H W W Survey report

7.3 Shaft, coupling preliminary alignment (Reverse or Face & Rim Method) 100% Dimensional Vendor requirements, API 686 H W W Equipment installation checlist

7.4 Conduct grouting activity Test Approved drawings, Vendor requirements H W R 3rp party report

7.5 Check that pipe, nozzle and instrument connections are free from stress 100% Visual Approved drawings H W R Equipment installation checlist

7.6 Flange face verification (Cleaning, gasket type, bolting) 100% Visual / Review Vendor requirements H W R Equipment installation checlist

7.7 Final tightening of the anchor bolts with calibrated wrench 100% Control Vendor requirements H W R PP13-00-Y-QDF-GAM-044

7.8 Shaft, coupling final alignment (DBSE, Run out, soft foot chek) 100% Dimensional Vendor requirements, API 686 H W W Equipment installation checlist

Approved drawings, Vendor requirements, API

7.9 Check that pipe (Suction, discharge) connections are free from stress 100% Visual 688
H W R Equipment installation checlist

7.10 Final flange bolt torquing 100% Control Vendor requirements H W R PP13-00-Y-QDF-GAM-044

7.11 Installation of coupling spacers & coupling guards 100% Visual Approved drawings H W R Equipment installation checlist
 6 of 6

SEC PP13
INSPECTION and TEST PLAN (ITP)
STATIC & ROTATING EQUIPMENT INSTALLATION
PROJECT: SEC PP13 Project
INSPECTION AND TEST PLAN (ITP)
CLIENT: SEC/WP
Discipline: Mechanical DOCUMENT Rev: 0
PP13-00-Y-QPT-GAM-016
Location: PP13 Dhurma Saudi Arabia NUMBER Date: 13.02.2016

INSPECTION
TEST / INSPECTION POINTS
Item Activity Description Reference Document Report Reference
REQUIREMENT GAMA
WP/
No. SUBCONT GAMA
RACTOR SEC

8 FINAL CONTROL

8.1 Final walkdown / preparation of punch list %100 Visual Check Approved drawings, Vendor requirements H W W Punch list

8.2 Closure of punch items %100 Visual Check Approved drawings, Vendor requirements H W R Punch list

9 MECHANICAL COMPLETION (MC) PACKAGE

9.1 Compilation, submission and handover of mechanical completion package %100 Review Approved drawings, Vendor requirements H W R MC Package

REPORT  REFERENCE:

LEGEND:
Inspection Point Definitions:
GAMA - Contractor ; WP - Client Representative ; SEC - Client ; H - Hold point ; W - Witness Point ; M - Surveillance/Monitoring ; R - Document
Review & Approval
HOLD POINT (H) : An activity that requires inspection/verification and acceptance by WP/SEC before any further progress of work is permitted.
The contractor shall not progress the activity beyond hold point without written acceptance or approval from WP/SEC. Hold point require
mandatory notification to WP/SEC
WITNESS POINT (W) : An activity that requires inspection/verification and acceptance by WP/SEC but their presence is not mandatory.
Subcontractor shall notify WP/SEC but there is no hold on the activity.

MONITOR POINT (M) : Monitoring or making observations to verify work activities, materials, equipment, etc. Conform to specified requirements.

REVIEW (R) : Document review and approval of subcontractors qualit documentation.

 PP13 COMBINED CYCLE POWER PLANT PROJECT

EQUIPMENT and MATERIALS Date

RECEIVING REPORT
Gama Güç Sistemleri Mühendislik Report
ve Taahhüt A.Ş.
(EMRR)
No

PO Number/Packing List : Date Received :

Supplier :

EQUIPMENT/ LENGTH
SIZE/DIAMETER QUANTITY Remarks
DESCRIPTION (Meter or
MATERAL NO (mm) (pcs)
mm)

FINDINGS:

INSPECTOR MATERIAL MANAGER QA/QC MANAGER OWNER / ENGINEER

Name: Name: Name: Name:

Sign: Sign: Sign: Sign:

Date: Date: Date: Date:

Doc. No: PP13-00-Y-LNA-GAM-001-FR001
 
 
Gama Güç Sistemleri Mühendislik PP13 COMBINED CYCLE POWER PLANT  
ve Taahhüt A.Ş.
DATE:   
OVERAGE, SHORTAGE & DAMAGE REPORT 
(OSDR)  REPORT NO:   
 
Date Received 
PO Number/Packing List:   Supplier :   Truck/Vessel Name:  
 
 
EQUIPMENT No/ TAG No / MTRL  SHIPPED  RECEIVED  DISCREPAN REASON 
NO  PACKAGE No  DESCRIPTION / SPECIFICATION  REMARKS* 
CODE  QTY  QTY  CY QTY  (OSD) 

                 

                 

                 

                 

                 

                 

                 

                 

                 

Re‐purchase Surveyor Required (Vendor/Insurance)
DISPLACEMENT/SOLUTION:  Repair at Vendor/MFGR Cost   Insurance Claim To be Applied
Re‐supply & Claim to Vendor Others: to be repaired at the site during work
 

REASON:     O (Overage)             S (Shortage)             D (Damage)          N  (Non‐conformance) 
*Remarks:  
 
 
MATERIAL ENG./INSPECTOR  QA/QC MANAGER  OWNER / ENGINEER (IF REQUIRED) 
Name:    Name:    Name:   
     
Sign:  Sign:  Sign: 
     
Date:  Date:  Date: 
       Doc. No:  PP13‐00‐Y‐LNA‐GAM‐002‐FR001 
 
 
 
 
 Report No /
Rapor No
TORQUE CONTROL FORM Date / Tarih

Page / Sayfa 1 REV. 0

PROJECT NUMBER / PROJE NO DRAWING NUMBER / RESİM NO

TANK NUMBER / TANK NUMARASI TANK SIZE / TANK ÇAPI

CODE OF PRACTICE /
TANK CAPACITY / TANK KAPASİTESİ
UYGULAMA KODU

ITP NO ITP ITEM NO

RESULTS OF MEASUREMENT CONTROL / ÖLÇÜ KONTROL SONUÇLARI

MATERIAL INFORMATION :

MEASURED VALUES TORQING / MEASURED VALUES TORQING /
ANK. NO RESULT / SONUÇ ANK NO RESULT / SONUÇ
ÖLÇÜLEN TORKLAMA DEĞERİ ÖLÇÜLEN TORKLAMA DEĞERİ

PREPARED BY CONTROLLED BY APPROVED BY

NAME SURNAME

DATE                                    

SIGNATURE

PP13‐00‐Y‐QDF‐GAM‐044