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    Installation STD - ONGC

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    vishwaracharya

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    © All Rights Reserved
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    260 1 : STANDARD ENGINEERING SPECIFICATION INSTALLATION OF HEAT EXCHANGERS AND VESSELS DOCUMENT NO. 2 D-303 PROJECT : SULPHUR RECOVERY UNIT TEIL JOB NO, : 6245 OWNER OIL AND NATURAL GAS CORPORATION LIMITED ONGC, URAN . : | 1 | | mI 18/10/07 | FIRST ISSUE FOR ENQUIRY we | - MADE | REVIEWED | APPROVED | pare | DESORPTION | May’ ey Heoy G TOYO ENGINEERING INDIA LIMITED MUMBAI, INDIA . 264 @ INSTALLATION OF VESSELS & HEAT ‘TOYO ENGINEERING INDIA LTD, ISSUED DATE: 18/10/07 EXCHANGERS: SRU - ONGG, URAN DOC No. : D-303 Page 1 0f9 |. General ‘Scope .... ee Related Engineering 2. Installation works .... 3. In-process check 3.1. Preparation of Foundation 3.2 Setting of Liners or Mortar pad 3.3. Anchor Bolts Setting .... 3.4 Setting of Equipment 3.5. Grouting of Anchor P. 3.6 Alignment... 3.7. Grouting of Base 4. Alignment . 4.4 Tolerance 4.2. Priority Criteria 4.3 Alignment of Vertical 4.4 Alignment of Skid-mounted Equipment 4.5. Alignment of Stacking-type Equipment... Specific Job requirements . CONTENTS Specifications ocket Equipment 5. Assembling of accessories 5.1 Intemal Parts 5.2. Platform and Ladder 5.3 Davit 7 PAGE NO NNN RNNOGO aaureeean nv ODED | : . e62 @ INSTALLATION OF VESSELS & HEAT : = EXCHANGERS Coe ovo ENOIMEE ING mNA LT : ISSUED DATE: 1an0IU7 SRU - ONGC, URAN Page 2019 Hee GENERAL 1.4 Scope 1.4.4. This Specification covers general requirements for the installation and inspection of vessels and heat exchangers (hereinafter collectively referred to as equipment), which may be included in the plant constructed by Toyo Engineering india Limited, (hereinafter referred to as TEAL). 1.4.2. This specification covers the general requirements for ather similar type of static equipment, such as silencers, filters etc. 1.1.3. Vessels, heat exchangers or tanks to be fabricated at site are not covered by this specification. 1.2 Specific Job Requirements Specific Job requirements which may be attached to this specification cover modifications to this specification, customer's special andi { of focal requirements as Well as specific jab data pertaining to this specification. Where Specific job Requirements are in contradiction to this specification, Specific Job Requirements shall govern, 1.3. Related Engineering Specifications The related Engineering Specification to supplement this specification is as follows: -301 “General Requirement in Equipment installation” 2, INSTALLATION WORKS Equipment shail be installed in correct position and oriéntation. Due care shall be paid to the following points during the wark. (1) Prevention of damage to foundation, foundation bolts, equipment, adjacent structures etc. | | ao oe @ ‘TOYO ENGINEERING INDIA LTD, | INSTALLATION OF VESSELS & HEAT EXCHANGERS DOC No. : D-303 ISSUED DATE: 48/1007 SRU - ONGC, URAN Page 3 of9 2) 8) (4) 6) (6) Where the equipment having skirt or flat support is directly placed on the foundation, the vessel shall be installed without excessive concentrated force against bottom piate. For horizontal equipment which are subject to expansion! contraction, the relative position between foundation bolts and bolt holes shall be set to allow free movement of the equipment in the correct direction of expansion / contraction. Where sliding plates are used, no liners shall be applied between base plate and sliding plate. Contact surfaces shall be cleaned and metal to metal coated with grease or graphite. After completion of installation of the equipment and connection with piping, the nuts of the anchor bolts at sliding side shall be loosened to give 1 to 2 mm of clearance, and then tightened with lock nuts leaving this clearance. Welding of liners shall be cartied out after completion of final alignment Inspection. In general, no weiding shall be permitted between base plate ‘and liners. Where wooden pillows are used, setting aid tightening of anchor bolts shall be in accordance with drawings and manufacturer's installation manual. ‘ 264 @ INSTALLATION OF VESSELS & HEAT . @ TRCHAIGERS DOC NO. : D-303 ‘Toro ENGINEERING INDIALTO ee ee 'SSUED DATE: 18/1007 | SRU - ONGC, URAN Page 4 of@ 3. IN-PROCESS CHECK 3.1 Preparation of Foundation (1) Cleanliness of foundation surface and anchor bolt pockets. (2) Flatness of foundation surface where chipped. 3.2. Setting of Liners or Mortar Pad (1) Numbers and size of liners or mortar pads. (2) Uniforrn contact of iners with foundation surface. (3) Surface of liner plates. (4) Mixing ratio and condition of mortar, in the case of mortar pads. (©) Elevation and level, (8) Position 3.3 Anchor Bott Setting (1) Size and setting position for projection and Centre. (2) Perpendiculatity (8) Free from oil and damage. (4) Thread lubrication 3.4 Setting of Equipment (1) Cleanliness and smoothness of mounting face (s). (2) Damage and foreign material on the surface. 3.5 Grounting of Anchor Pocket (1) Mixing ratio and condition of grouting mortar (2) Filling method and complete penetration (8) Curing period 265 @ INSTALLATION OF VESSELS & HEAT aa EXCHANGERS “FO¥O ENGINEERING INDIA LTO| ISSUED DATE: 18/10/07 SRU -ONGG, URAN (4) Atter curing, cracks peeling-off and cavities. 3.6 Alignment (1) Elevation (2) Position (8) Pespendicularity or level 3.7 Grouting of Base (1) Mixing ratio and condition of grouting mortar (2) Filling method and complete penetration. 4, ALIGNMENT 4.1 Tolerance Alignment of the equipment shall be carried out specified: (1) Tolerance shall be as in the following table: Te [artical Elevation 1 Postion DOC No. : D-303 Page 5of8 as follows, unless otherwise Unit; mm. ‘Haraontal Porpendiculanity. 0.8/1 000, {And not more than 19 mm) Tove : rs | (And not more than 19 sen) “Oar 006 J (2) Elevation shall be measured on the basis of level marking on the foundation, (3) Position shall be measured on the basis of Centre marking of the foundation. 42 Priority Criteria @ INSTALLATION OF VESSELS & HEAT De @ ExcHaneces DOC No. : 0-303 ‘TOYO ENGINEERING INDIA LTO] a ISSUED DATE: 18/10/07 | SRU - ONGC, URAN Page 6 of 9 424 When the criteria stipulated in Par. 4.1 above interfere each other, the following ‘order of priority may be given: (1) Vertical equipment (2) Petpendicularity (b) Position (©) Elevation (2) Horizontal equipment (a) Horizontality (b) Position (©) Elevation Regardless of the above priority, where an equipment is connected directly to special piping or another equipment, relative position and elevation shall be given the priority @ INSTALLATION OF VESSELS & HEAT oe EXCHANGERS TOYO ENGINEERING INDIALTO, = ISSUED DATE: 19/1007 SRU - ONGC, URAN Page 7 of 9 4.3 Alignment of Vertical Equipment 44 45 454 45.2 In general, alignment of vertical equipment shall be performed on 3 points from top 10 bottom of one orientation at two orientation of right angle to each other. Alignment of Skid-mounted Equipment Alignment of skid-mounted equipment shall be performed for horizontality, position and elevation of skid-base. Alignment check for each component is not required Alignment of Stacking-type Equipment Alignment of stacking-type equipment shall be performed based on relative position and elevation of connecting nozzles, adjusting by placing shim plates between base plates of lower equipment and upper equipment. In the case of flange connection, applying paste on gaskels, inserting gaskets and ‘bolt tightening shall be confirmed : RER ‘TOYO ENGINEERING INDIA LTD. @ INSTALLATION OF VESSELS & HEAT | i 2 TXCHANGERS DOC No. : D-303 ISSUED DATE: 48/1007 SRU - ONGC, URAN [Page # oF ASSEMBLING OF ACCESSORIES 5.1 Internal parts Instaltation of internal parts such as, main beam, distributor, demister, grating etc., shall be performed in accordance with drawing, with consideration of work sequence for catalyst / packing loading of tray assembly work. 5.2 Platform and Ladder 5.2.1. Platforms and ladders may be mounted any time before or after the installation of the equipment. However, when mounted before installation, it shalh be confirmed that those will not affect the erection work of equipment, 5.2.2 When platforms and ladders are fixed to vertical towers and vessels subject to ‘expansion / contraction, slot holes of platforms, ladders oF lugs and loosening of muts shall be confirmed. 5.2.3 Gorrect setting of step bolts and washers shall be checked. 5.24 When deformation of checker plates of platform floor is found, repair shall be carried out by heating or reinforcing. 5.2.5 Welding slag of platform and ladders shall be completely removed by chipping chisel & hammer. 5.2.6 When handrails are assembied by welding at site, the weld bead shai! be finished flush by gfinding, 5.2.7 Smooth movement and correct position of safety gate (bar) shall be checked. §.2.8. For cold service equipment, insulation plates or washers shall be inserted between lug and platform / ladder, 269 + @ INSTALLATION OF VESSELS & HEAT z fa. of EXCHANGERS DOC NO. : D-303 OVO ENGINEERING WOIALTO, = ISSUED DATE: 18/10/07 SRU - ONGC, URAN Page 9 of 9 5.3 Davit 5.3.1 Davits shall be mounted in accordance with drawings. 5.3.2. After mounting of davits, free movement shail be checked. Rev. Revision history 270 Annexure (3) D-303 Sheet 1 of 1 Date T Description : . RPL STANDARD ENGINEERING SPECIFICATION INSTALLATION OF PUMPS AND BLOWERS DOCUMENT NO. : GA-301 PROJECT : SULPHUR RECOVERY UNIT TEIL JOB NO. : 6245 OWNER OIL AND NATURAL GAS CORPORATION LIMITED ONGC, URAN ae | | i 0 | 18/0/07 | FIRST ISSUE FOR ENQUIRY aaareea MADE «| REVIEWED [ Rev [pare DESCRIPTION i AY owt TOYO ENGINEERING INOIA LIMITED MUMBAI, INDIA. | @ INSTALLATION OF PUMPS AND DOC No. : rom Ss ‘TOYO ENGINEERING INDIA Lr! oe |__GA-301 ISSUED DATE: 18/10/07 SRU - ONGC, URAN [__Page tof 11 CONTENTS PAGE NO 1. General .. es 2 4A Scope ..... a 2 42 Specific Job requirements 2 1.3 Related Engineering Specifications 2 2. Execution of works 2 2.4 Manufacturer's installation Manual . 2 2.2 General Requirements 3 2.3 Installation 3 2.4 Alignment ... 4 3. In-process check... 4 4. tem for in-process check 5 4.1. Preparation of foundation 5 4.2 Setting of Temporary Liners or Mortar pad 5 4.3 Anchor Bolts settiAg monn : 5 4.4 Pump base alignment 6 4.5 Grouting of anchor pocket 6 46 Selling of permanent liners 6 4.7 Alignment of shafts .... : 6 4.8 Grouting of pump base ........ Seen aareey 6 49 Final alignment alter piping connection . 6 5. Procedure and acceptance standard for inspection and test 7 5A Alignment : oe 7 5.2 Final alignment 8 5.3. Trial running .. 9 6. Care and custody ... 1 6.4. Initial charge of lubricant oll and grease | "1 62 Periodical rotation eee "1 @ INSTALLATION OF PUMPS AND em BLOWERS. TOYO ENGINEERING INDIAL ISSUED DATE: 18/10/07 SRU - ONGC, URAN Page 2 011% 13 24 General Scope (0) This specification covers the general requirements for the installation and inspection of pumps, blowers and other general rotating machinery, as well as gearboxes for the general service (hereinafter collectively referred to as pumps), which may be included in the plant constructed by Toyo Engineering India Limited (hereinafter referred to as TEIL). (2) Procedure for alignment of the pump and driver in this specification does not cover belt or chain driven pumps. Specific Job Requirements Specific Job requirements which may be attached to this specification cover modifications to this specification, customer's special and { ar local requirements as well as specific job data pertaining to this specification Where Specific job Requirements are in contradiction to this specification, Specific Job Requirements shall govern. Related Engineering Specifications The related Engineering Specification to supplement this specification is as follows: 0-301 * General Requirement in Equipment installation” EXEGUTION OF WORKS. Manufacturer's Installation manual This specification stipulates standard pracedure for installation of pumps. However, when the manufacturer's installation manual, approved by TEIL, is available, the work shall be carried out in accordance with the manufacturer's installation manual : | | | @ INSTALLATION Ore AND DOENG | TOYO ENGINEERING INDIA LTO] GA-304 SRU - ONGC, URAN Page 3 of 11 22 232 233 234 General requirements General requirements, which are common to equipment installation, shall be in accordance with Engineering Specification D-301. Installation installation and alignment of pump shall generally be carried out in the order as follows: (1) Prepare the surface of foundation for installation. (2) Set temporary liners in accordance with Engineering Specification D- 301 (3) Place pump with base on the liners and set anchor bolts. (4) Align provisionally the pump base. (5) Fixthe anchor bolts by pouring mortar into anchor pockets. (6) Set permanent liners as near as to and both sides of each anchor bolt, after the mortar has cured. (7) Remove temporary liners. (8) Tighten anchor botts. (9) Align the pump and driver and tighten hold-down bolts. (10) Grout the base plate. (11) Connect piping systems. (12) Check the final alignment of the pump and driver; couple the shafts between pump and ériver. Installation of the pump base and pump shall be carried out within the tolerances specified in Sect. 5 of this specification. Leveling of pump base shall be carried out both axial and radial directions. For vertical pump of cold services, insulation of casing pipe shall be provided before installation @ dma ad PUMPS AND Ocho TOYO ENGINEERING INDIA LTD, oe GA-301 ISSUED DATE: 16/1007 $RU - ONGC, URAN Page 4of 11 24 Alignment 2.4.1 The alignment of the pump shall be carried out on the basis of the finished metal surfaces being as near as possible to the Centre of the shaft. 2.4.2 Parallel deviation and angular deviation of the driving and driven shafts shall be individually measured. 2.4.3 Where dial gauge is fixed on arm with a magnetic base, the following precautions shail be taken for decreasing errors caused by change of measure points. (1) Fix firmly. (2) Shorten the arm length as much as possible. (3) Use small type dial gauge (lightweight). (@) — Pilt measuring point of the dial gauge at fight angle to the shaft, pointing tothe Centre of the shaft. 24.4 When the manufacturer specifies the offset figures, the alignment shail be performed incorporating the offset into the tolerance. 24.5 After completion of alignment, it shall be confirmed that the shaft can be rotated smoothly by hand. 2.4.6 After confirming the direction of rotation and freedom of rotation, the shafts shall be coupled. 3. in-process check Prior to, during and after completion of the installation works, the following synopsis of check, inspection and tests shall be performed. However, where the manufacturers installation manual includes inspection, this shell be carried out according to the manufacturer's installation manual. c 276 T { @ | INSTALLATION a ue AND poc No. : | Tova enaneERING WA LTO| caso | | ISSUED DATE: 18/1007 RU - ONGC, URAN Page Sof 11 A Timing ‘Check, Inspection and Test ltems 1 Prior to proceeding with the works_| (1) Preparation of foundation. 2” Installation of pump base (1) Setting of temporary liners or mortar pad (2) Anchor botts (8) pump base alignment (4) Grouting of anchor pockets (6) Setting of permanent liners 3 Installation of pump and driver | (1) Alignment of shafts (2) Grouting of pump base ii (3) Final alignment after piping connection 4 Ater completion of installation (1) Motor rotating direction (2) Motor no-load test (3) Turbine solo-run test * (4) Trial running : Vibration, temperature, sound et Note * Only for turbine driven pumps. Item for in process check 4.1 Preparation of foundation (1) Cleaniiness of foundation surface and anchor bolt pockets. (2) _ Flatness of foundation surface where chipped. 4.2 Setting of temporary liners or Mortar pad { (1) Numbers and size of temporary tiners or mortar pads. (2) Uniform contact of liners with foundation surface. (3) Surface of liners plates. (4) Mixing ratio and condition of mortar, in the case of mortar pads (5) Elevation and ievel. (6) Position. 4.3 Anchor bolts setting (1) Size and setting position for projection and Centre. (2) Perpendicutarity. (3) Free from oil and damage. (4) Thread lubrication, | : . 277 @ STALE ATION OE RUNES AND BOeNO “oYO ENGINEERING INIA LO) GA-301 ISSUED OATE: 181007 | SRU - ONGC, URAN Pago 6 oft 44 45 46 47 48 49 Pump base alignment (1) Elevation. (2) Position. (8) Level or Perpendicutarity Grouting of anchor pocket (1) Mixing ratio and condition of grouting mortar. (2) Filling method and complete penetration: (3) Curing period (4) After curing, cracks peeling-off and cavities. Setting of permanent liners (1) Uniform contact of permanent tiners with the foundation surface and pump base (2) Position. Alignment of shafts (1) Parallel deviation (2) Angular deviation. (3) Distance between the couplings. Grouting of pump base (1) Mixing ratio and condition of grouting mortar, (2) Filling method and complete penetration. Final alignment after piping connection - Same as above Par. 4.7. | : : 278 @ INSTALLATION OF PUMPS AND DOCNO. : on BLOWERS ‘TOYO ENGINEERING INDIALTO: emeneOeNci ISSUED DATE: 18/10/07 SRU - ONGC, URAN Page Tof 14 5. Procedure and acceptance standard for inspection and test 5.4 Alignment 5.1.1. Alignment of the pump base shall be carried out as follows, unless otherwise specified a) Tolerance shall be as in the following table: Unit: mm [oe Type fe ———_” Vertical Horizontal item ~ a Elevation #30 (oe SY Va ceaeaaaeae Perpendicularity ~~ 0.171000 Level z = 0.471 000 (2) Elevation of finished surface of base plate shall be measured on the basis of the level marking on the foundation. 8) (3) Position of the pump Centre marked on the base frame, shall be measured on the basis of the Centre marking of the foundation. For measuring of the perpendicularity or level, the finished surface of the base frame shall be the basis. 5.1.2 Alignment of the shafts shall be carried out within the tolerance in the following table, unless otherwise specified: ay Tolerance for parallel deflection of shafts ~~ Shaft Speed (rpm) Tolerance ee jess than 1 000 0.4 ~ 1000 to 5 000 0.05 2 ‘over 5 000 0.03 , 279 T ISTALI AND g | ee | coe )YO ENGINEERING INDIA LTD GA-301 =e SRU - ONGC, URAN Page 8 of 11 (2) Tolerance for angular deflection of shafts shall be in accordance with the coupling manufacturer's specification. Tolerance 0.07 mm shall be applied when there is no requirement in manufacturer's specification. (3) Method of the alignment is as follows: (2) _ Fix two dial indicators on the shaft 2, so that one of their tips comes in contact with the circumference of shaft 1, another with the face of shaft 1. The two contact points on shaft 1 shall be as, near as possible to each other. ” x —o On DRIVER SHAFT (Sha 1) PUMP SHAFT (Shatt 2) (b) Turn shaft 2 fully once, and check fluctuation in the tip contact. () Set the scales of two-dial indicator to zero at the top point of shaft 1 (d) Tum shaft 2 slowly through 360°, and read indications of the two dial indicators at every 90°. {e) Tum shaft 1 by 180°. Repeat the procedure as described in Par. (). () Result of the alignment shalt be the average of the two measurements of Par. (d) and (e). 5.1.3 Distance between the couplings shall be confirmed to meet the dimension specified in the drawings, after the shafts are set to the base line. 5.2 Final alignment @ TOYO ENGINEERING INDIA LTD| ISSUED DATE: 18/10/07 INSTALLATION OF PUMPS AND DOC No. : BLOWERS east | SRU - ONGC, URAN Page 9 of 11 5.2.1 After the connection of the piping system, alignment of the shafts shall be rechecked and shail be within the tolerance specified in Par. 5.1. 5.22 If the alignment is out of tolerance, the piping system shall be disconnected and adjusted so as not to stress on the pump. 5.3 Telalrunning During and after trial running, the following items shall be inspected: 5.3.1 Vibration shall be inspected as follows: (1) Pump The unfiltered vibration shall be measured and shall not exceed the value specified in sub-section 2.8.4 VIBRATION AND BALANCING of API 610, 1989. 10200 a0 0 1000300 — A000 nites Piteros 03] vari vnc, ee ints po oa Boom 16002000 Pump speed (revolutions per minute) Figure 5.3.1 (a) Bearing-Housing Vibration Limits (Antifriction Bearings) sc repepemcentnonnenrepematenetrtnintntn cence | | T @ INSTALLATION OF PUMPS AND Bocho TOYO ENGINEERING INDIALTD] GA301__ | ISSUED DATE: 18/10/07 SRU - ONGC, URAN Page 10 of 1t 50 40 30 25 20 Undue 10 os. os os oa 03 ea to peak (ils) 24] nin velo, | | | al 02 uo a0 00 TFT F000 “RHE OTT | Purp sped (revolutions per ints) | | Figure 5.3.1 (b) Shaft Vibration Limits (Sleeve Beanngs) { (2) Blower i ~~ Specified Speed Vibration Peak-to-Peak (rpm) @)* less than 2 000 63.5 2.000 to 4.000 50.8 over 4 000 38.1 Note *; Measured on the bearing housing, | 5.3.2 Temperature at the surface of bearing housing shall not exceed 80° C or ambient temperature plus 40° C, whichever is lower, unless otherwise specified. 5.3.3. Abnormal noise shall not be produced at bearing housing. 5.3.4 Gear coupling shall be checked for correct contact and absence of wear. 5.3.5. Diaphragm coupling shall be checked for no abnormal deformation. TOYO ENGINEERING INDIALTD, ISSUED DATE: 18/0107 SRU - ONGC, URAN Page 11 of 14 @ INSTALLATION OF PUMPS AND = BLOWERS 64 62 Care and custody Initial charge of lubricant olf and grease After the final alignment, initial charge of lubricant oil and grease shail be performed in accordance with manufacturer's manual. Periodical rotation Hand rotating of pump and driver shafts shall be performed at least once 2 month, in order to prevent sticking of the shafts, spoermneonentecmpreepnmmeeiinemrnnemanarmataiteernetty tse 283 Annexure (3) GA-301 Sheet 1 of 1 Revision history Date Description sjccimntemceerpe ney senepenrinenene renee enna STANDARD ENGINEERING SPECIFICATION a @ a INSTALLATION OF TURBINES AND COMPRESSORS. DOCUMENT NO. : GB-301 PROJECT : SULPHUR RECOVERY UNIT TEIL JOB NO. : 6245 OWNER OIL AND NATURAL GAS CORPORATION LIMITED ONGC, URAN 0 | talt0/07_| FIRST ISSUE FOR ENQUIRY | REV DATE DESCRIPTION eye REVIEWED BY ‘APPROVED BY - @ TOYO ENGINEERING INDIA LIMITED MUMBAI, INDIA TOYO ENGINEERING INDIA LTO| | issueo oare-sewo? SRU - ONGC, URAN [Pane tora © INSTALLATION OF TURBINES AND | DOC NO. : ‘COMPRESSORS GB-301 35 CONTENTS PAGE NO. Generel ccs Scope Specific Jab requirements ... Related Engineering Specifications Manufacturer's Installation Manual Execution of Work General Requirements Installation Alignment .. Checking during Installation : Checking of Preparation of Foundation .... Setting of Liners for Jack Bol... : Setting of Anchor Bolts Provisional Alignment of Equipment Grouting of Anchor Box Provisional Alignment of Shafts pene Grouting of Baseplate and Frame, and Tightening of anchor Bolts ... ase Re-checking of Shaft Alignment Alignment after Installation of Main Piping Assembly of Equipment... inspection after Installation Alignment Final Alignment Inspection at Trial Run Custody... T © INSTALLATION OF TURBINES AND | DOC NO. : ‘TOYO ENGINEERING INDIA LTO, COMPRESSORS GB-301 eee eee aeaaal a 1SSUED DATE: 18710007 SRU - ONGC, URAN Page 20111 |. General 1.4 Scope This Specification covers general requirements for the installation and inspection of centrifugal, reciprocating and axial compressors as well as of steam turbines for Sulphur Recovery Unit for M/s. Oil. AND NATURAL GAS CORPORATION LTD. 1.2 Conflicts Any conflicts between the requirements of this specification and any customer's special and / or local requirements shall be refered to PMC for resolution prior to the execution PMC’s decision shall govern. 4.3. Related Construction Procedures Related Engineering Specifications to supplement this Specification are as follows D201 * General Requirements in Equipment Insiallation™ H315 " Cleaning of Piping” 1.4 Manufacturer's Installation Manual Where manufacturers installation manual approved by PMC is available, the work shail be catried out in accordance with the manufacturer's installation manual. 2. Execution of Work 2.4 General Requirements 28 @ INSTALLATION OF TURBINES AND | DOC NO. : TOYO ENGINEERING inDIA LTD; COMPRESSORS: GB-301 4810107 SRU - ONGC, URAN Page Sof 11 Centrifugal, reciprocating and axial compressors, and steam turbines (hereinafter referred to as Equipment), shall be installed in accordance with the general requirements specified in Equipment Installation Specification D- 301 2.2. Installation 2.2.4 In general, the Equipment shall be installed and aligned in the following sequence (1) Preparation of foundation (2) Setting of liners for jack bolts (3) Tentative installation of base plate and frame on the liners, and setting of anchor bolts (4) Provisional alignment of the Equipment (8) Grouting of anchor box (6) Provisional alignment of the shaft (7) Grouting of base plate and frame, and tightening of anchor bolts (8) Re-checking of the alignment of the compressor and its driver (9) Connection of main piping (10) Final alignment of the compressor and its driver 2.2.2 Finishing mortar work on the foundation shall be performed after the final alignment. 2.3 Alignment 2.3.1. Timing of alignment Alignment of the Equipment shall be performed at the following timing (4) During installation coavial oF offset i ISSUED DATE: 18/10/07, © INSTALLATION OF TURBINES AND | BOC NO. : ‘TOYO ENGINEERING INDIA LTO| ‘| COMPRESSORS GB-301 ‘SRU - ONGG, URAN [Page 4 of 14 2) (3) Afier grouting of base plate : + coaxial or offset After final alignment : Coaxial or offset 2.3.2 Alignment of the shafts shall be performed in the following procedure a) unless otherwise specified by the manufacturer Install an alignment jig on shaft A and attach a dial gauge to the jig as. shown in Fig. 2.3.2. Dial gauge | \ GO" Coupiin Shaft A pe . cms Shaft B — it Fig. 2.3.2 (2) Rotating Shaft A by one full tum, make sure the correct indication of the dial gauge. (3) With the dial gauge tip at the top (0°) of the coupling, set the dial gauge indication to zero. (4) Slowly rotating shaft A, read the dial gauge at every 90°. (5) Tum Shaft B by 180°. Repeat the steps (2), (3) and (4) to check the runout of the coupling at four points. (6) Remove the alignment jig from Shaft A and install the jig on Shaft B. Set the dial gauge on Shaft A and repeat the steps (2), (3), (4) and (5). 2.3.3 When offset is specified by the manufacturer, the alignment shali be made so thal the offset is kept within the tolerance. 288 @ INSTALLATION OF TURBINES AND ‘TOYO ENGINEERING INDIA LTD, COMPRESSORS SRU - ONGC, URAN Page Sof 11 34 3.2 2.3.4. Proper alignment shall be confirmed by rotating the shaft with hands or tools, Checking during Installation Checking of preparation of Foundation The following shall be checked and confirmed » (1) Foundation and anchor box are clean. (2) The foundation surface has been chipped to flatness. Setting of Liners for Jack Bolt The following shall be checked and confirmed (1) Liners are in quantity and size specified by the drawing, (2) Uners are not deformed. (3) Mixing ratio and curing condition of mortar shall meet Specification D-301 (4) Jack bolt is positioned as shown in Fig. 3.2 Jack bolt Baseplate/Frame Grout allowance about 50mm. JL. Pad allowance At Ran ma : i : 290 T @ INSTALLATION OF TURBINES AND | DOC NO. : ‘TOYO ENGINEERING INDIALTD, COMPRESSORS GB-301 ISSUED DATE: 18/1007 SRU - ONGG, URAN Page 6 of 11 33° Setting of Anchor Bolts The following shalt be checked and confirmed (1) Location and dimensions of anchor bolts are as specified in the drawing. (2) Anchor bolts are perpendicular within the tolerance specified in D-301 (8) Mortared part of anchor bolts is free from grease and oil (4) Threaded part of anchor bolts is free from damage. (6) Threaded part of anchor bolts is coated with lube oil or grease. 3.4 Provisional Alignment of Equipment Elevation, position and level of the Equipment shall be within the tolerance specified in Table 5.1.1 3.5 Grouting of Anchor Box The following shai be checked and confirmed (1) Mixing ratio of mortar meets Specification D-301 (2) Anchor box is completely filed with mortar. (3) Mortar has’ become sufficiently hardened afler the specified curing time. (4) Mortar is free from cracks and lamination after the curing time. 3.6 Provisional Alignment of shafts Parallelism, angular deviation and distance between the couplings shall be checked, Non-parallelism of the couplings shali not exceed 0.1 mm between their circumferences. : | j | | | T @ INSTALLATION OF TURBINES AND | DOC NO. : ‘TOYO ENGINEERING INDIA LTO. COMPRESSORS GB-301 ISSUED DATE: ten0007 | SRU - ONGC, URAN Paetott | 3.7 Grouting of Baseplates and Frame, and Tightening of Anchor Bolts The following shall be checked and confirmed : (1) Mixing ratio of mortar meets Specification D-301 (2) _ Inside of the equipment base is securely filled with mortar. (3) Mortar has become sufficiently hardened after the specified curing time. (@) Mortars free from ctacks and lamination after the curing time. On the fourth day after grouting, all jack bolts on the base plate or frame shall be loosened and the foundation bolts shall be tightened symmetrically, one after another. 3.8 Re-checking of Shaft Alignment Parallelism, angular deviation and distance between the couplings shall be checked. Non-parallelism of the couplings shall be as specified in Par. 9.1.2. In case the alignment is out of the tolerance, realignment shall be made as follows : (1) Forsteam turbine and compressor: . Adjust shims for casing support bearing pedestal. (2) For reciprocating compressor Adjust shims for driver frame. 3.9 Alignment after Installation of Main Piping It shall be confirmed that the measurements are within the tolerance specified in par. 5.1.2 4. Assembly of Equipment wD @ INSTALLATION OF TURBINES AND | DOG NO. : TOYO ENGINEERING INDIA LTD, COMPRESSORS GB-301 j ISSUED DATE: 18/10/07 SRU - ONGC, URAN Page 8 of 11 In case the Equipment has been delivered disassembled condition, assembly work shall be carried out in accordance with manufacturer's erection manual i in consideration with the following general precautions (1) Wear clean working clothes to keep the Equipment clean from foreign matters. (2) Using compressed air, remove completely foreign matters from the casing inside the Equipment, control valves and accessories. Clean carefully pipes and valves which have been stored outdoors. (3) To clean the inside of bearing housing, mechanical seal and cylinder, use vinyl sponge or special paper towel (4) Adjust the clearance between the shaft and internals such as bearings within the tolerance specified by the manufacturer. (5) For iifing the shaft, keeps it horizontal using a lifting jig or other suitable method. Never allow the shaft to hit and damage any internal parts. i (6) When assembling internal parts such as bearings, make sure their proper location and direction, referring to match marks. (7) When fluid packing is applied ta casing / housing contact surface for steam oF gas application, coat the inside surface from bolts densely and the outside from the bolts lightly. (8) When fluid packing applied to oil contact portions, coat them lightly Never close lubricant grooves with excess coating () Oil flushing after assembly requires sufficient preparation. Install temporary piping and strainers, remove control valves and cartridge of filters, referring to manufacturer's flow diagram, (10) Carefully adjust the governor and interlock system. Make sure their proper performance. t T @ INSTALLATION OF TURBINES AND ‘TOYO ENGINEERING INDIALTD| COMPRESSORS ISSUED DATE: 18/0007 SRU - ONGC, URAN 5, Inspection after Installation 5.1 Alignment 5.1.1. Provisional alignment of the Equipment shall be carried out as follows unless otherwise specified by the manufacturer. Tolerance shail be as specified in the Table 5.1.4 Table 5.1.4 Unit : mm jageeeerateaee: eae ‘Compressors and | ‘Reciprocating steam turbine compressor [Elevation 7 #3 £3 [Position oe again esncas] Bearing pedestal levelness 0.057 4000 Crossguide levelness in crankshaft eae 0.117000) direction ‘Squareness of crossguide to ee = 0.171008 crankshaft | Frame levelness in crossguide 7 0.1 7060 direction Remarks: 1. Elevation of the finished surface of baseplate shall be measured from the level marking on the foundation. 2. Position of the center of the Equipment, marked on the base frame, shall be measured from the center marked on the foundation, 3. Leveiness shall be measured with a master level. 5.1.2. Alignment of the shaft shall be within the tolerance specified in Table 5.1.2 unless otherwise stipulated by the manufacturer. i t i I ' i | © INSTALLATION OF TURBINES AND | DOC NO. : ‘TOYO ENGINEERING INDKA LD, ‘COMPRESSORS GB-301 SRU - ONGC, URAN Page wort | Table 6.1.2 - ‘Compressors and steam turbine | Reciprocating compressor Non-perallelism of coupling Less than 5000 rpm 0.05 : circumferences on 5000 rpm and more 0.03 04 Face deflection as 0.07 Crankshaft web defiection, measured at every 90°, | Distance between the couplings Remarks: 1 180° re Follow the coupling manufactures drawing. ~ 20° 008 90° Non-parallelism and face deflection shall be measured with a dial gauge. For some types of reciprocating compressors, however, face deflection shall be measured with a thickness gauge. 2. Crankshaft web deflection shall be measured with a caliper type or dial-type inside micrometer. 5.2 Final Alignment ‘The alignment of the Equipment shall be finally checked in the foilowing manner: 5.2.1 After the main piping is connected, confirm ‘the alignment in accordance with Par. 5.1.2 5.2.2 {the alignment is found out of the tolerance, loosen the piping flanges and make piping adjustment so as to release the Equipment from excess stress, then check again the alignment . 295 F @ INSTALLATION OF TURBINES AND | DOC NO.: TOYO ENGINEERING INDIA LTD, COMPRESSORS GB-301 ISSUED DATE: 18710107 'SRU - ONGC, URAN Page 11 of 11 5.3 Inspection of Trial Run During trial run, the following inspection shall be made 5.31 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 Accurately measure and record gas pressures and temperatures until the bearing temperature stabilizes. Measure shaft vibration. For compressors and steam turbines, unless otherwise specified by the manufacturer, shaft vibration shall not exceed 50.8 microns to the following, whichever smaller: A= 25.4 V12000 (um) n Wher A= Amplitude of unfiltered vibration, in mils microns peak to peak. n= Maximum continuos speed, in revolutions per minute. Vibration of a reciprocating compressor shall be in accordance with manufacturer's specification Make sure that no abnormal noises are produced at the casing and bearing housings. Make sure that no leakage of steam and gas is observed at connecting surfaces and flanges. Make sure that all auxiliary equipment functions satisfactorily. Custody After final centering and oil flushing, the lube oil pump shall be operated once @ week for one hour to lubricate the bearings. STANDARD ENGINEERING SPECIFICATION PIPING CONSTRUCTION WORKS DOCUMENT NO. : H-301 PROJECT : SULPHUR RECOVERY UNIT TEIL JOB NO. + 6245 OWNER OIL AND NATURAL GAS CORPORATION LIMITED ONGC, URAN i — - | se eee at REV! DATE DESCRIPTION © | 1e/toro7 | FIRST ISSUE FOR ENQUIRY We LM) MADE REVIEWED | API VED BY BY BY @ ‘evo TOYO ENGINEERING INDIA LIMITED MUMBAI, INDIA Rev. TOYO ENGINEERING INDIALTD. ISSUED DATE: 18/1007 Date PIPING CONSTRUCTION WORKS: SRU - ONGC, URAN Revision History Description 298 D eam PIPING CONSTRUCTION WORKS: TOYO ENGINEERING NDIALTD. ISSUED DATE: 18/10107 SRU - ONGC, URAN CONTENTS PAGE NO 4 General 3 44 Scope... 3 1.2. Specific Job Requirements 3 4.3 Codes and Standards . 3 1.4 Related Engineering Specifications 3 1.5 Units... 3 2 — General Requirement 4 2.1. Qualification ... 4 22 Material... 4 2.3 Drawing and Document .. 4 3 Fabrication 5 3.1 General... 5 3.2. Cutting 8 33 End Preparation 6 3.4. Alignment and Trimming 7 3.5 Preheat and Interpass temperature... acon : 10 3.6 General Requirement for Walcing ae 1 3.7 Welding Rods : . - 12 3.8 Welding 15 3.9 Heat Treatment 20 3.40 Bending ...... 25 3.41. Marking ... 25 BAZ Storing 25 4 Assembling and Erection 26 44 General . 26 42 Flanged Joint... a 43 Threaded Joint 27 4.4 Mechanical Joint 28 4,5 Tubing Joint : oe 28 5 Inspection, Examination and Testing .... . 28 5.1 Extent of Inspection, Examination and Testing 28 5.2 Non-Destructive Examination... 33 6 Cleaning after Piping Assembling and Election 36 x © ¢ 44 12 13 14 15 ‘YOVO ENGINEERING INDIA LTD. ISSUED DATE: 18/1007 @ PIPING GONSTRUCTION WORKS SRU - ONGC, URAN GENERAL, Scope This specification covers minimum Requirements for welding procedure specification (WPS) which shall be established for the piping construction work of the Project. ‘Specific Job Requirements Where Specific Job Requirements are in contradiction to this specification, ‘Specific. Job Requirements shall govern. Codes and Standards International codes and standards supplementary in retated to this specification shall be as follows: (1) ANSI /ASME B31.3 ‘Chemical Plant and Petroleum Refinery Piping (2) ANSVASME B1,20.1 ipe Threads, General purpose {inch} (3) ASMEVANSI 816.5 Pipe Flanges and Flanged Fittings (4) ASME Boiler and Pressure Vesse! Cade Section Vill, Section V. (6) Indian Boiler Regulation (IBR). Related Engineering Specifications The related Engineering Specification to supplement this specification is as follows: (1) 103 Piping Materials, (2) -H-109 Pipe Supports 8) H315 Cleaning of Piping (4) 4317 Pressure Testing of piping (S) 4321 Welders Qualification Test @) 1331 Minimum requirement for Welding Procedure Specification Units The SI unit shall be applied as the measurement system for documents and ‘drawings. Nominal size of piping components shall be measured in Inches, for which the abbreviation is NPS. Nominal flanges rating shall be as per the applied codes and standards. @ PIPING CONSTRUCTION WORKS | POC NO. : TOYO ENGINEERING INDIA LTD. ‘H-301 {SSUED DATE: 16/1007 SRU - ONGC, URAN [Page 4 of 36 2. GENERAL REQUIREMENT € 24 Qualification (1) Persons who are engaged for welding work including tack welding and support welding shall Have passed the Engineer In-charge qualification test stipulated in Engineering Specification H-321 (2) Welding Procedure Specification and the Procedure Qualification Record as per Engineering Specification H-331 shall be obtained for welding work. (3) Persons who are engaged for pipe fitting, assembling, and erection work, using temperature indication crayon for the heat treatment etc, shall be fully trained and shall have the qualification of Employer. License, certificate, pass or qualification issued from Authorities, if available, shall be effective. (4) The inspector nominated for the job, must be a specialist or an expert in respective examinations and licensed or qualified by an internationally recognized Association and fof by any statutory requirement applicable. 2.2. Material 2.2.2 Ibis applicable to use other alternate materials, which have been approved by Engineer in-charge based on the Engineering Specification H-103. 2.2.3. Selection of welding rod shail be in accordance with Par. 3.7 in this Engineering Specification. 2.2.4 Quality certificate of technical gas to be used for the work such as argon gas, propane gas, etc, shall be provided with approval of Engineer In-charge before 2.2.1. Piping Materials shall be in accordance with Engineering Specification H-103. | k work starts. | 2.3 Drawing and Document 2.3.1. Drawing and document, which cover the piping construction work, shall be issued by Engineer in-charge in accordance with “Drawing and Dacurnent List”. 2.3.2 Piping work shall be carried out with Engineer In-charge issued “Final” drawing ‘and document unless otherwise specified orm PIPING CONSTRUCTION WORKS ‘TOYO ENGINEERING INDIA.LTD. SRU - ONGC, URAN 3. FABRIGATION 3.1 General 3.1.1. Fabrication requirement shall be in accordance with ASME B 31.3 unless otherwise specified. 3.1.2. Fabrication shall be executed in accordance with the drawings, documents and the related Engineering Specifications stated in Par. 1.4 and 23 of this ‘Specification. 3.1.3. Stainless stee! pre-fabrication work including material storing shall be well separated from other steel pre-fabrication works. Tools and equipment to be sed shall be suitable for stainless steel and shall not be used on any other materials, or vice versa. 3.1.4 The bolt holes of flanges shall be located symmetrically from a vertical center {ine in a horizontal pipe line, and from plant north in a vertical pipe line unless otherwise indicated in the drawing, 3.1.5 Marking of piping materials shall be in accordance with Engineering ‘Specification H-106. 3.2 Cutting 3.2.1 Cutting line shall be marked on pipe. Where the material marking will become invisible after cutting, additional material marking shall be provided. 3.2.2 In the case of gas cutting, cutting surface shall be ground off to remove any ‘edge and roughness and be made flush and smooth so as not to harm welding quality. In the case of automatic or semi-automatic gas cutter, the cut edge may be beveled without such grinding off. 3.2.3 In the case of gas cutting, cutting slag stuck inside pipe shall be completely removed, especially for boring of pipe for weld branch. 3.2.4 Abrasive disc used for cutling or grinding of austenitic stainless steels or other high Cr-Ni steel shall not be used for carbon steels, or vise versa. 3.2.5 The following processes shall be used for cutting and edge preparation of stainless steels, nickel alloys and aluminum alloys. - Grinding ~ Machining -Plasma cutting 80g 3 2 @ me PIPING CONSTRUCTION WORKS ‘TOYO ENGINEERING INDIALTO. DOC NO. : | ISSUED DATE: 16/1007 SRU - ONGC, URAN 3.3 Edge Preparation 3.3.1. Edge preparation for butt weld shall be in accordance with Table 3.3.1, or shall be prepared consistent with the procedure qualification detail. (1) Welding Bevels for Butt Welds Table 33.1 Thickness of Pipe | Type of End ‘Shape of Groove | t<3 1 t co 5 3784259 8 ts22 v (2) Shape of beveling other than mentioned in Table 3.3.1 shall be in accordance with the WPS approved by Engineer-In-charge. (2) Allwaid bevels and weld surfaces shall be free from cracks, porosity, slag inclusion and other defects indicative of poor manufacture. } | 18408 tos25° srs a250 LA t<22 Double-V r feecaa : ani | t om PIPING CONSTRUCTION WORKS TOYOENGINEERING INDIALTD. | tssuep pate: 18/1007 SRU -ONGC, URAN 3.4 Alignment and Trimming 3.4.1 Root gap for butt-weld shall be in accordance with the WPS. 3.4.2 In the case of butt welding pipe and / oF fiting having unequal wall thickness, of which the difference is more than 3 mm in outer surface and / or 1.5 mm in inner surface, the end of the thicker pipe shall be trimmed by grinding as per the Fig. 3.4.2 (a), (b) and (c) shown below. The gradient of this trimming shall be less than 30 between worked and nonworked parts shown as below. iw 300° Over » ‘Max 30° = 1.5 or Over Fig 34.2 Note: in the case that “Special End Detail” is specified in the Specification H-103, for the pipe and / or fiting of which the nominal wall thickness is 30 mm ‘and over, the end preparation shall be in accordance with such provision. 3.4.3 Branch connections which about the outside surface of the run pipe shall be contoured for groove welds which meet the WPS requirements [see Fig. 3.4.3 {a) and (b)). Branch connection which are instead through a run opening shall be inserted at least as far as the inside surface of the run pipe at all points [see Fig. 3.4.3 (c)]. i 804 ot PIPING CONSTRUCTION WORKS. BOC NO. : TOYO ENGINEERING INDIA LTD. ne ISSUED DATE: 18/1007 SRU - ONGC, URAN m ! tm PE ‘9 Root gap per WPS: i= The lessor of3.2mm oF 0.57 Figa4s 3.4.4 When a pipe having a longitudinal weld seam is used in a horizontal line, the pipe shall be laid so that the longitudinal weld seam is not on bottom or top of the pipe. Allocation and relation among circumferential longitudinal and other (branch, support, etc.) welds are shown in the Fig. 3.4.4 (a), (b) or (c). (1) Circumferential joint u Remarks : 11 shall be five times the pipe thickness or aver Fig: 3.4.48) ce @ TOYO ENGINEERING INEWA LTD. PING CONSTRUCTION WORKS: ISSUED DATE: 1 SRU - ONGC, URAN [Page 9 of 36 (2) Branch pipe and weld line on run pipe Remarks: 1. Land L,show the distance between both toes of the bead. 2. Ushall be three times the pipe thickness or over. 3. Ly Shall be five times the pipe thickness or over. Detail when a suppor is welded to a bend or pipe the weld shalt not cross the weld ofthe Bend or Pipe. Both sides shall be rounaly welded. WELDING SHOE Remark: L shall be minimum 6 mm. Fig: 3.4.4 (0) (3) Support / Shoe and weld seam of main pipe a 4 PIPING CONSTRUCTION WorKS | POC NO.: TOYO ENGINEERING INDIA LTD, 4-301 ISSUED DATE: 18/1007 SRU - ONGC, URAN Page 10 of 36 3.4.5 Each butt, socket and support joints shall bear an identification number, which shall be maintained in the piping sketch/ drawing. These numbers shall appear (on the fit up/ weld visual reports and NDT records. 3.5 Preheat and Interpass temperature 3.5.1 Preheating shall be performed by propane flame or by another appropriate method prior to commencement of welding including tack welding. Any flame heating shall be applied as evenly all round as possible, avoiding hot spots. 3.5.2 Materials and preheating temperature shall be, unless otherwise specified, as Table 3.8.2. The thickness in Table 3.5.2 is that of the thicker component measured at the joint. Table 3.5.2 Material specification ‘ASTM NPS Thickness | Temperature tm) (cy Ai20 all 1<25 not required = APIBL Gr. B Note 1 1_|A53 Gr. AB ne A106 Gr. AB alt (225 80 and above A333.Gr.1 A524 Gr. Ill A 515 Gr. 60 3 )A333Gr. Pt all 12127 ‘80 and above ____| 4204 Gr. ve 4 [A335 Gr. P12 all all 150 and above A336 Gr. Pit 5 [A336 Gr. P22 al all 780 and above A335 Gr. PS a A335 Gr. PO & [A312Gr. TP 304 all all A312 Gr. TP304L A312 Gr. TP316 A312.Gr. TP316L 3 {A333 G3 all all 95 and above Note 1. — In acase where the ambient temperature is below 5°C, preheating toa temperature 40°C minimum shall be applied to P-1 and P-8. 3.5.3 The preheat zone shail extend at least 25 mm beyond each edge of the weld.

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