ERECTION AND INSTALLATION MANUAL DOC.

No:
STC ( MECHANICAL EQUIPMENTS)
STC-ME-P0001

CONTENTS
PAGE
1. General 2
2. Code Requirements 2
3. Cleaning 2
4. Erection Materials 2
5. Location Tolerances 2
6. Piping Connections 2
7. Grouting 3
8. Equipment Piping 3
9. Pump Suction Strainer (If applicable) 3
10. Welding 3
11. Shaft Alignment 4
12. Dowelling 4
13. Motors 5
14. Equipment Checkout 5
15. Miscellaneous Equipment 5
16. Instrument and Control Equipment 6
17. Defects 6
18. Manufacturer’s Field Representative 6
19. Equipment Protection 6
20. Repair of Painted Surfaces 6
21. Maintenance Tools 6
22. Equipment Tags 7
Addendum :
ERECTION AND INSTALLATION MANUAL
(INSTRUCTION INSTALLATION HORIZONTAL)

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STC ( MECHANICAL EQUIPMENTS)
STC-ME-P0001

1). General. This subsection covers the general requirements for equipment erection

Erection procedures not specified herein or in the other subsections of this specification shall
be in accordance with the recommendations of the equipment manufacturer and good
engineering practice. Such procedures shall be acceptable to DCAP.

Equipment shall be checked prior to its installation to ensure that it is in conformance with
the manufacturer’s drawings. Any discrepancies shall be reported to the DCAP.

Motors and other equipment having electrical connections will be electrically connected
under DCAP’s Specification TSP-B. All other erection work on this equipment shall be
performed under these specifications.

2). Code Requirements. All erection procedures shall conform with accepted good
engineering practice, the latest applicable requirements of the ANSI Code for Pressure
Piping, the appropriate sections of the ASME Boiler and Pressure Vessel Code, AISC, ANSI,
ASTM, AWS, EEI, IEEE, NEC, ASHRAE, SMACNA, AMCA, ARI, and all laws and local
regulations.

3). Cleaning. All equipment shall be cleaned of all sand, dirt, and other foreign materials
immediately after removal form storage and before the equipment is brought to the site or
buildings. All piping and tubes shall be air blown, without exception, prior to erection.

4). Erection Materials. All materials required for complete erection of the equipment shall be
furnished. The material shall include, but not be limited to, grout, shims, wedges, dowels,
anchors, supports, bolting, gaskets, packing, welding rod, and consumable gases.

Concrete equipment bases, unless otherwise indicated on the drawings will be furnished by
others.

Anchor bolts 20 mm in diameter and larger will be furnished cast into the concrete
equipment bases. Anchor bolts smaller than 20 mm shall be furnished and shall be self-
drilling cone type expansion. Anchor bolts shall be manufactured by Fastenic or Hilti.

All bolting required for structural attachments shall be furnished and shall conform to ASTM
A307

5). Location Tolerances. All equipment shall be located within 3 mm of the dimensioned
locations indicated on the drawings.

6). Piping Connections. All equipment having piping connections shall be leveled, aligned,
and wedged in place but shall not be grouted or bolted prior to the initial fitting and
alignment of connecting piping. All equipment shall, however, be grouted or bolted to its

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STC-ME-P0001

foundation. All equipment shall, however, be grouted or bolted to its foundation prior to
final bolting or welding of the connection piping.

Piping shall be supported so as to place no loads on equipment. This shall be proven, at no

cost to DCAP, by DCAP-witnessed testing.

All flanged joints shall be checked and tightened after approximately 10 days of operation at
normal operating temperatures.

7). Grouting. The metal bases of all equipment installed under these specifications shall be
solidly grouted in place. Grouting materials shall be non shrinkage type and grouting
procedures shall be according to producer recommendation.

8). Equipment Piping. All piping, valves, and fittings furnished with the equipment shall be
installed in accordance with the requirements of Mechanical.

All equipment drains shall be piped to bell-ups or floor drains. Connection to bell-ups shall
be caulked unless otherwise directed by DCAP. Equipment oil drain points shall be provided
with a bronze plug cock of the same size as the connection, and a screwed cap or plug by
the Contractor.

9). Pump Suction Strainer. All pump suction strainers shall be installation before starting the
associated equipment. The Contractor shall furnish, install, and later remove a temporary
cone strainer for each pump installed.

10). Welding. Welding of connections to the pressure containing parts shall be done only by
welders qualified under Section IX of the ASME Boiler and Pressure Vessel Code.
Welder qualification, records, and pipe welding shall be in accordance with the requirements
of EGAT’s specification.

Sections of welds shall be removed for testing if so requested by the DCAP. The costs of
removal, replacement, and testing shall be borne by the Contractor regardless of the test
results.

Welds may be checked by the DCAP using an independent Nondestructive Testing

Contractor. The Contractor shall provide access and the use of in-place scaffolding if
required. The costs of testing, repair, and retesting shall be to the Contractor’s account if
defects in excess of the applicable code are discovered.

When welding to equipment which is in the assembled condition, separate ground leads
shall be attached to the equipment, pipes, or components to prevent stray welding currents
from arcing the internals of the equipment. Wherever possible, the ground lead shall be
67.4 mm2 cable or larger directly and mechanically connected adjacent to the welding area
and returned directly to the welding power source.

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Welding of structural components shall be in conformity with the applicable requirements of

the AWS Structural Welding Code, AWS D1.1-85 as issued by the American Welding Society.
Welding of piping components shall be in accordance with the requirements stated herein.
All welding procedures shall be submitted to DCAP for review prior to commencing the work.

Miscellaneous structural steel required for fabrication and attachment of equipment and
material supports shall conform to ASTM A36. Miscellaneous steel shall be attached to
building steel by means of clip angles bolted with high strength steel bolts conforming to
ASTM A307, or by welding to the web of building beams.

Welding of supports to structural steel which forms a part of the building supporting
structure shall be accomplished by the shielded metal arc method only. Quality of welding
shall be at least equivalent to that provided by AWS D1.1 Structural Welding Code - Steel.
Structural beams shall not be heated more than necessary to attach the support. Welds
shall run parallel to the axis of the span. Welds shall be staggered, with cooling allowed
between subsequent deposits. Loaded beams shall be unloaded or shored prior to welding
if 10 percent or more of the flange or web cross-sectional area could be heated to over 260
o
C at any one time. All welded steel shall be prime coated ready for finish painting.

11). Shaft Alignment. The alignment of rotating machinery shafts shall be as close to perfect
as practicable. Parallel offset between coupling halves shall not exceed 25 microns with
proper allowance for expansion of expansion of the driver or driven unit when operating.
The faces of coupling halves, with the halves square on their shafts, shall be parallel within
25 microns. Parallel offset measurements shall be made with a dial indicator. Angular offset
measurements shall be made preferably with a dial indicator. Feeler gauges shall be used to
measure angular offset when the coupling is on motor having sleeve bearings, and when
space limitations prevent the use of a dial indicator.

Alignment records shall be maintained by the Contractor for each piece of equipment.
Records shall be submitted to the DCAP. Each alignment shall be withnessed and approved
by EGAT. These requirements apply, regardless of the manufacturer’s recommendations,
even if more stringent.

12). Dowelling. Shaft driven mechanical equipment, including the motor drives, with a rating
of 15 kW or larger, shall be doweled using tapered dowels after shafts have been aligned
and accepted. Doweling shall not be accomplished until after 48 hours of operation have
been successfully demonstrated.

After 48 hours of operation, coupling alignment shall be rechecked by the Contractor. If the
coupling alignment has changed appreciably and is no longer within the alignment
tolerances specified in the above article longer within the alignment tolerance specified in
the above article titled Shaft Alignment, corrective measures shall be taken as directed by
EGAT. If the coupling alignment is still acceptable to DCAP, permission shall be requested to
proceed with equipment doweling.

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DCAP may elect to authorize the Contractor to dowel a piece of equipment without the
specified alignment recheck if the equipment has been running satisfactorily for the specified
length of time.

Doweling shall include step drilling the dowel holes in the equipment, base, or soleplates,
taper reaming the holes, and installing dowels as specified herein. Doweling grouting shall
be as specified in Section 7, Grounding.

Each component or item of equipment to be doweled shall receive one dowel in each of two
opposite corners, near an anchor or hold-down bolt.

Dowels shall be American National Standard taper pins, tapered 21 mm/m. Dowels and
dowel dimensions, hole drilling sizes, and number of drill steps shall be in accordance with
ANSI Standard B18.8.2. The large end of each dowel shall be turned down, threaded, and
provided with a heavy hex nut for withdrawal purposes.

Unless otherwise specified by the equipment manufacturer, dowel sizes shall be as follows.

Kilowatt Range Taper Pin Basic Pin

of Equipment Size Number (Major) Diameter, mm
18 to 75 6 8.7
76 to 150 7 10.4
151 to 375 8 12.5
376 to 1,000 9 15
Above 1,000 10 18

13). Motors. Each electric motor shall be examined for damage and the insulation meggered
before energization. If the motor insulation megger Values are below rated kV ping one
megohm for all windings, the motor winding shall be dried by application of a metered dc
current to the windings in a manner acceptable to DCAP.

All motors shall be checked for proper rotation before connection to the driven equipment.
A record shall be kept at all motor rotation checks.

Stainless steel shims, cut to the same size as the motor foot, shall be installation beneath
each motor wherever practicable when aligning shafts so that future realignment may be
performed without grinding the motor base-plate.

14). Equipment Checkout. All equipment shall be cleaned. Rotating machinery shall be
lubricated, checked for freedom of movement by hand if possible, and all prerequisite
operating conditions established before the application of motive power. Equipment subject
to pressure shall be checked for leakage.

After erection, all equipment having moving parts, electrical apparatus, or equipment
subject to pressure shall be given trial operation in accordance with Particular Conditions.

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15). Miscellaneous Equipment. Items of miscellaneous equipment such as fire hose and
racks, locally mounted pressure and flow transmitters, pilot controls for control valves, etc.,
shall be installed in locations in accordance with the drawings if indicated. Such items not
indicated on the drawings shall be installed in easily accessible locations and subject to the
acceptance of DCAP. All such items shall be rigidly supported from the building structure by
means of suitable brackets acceptable to DCAP.

16). Instrument and Control Equipment. Instruments and control equipment shall be
installed in accordance with DCAP ‘s specification TSP-C.

17). Defects. All defects in erection shall be corrected to the satisfaction of DCAP. The
dismantling and re-assembly of equipment to remove defective parts, replace parts, or
make adjustments shall be included as a part of the work under these specifications.

18). Manufacturer’s Field Representative. The service of manufacturer’s field representatives

to inspect and advise in the erection work shall be furnished by the Contractor. The
presence of these representatives shall not relieve the Contractor of responsibility for
obtaining a proper equipment installation.

19). Equipment Protection. All equipment to be erected under these specifications shall be
protected from damage of any kind from the time it is unloaded until it is ready for initial
operation. Any damage incurred shall be repaired to original, as new condition at the
Contractor’s expense. This applies until the equipment is turned over, and all punch list
items are completed to DCAP’s satisfaction.

Equipment having glass components such as gauges, or equipment having other easily
broken components, shall be protected during the construction period with plywood
enclosures or other suitable means.

Machine finished surfaces, polished surfaces, or other bare metal surfaces which are not to
be painted, such as machinery shafts and couplings, shall be provided temporary protection
during storage and construction periods by a coating of suitable nondrying, oily type, rust-
preventive compound.

20). Repair of Painted Surfaces. After erection, touchup paint shall be applied by the
Contractor to all damaged areas on shop painted equipment surfaces. The Contractor shall
furnish and apply touchup paint. Surface shall be properly prepared before application of
paint. The touchup paint shall be of a type equivalent to the shop paint.

Where touchup paint is provided by the equipment supplier, that paint shall be used for
touchup and all surface preparation and paint application procedures furnished by the
supplier shall be followed.

21). Maintenance Tools. Except as otherwise specified, all special tools supplied with
equipment for maintenance purposes may be used for erection purposes. All such tools

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shall be stored as directed by DCAP. The Contractor shall be responsible for all damages of
those tools during installation.

22). Equipment Tags

All equipment (mechanical, electrical, control and instrumentation) shall be affixed with tags
to facilitate identification.

Tags shall be made of 3 mm thick hardened aluminum plate, 30x70 mm size. Each tag shall
be fixed in place with 1 mm diameter stainless steel spring wire having both ends crimped
inside a piece of metal tube.

Tags shall be engraved with system name to which equipment belongs, its function and
identification number. Only capital letters, 4 mm high shall be used. Lettering shall be
neatly laid.

DCAP will establish an identification numbering system to provide consistent numbering

throughout.

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