Construction QA/QC

Rotating Machinery

Rev. No. Rev. Date Description of Revision Revised by Approval

00 21/April/2016 New KIA

PROPRIETARY & CONFIDENTIAL

This document and the information contained herein is E2C proprietary know-how. This document or any part
therefore should not be reproduced stored in a retrieval system or transmitted by any means, electronic or
otherwise, or divulged without permission of E2C.

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 CONSTRUCTION QA/QC
ROTATING MACHINERY DATE: April 21, 2016

TABLE OF CONTENTS

1. Scope ............................................................................................................................. 3
2. Applicable Standards ..................................................................................................... 3
3. Witness Inspection Items ............................................................................................... 3
4. Test and Inspection Agenda - General .......................................................................... 3
4.1 Inspection before Installation ................................................................................ 3
4.2 Installation of Equipment ...................................................................................... 4
4.3 Levelling of Equipment ......................................................................................... 4
4.5 Piping..................................................................................................................... 5
4.6 Alignment .............................................................................................................. 6
4.7 Instruments ............................................................................................................ 6
5. Final Checks - General .................................................................................................. 6
5.2 Inspection and Preparation before Test Orientation .............................................. 6
6. Documents to be Submitted........................................................................................... 7

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 CONSTRUCTION QA/QC
ROTATING MACHINERY DATE: April 21, 2016

1. Scope
1.1 This specification covers the requirements for tests and inspections of Rotating Machinery
to be required during construction at t h e c l i e n t s i t e . This document may be modified
during the construction to ensure that all work and equipment shall conform to the
applicable drawings, specifications, regulations and project standards.

1.2 This specification shall be applied to the inspection items, method and criteria for
installation/construction work performed by the construction contractor under control of
Client.

2. Applicable Standards
Client Engineering Standards
Cast-In-Place Reinforced Concrete
Epoxy Coating of Steel Reinforcing Bars
Grouting for Equipment and Structural Foundation
Fabrication, Installation of Anchor Bolts, and Embedded Steel
Machinery Installation and Criteria for Installation Design

American Petroleum Institute

API-686 Machinery Installation Design and Installation

3. Witness Inspection Items

3.1 All installation and construction work shall be subject to test and or inspection under
witness by Client Project Group at any reasonable time and place before, during and after
installation.

3.2 Witness test and inspection items shall be in accordance with Client requirement and the
applicable codes or regulations in force.

4. Test and Inspection Agenda - General

4.1 Inspection before Installation
4.1.1 Prior to commencing the installation work, any damage during the transportation and the
condition of the machined surfaces shall be inspected thoroughly visually and by comparing
with approved drawing.

4.1.2 The rust prevention coating applied at shop for shipping purpose shall be removed by
suitable solvent/detergent, or damp rags, then further inspection shall be followed.
4.1.3 The internal inspection shall be performed through available opening to check any
damage, rust & loosening during shipping, and drain or remove any water or other temporary
materials remaining or left in the equipment. Any abnormal conditions revealed by this
inspection shall be discussed for resolution to rectify with Construction Contractor/CMC/
Client, and Manufacturer's representative.

4.1.4 The bottom face of the equipment base plate shall be checked visually for cleanliness.

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4.1.5 The concrete surface of the foundation shall be checked to see that it is properly prepared
for grouting, and then be cleaned completely with air, etc.

4.1.6 Machinery foundation installation shall be as per API 686 Chapter-4.

4.1.7 The inspection reports of foundation and anchor bolt template shall be reviewed.

4.1.8 Machinery rigging and lifting shall be in accordance with API 686, Chapter 2.

4.1.9 All rigging equipment i.e. sling wire, shackles winch and crane shall be certified by third
party inspection and certificate shall be submitted to the Project Group for approval before
erection.

4.2 Installation of Equipment

4.2.1 Verification of liners and wedges. Liners and wedges shall be made of carbon steel,
and be prepared by machining or grinding as follows:

Item Length Width Thickness Slope

Liner 100-150 50-75 1.6,2.3,3.2,4.5,6,9,12,16,19 --
Wedge 100-150 50-75 6,9,12 4°-5°

4.2.2 When the wind velocity is in excess of 15m/sec. and under stormy winds or heavy rain,
installation work for the heavy equipment shall be stopped.

4.2.3 Special Crew

4.2.3.1 During heavy equipment installation, a special crew shall be organized - General
supervisor, signal/flagman, crane operator, rigger, safety supervisor, etc.

4.2.3.2 The function of each individual of the crew shall be clearly defined.

4.2.4 The location, orientation and elevation of equipment shall be checked and confirmed by
using tape measure or optical instrument in accordance with approved drawing. The maximum
tolerance of location and elevation shall be +3mm, unless otherwise specified in the drawing
or specification.

4.2.5 In case two (2) pumps are to be installed for one pipe line, the variation of each pump for
elevation & location shall be within 3mm.

4.3 Levelling of Equipment

4.3.1 Levelling shall be performed using a machinist, spirit level, or precision square level on
the machined surface of the driver base plate, or on the suction/discharge flange of the vertical
nozzle of the equipment in the direction, and cross direction of the shaft. The maximum

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tolerance of both directions from the level shall be 0.5mm/m unless otherwise specified in the
Instruction Manual. Each level reading recorded shall be an average of two readings using
level in normal and reverse position on same spot.

4.4 After leveling inspection is finished, the Construction Contractor shall inspect and
report regarding the following requirements.

4.4.1 The lock nuts of the anchor bolts are torqued and tightened firmly. The shims and
wedges shall be tack-welded to each other and any excess in the shims and wedges shall be cut
off with a gas cuter.

4.4.2 Grouting shall be accomplished in accordance with API 686.

4.4.3 See API 686, Chapter-5 for Machinery Grouting Installation.

4.4.4 Visual inspection and hammering test for grouting shall be performed to detect voids or
other imperfections.

4.4.5 If the inspection and hammering test reveals some voids or imperfections, they shall be
repaired in accordance with the repair procedure approved by CMC / Client.

4.4.6 Recheck for leveling of the equipment shall be performed after curing the grouting.

4.5 Piping
4.5.1 All machinery piping shall be installed in accordance with API 686, Chapter-6
including Appendix A checklists.

4.5.2 Completeness and proper installation of the auxiliary piping shall be checked as per the
specific piping and instrument diagram (P& ID) of the machine. For example:

 Oil systems (lube, seal, control)

 Heating
 Cooling
 Drain and vents
 Buffer gas

4.5.3 Check that all piping elements are easily dismountable so as to ensure smooth
mechanical maintenance.

4.5.4 Check that all auxiliary piping elements already mounted are not plugged.

4.5.5 If the auxiliary piping is to be chemically cleaned according to instructions specified for
each machine by vendor, check the good result of work. Be sure that neutralization of the
cleaned pipes has been made. The piping internal protection will be achieved (prior to re-
assembling) with lubricating oil/protecting products.

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4.5.6 Check that suction and discharge lines have been completed, tested and accepted by
Piping Department.

4.5.7 While checking flange parallelism the suction and discharge lines shall only be
supported by their definitive supports and all flange bolts shall be removed, the distance
between piping flanges should be equal to gasket thickness (plus orifice plate, if any) less the
expleted thinning of the gaskets.

4.6 Alignment
4.6.1 Machinery field alignment shall be in accordance with API 686, Chapter-7.

4.7 Instruments
4.7.1 Confirm that all instrumentation specified on the manufacturer’s drawings, and/or shown
in the machine P & ID diagram, delivered with the machines have been installed or are
properly stored with items tagging until start-up.

4.8 Confirm that instrument or instrument loops, appearing on the process or utility P & ID
and / or in the machine drawings, provided for safety of the machine have been checked by the
Instrument department.

5. Final Checks - General

5.1 After completing final alignment, the following items shall be checked:

5.1.1 The equipment will rotate freely by hand or with a turning device in the marked direction
of rotation.

5.1.2 The marked direction of rotation of the driven equipment is the same as that of the
driver.

5.1.3 Proper installation of instruments, no load test of driver including a test of protection
device such as trip check specially for steam turbine.

5.1.4 The equipment is coupled and is rotating freely by hand or with a turning device

5.1.5 The setting of the coupling guard is checked to be in accordance with the construction
drawings.

5.2 Inspection and Preparation before Test Orientation

5.2.1 Prior to the test operation of the equipment, the following confirmation shall be made
under witness of CMC and/or the Manufacturer.

a. Chemical cleaning and oil flushing, of unit internals have been completed
satisfactorily.
b. The equipment can be easily rotated in the marked direction of rotation by hand, or
turning device.

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c. All rust preventives, oil, grease, etc. used to protect the equipment during construction
have been removed using solvents.
d. The equipment have been filled with the proper lubricants as indicated in the
Instruction Manual.
e. All accessories, such as pressure gauges, safety valves etc., have been properly
installed.
f. Cooling water for the cooling jackets if any, shall be in operation.
g. Oil circulation for bearing, mechanical seal etc. shall be in operation.
h. All transportation/erection stiffeners, mechanical jacks and stoppers have been
removed.
i. All piping spring supports have been set as per design requirement.
j. All connected process piping has been flushed and cleaned per flushing plan
separately.

5.2.2 Running Test/Performance Test

After completing the installation work, if and when required, rotating machinery shall be
operated with no load or reduced load, under the witness of CMC/Client in accordance with
Manufacturer’s instruction. If any abnormal sound, vibration or oil leakage is found during the
running test, the operation shall be stopped until the corrective countermeasures are taken.

5.2.3 Hot Alignment

5.2.3.1 For equipment operating at extreme temperature conditions, if specified in instruction
manual and if so recommended by manufacturer, hot alignment after specific operating period
may be performed in accordance with manufacturer’s instructions and procedures. Adjustment
so required shall be incorporated and recorded.

5.2.3.2 The value of the hot alignment shall be clearly indicated on the same plate to be
attached to the coupling guard or shall be clearly painted on the coupling guard.

6. Documents to be Submitted
6.1 After final inspection, all check lists and test and inspection records shall be issued in the
form of QC Dossier.

6.2 The QC Dossier shall be submitted in accordance with Inspection for field construction.

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