Execution Procedure Rotating

PT.
KELSRI
Engineering & Construction Management
EXECUTION PROCEDURE
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MECHANICAL ROTATING EXECUTION PROCEDURE
P T. KELSRI
Certificate
Certificate& Construction ManagementDOCUMENT TITLE : EXECUTION PROCEDURE DOCUMENT
Engineering
No. 167860 NO. : No. 167860
KI-750503-001
REV.
0
ROTATING EXECUTION PROCEDURE

FOR
EQUIPMENT INSTALLATION & MECHANICAL WORK
SP MERBAU AND SPG PAGARDEWA SUMBAGSEL
(PACKAGE III)
SP MERBAU/KQ-710503-001
PT. KELSRI
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EFFECTIVE DATE
25/10/2005ORIGINATORREVIEWED BYAPPROVED BYBonny Luhur
Rigging/Mech.EnginnerFadjar Setyawan
Site Manager Budi.HK
Project Manager CONTENTS

References 1 / 142.
General 1 / 143.
Preparation for Installation 1 / 144.
Preparation of Fokundation 1 / 145. Grouting
3 / 146. Installation 6 / 147.
Leveling 7 / 148. Alignment
10/149. Inspection before operation test 13/1410. Inspection Report
14/14REVISION RECORDSREV.DATEDESCRIPTIONORIGINATOR
REVIEWED BYAPPROVED BY02510/2005Issued for

AprrovalBLFJRBHKDISTRIBUTIONREMARKS1ORIGINAL2
3
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Reference
Vendor's instruction manual including relevant drawings ( hereinafter called"
Instruction Manual" ) shall be used as a part of this procedure.
Should there be any conflict between the information supplied in the documents,
General
Instruments and tools provided by PT. KELSRI to be used in leveling and alignment
shall be satisfied the conditions shown in the Table 1.
Table 1
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INSTRUMENTS
ITEM
SIZE AND ACCURACY
SERVICE
Spirit level
(1) Length 150 mm and longer, sensitivy 0.02 mm/m
made of steel
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(2) Length 150 mm and longer, sensitive 0.05 mm/m
Leveling
Straight edge
(1) Length 1,500 mm ( I Beam Type )
made of steel
(2) Length 500 mm ( I Beam Type )
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Dial Gauge
Min. graduation 1/100 mm
Thickness gauge
(1) Length of leaf 100-150 mm,
made of steel
(2) Length of leaf 200-300 mm
Alignment
Taper gauge made of steel
Length of leaf 150 mm, width of leaf 10-15 mm
Right angle rule made of steel

Effective length 300 mm, width 30 mm
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Vernier Caliper
Length 200 mm, graduation 5/100 mm
(inner and outer use)
Fine measurement
Inside and Outside
Accuracy : 1/100 mm (min)
(Cplg gap & shims)

micrometer
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Preparation for Installation
Prior to starting the work the following ( paras 4.1. through 4.3. ) shall be confirmed to be
satisfactory under witness of the Client Supervisor. Any defects found shall be referred
to the Client Supervisor and be repaired or improved properly and immediately
accordance with the instruction of the Client supervisor.
4. Preparation of foundation
4.1. Concrete Foundation
4.1.1. The following condition of the concrete foundation shall be checked against the
relevant drawings :
Whether center line is marked.
Accuracy of height and whether elevation line is marked.
Dimensions
Curing line
The top of the concrete foundation shall be lower than the finished height by the grout
thickness indicated on the foundation drawings.
4.1.3. Flatness and level shall be checked at the points where pads and / or liners are to
be installed.
4.1.4. The surface of the concrete foundation shall be checked to see that it is chipped
for grouting.
4.2. Anchor Bolts
4.2.1. The following conditions of the anchor bolts embedded in the foundation
shall be checked the drawings :
Position
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Tolerance shall be 1.5 mm from the dimension indicated on the related equipment
drawings, unless otherwise specified
Projection
The projection of the bolts above the foundation surface shall be of proper length
relative to the final level of the foundation finish.
Condition of bolts and nuts
Threaded parts shall be completely coated with grease or machine oil allowing the
nuts to be unscrewed smoothly
4.2.2. Anchor bolts with pipe sleeves to allow adjustment of the final positioning of
the bolt shall be checked with the following :
Position
Anchor bolts shall be accurately located as shown on the relevant equipment
drawing.
Projection
The projection of the bolts above the foundation surface shall be of proper length
relative to the final level of the foundation finish
Condition of bolts and nuts
Threaded parts shall be completely coated with grease or machine oil, allowing the
nuts to be unscrewed smoothly
Sleeve
Unless otherwise specified in the Instruction Manual, pipe sleeves shall be
approximately 50 mm larger in diameter that the anchor bolt.
When anchor holes are used for anchor bolts, the anchor bolts shall be installed in
the anchor holes after the equipment istemporarily placed in the right position.After
the anchor hole is grouted by mortar has sufficiently hardened leveling work shall
be commenced. Anchor holes shall be cleaned before temporary installation of
the equipment.
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4.3. Condition and Protection of Equipment
4.3.1. Unpacking shall be performed under witness of the Client Supervisor

and/or Vendor representative. All spare parts and dismantling tools, etc., shall be
repackaged and returned to to the warehouse as instructed by the Client
Supervisor. Fragile parts, such as level oil, capillary tubes, etc., shall be removed in
accordance with instructions of the Client Supervisor.
4.3.2. After being thoroughly inspected, the equipment shall be transported to the
Job site.
4.3.3. The condition of the machined surface shall be checked, and if necessary, the
machined surface shall be coated properly with a rust representative.
4.3.4. Temporary covers on all openings shall be tightened firmly and shall not be
removed during installation until the related pipelines are to be connected.
4.3.5. The both face of the base plates shall be cleaned. When oil,grease dirt or
any loose particles are found, it shall be washed off by water or other suitable
solvents before installation.
4.3.6. Coupled equipment shall be uncoupled and left uncoupled until the no-load
test for the driver is finished.
4.3.7. Coupling elements with clear identifications shall be stored properly in the
warehouse.
5. Grouting
5.1. Preparation for Grouting
a. The top surface of the foundation shall even be chipped and be wetted
thoroughly with fresh water prior to be grouting work. If pipe sleeves are used for
anchor bolts, standing water in the sleeves shall be removed ( see figure 1 ).
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Figure 1
Chipping of Foundation
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b. Making pad at side of anchor bolt ( see figure 2 )

Pad should be made at side of anchor bolt and elevation about 10 mm below
elevation top of grout.Dimension of padding plate about (150 mm x 95 mm x 12 mm ).
Figure 2.
Padding
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Prior to pouring non-shrink grout or epoxy grout, formwork shall be made ( see figure 3
)
Figure 3.
Formwork
5.2 Material
Pumps
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Non-shrinking grout material shall be used under the outer frame of the base plate, in
the base plate and in the sleeves.
Compressors
Epoxy grout material ( ceilcote 648 CP or Equal ) shall be used under the frame of the
base plate.
Lube Oil / Seal Oil Console
Non-shrink grout material shall be used for the base plate.
5.3 Items to be grouted by Epoxy Grout

The following items shall be grouted by Epoxy Grout material;
- Pumps
- Compressors, Turbines and Generators
- Lube Oil / Seal Oil Console
5.4. Grouting Procedure
5.4.1 For the grouting work, manufacturer's instruction shall be applied.

5.4.2 The grout shall cover all liners and wedges.
Before grouting, base plate bottom and chipping surfaces shall be free from oil and
dust. So, the base plate bottom will be cleaned up.
5.4.3 Grout material
Will be used non-shrink grout material ( Masterflow 870 ). Material shall conform to
USCE CRD-C 621 and ASTM C 109 for strength. Mixing and placing shall be in
accordance with manufacturer's recommendations.
Figure 4.
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Epoxy grout details
6. Installation
Installation of equipment shall be executed in accordance with this specification,

taking precautions so that the anchor bolts and foundations will not be damaged and the
equipment not distorted.
When anchor holes are used, the curing time of the grout mortar filled in holes shall be
checked before the starting of the leveling work.
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Figure 5.
Installation of Equipment
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Leveling of Equipment
7.1. Liners and Wedges
7.1.1. In general, liners and wedges shall be prepared as indicated in
Table 2. The dimensions may be modified as necessary for each application.

The material shall be carbon steel.
Table 2
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Item
Length
Width
Thickness
Slope
liner
100 - 150
50 - 75
1.6, 2.3, 3.2,
4.5, 6, 9, 12,
16, 19
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wedge
100 - 150
50 - 75
6, 9, 12
4o - 5o
7.1.2. A pair of wedges shall be used and the inclined surface of each
wedge shall contact with each other more than
60 percent of the surface.
7.1.3. Liners and wedges shall be located on both sides of each anchor
bolt and shall be placed close to the anchor
bolts. Where the distance between the anchor bolts is
larger than 80 cm, extra liners and wedges shall be
located between the anchor bolts to prevent the base plate
from bending.
7.1.4. The concrete surface where the liners plates will be placed, shall
be chipped smoothly and then be cleaned completely.
7.1.5. A Final check shall be made to ensure that the center of
the equipment matches the center liner marked on the
foundation.
7.2. Leveling
7.2.1. Before leveling performed, elevation of the equipment shall be
erected ( the some with design elevation ).
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Leveling shall be performed using a spirit level on the machined surface of the drivers
base plate, or on the suction flange or discharge flange of the vertical nozzle on the
top of the equipment unless otherwise specified. Leveling shall be measured on the
direction on the shaft and lateral. Adjustments shall be made by inserting or removing
liners and wedges.
7.2.2. The maximum tolerance from the level shall be 0.1 mm/m, unless
otherwise specified in the Instruction Manual.
7.2.3. There should not be free nuts and/or liner wedges after leveling is
finished then the lockouts of the anchor bolts
shall be tightened firmly.
7.2.4. After the lockouts of the anchor bolts are tightened firmly the liners and wedges
shall be tack-welded to each other, and any excess of the liners and/or wedged shall
be cut of with a gas cutter or grinders
7.2.5. Liners need not to be removed if tack-welding is made and
the liners are covered with grouting to prevent
possible rusting.
Figure 6.
Leveling
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Leveling of Vertical Pump

Following are the general guide for leveling work of vertical pumps. Detailed
procedure for individual application shall be determined by the Client Supervisor.
7.3.1. Level of a vertical pump shall be measured and attained on its top surface of
the bracket on the mounting plate in two directions at an angle of 90 deg.
7.3.2. For a vertical pump mounted on concrete foundation leveling work shall be
performed by adjusting liners or wedges under a mounting plate adjacent to each anchor
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bolt.Allowance shall be the same as those for horizontal pumps unless

specifically stated by pump vendor .
8. Alignment of Equipment
8.1. Initial Alignment ( First Alignment )

Before grouting of the equipment, first alignment of equipment shall be
performed with use Reverse indicator method. At this stage the pump and its driver soft
foot checks shall be performed ( see figure 7 )
Figure 7.
Alignment
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8.2. Second Alignment

This will be performed after the equipment is grouted. In general,
the reverse indicator method shall be utilized. The reading
shall be taken with a dial gauge at four points at 90 degree
intervals, and shall be adjusted by inserting shims under the
lug or the saddle of the driver and/or gear box, based on the
alignment map, or calculation. Tolerance of
alignment shall be 0.1 mm. The material of the shims for
alignment shall be of stainless steel. The size of the shims shall be at
least 150 mm in width, and 0.03, 0.04, 0.05, 0.1, 0.2, 0.5, 1, 2 and
6 mm In thickness; and if legs or saddles of equipment are
smaller than 150 mm in width, the size of the shims shall be
the same as the width of the equipment. All rotating equipment
must be checked for soft foot during the alignment performing
and manufacturer's instruction shall be followed.
8.3. Final Alignment / Alignment After Connecting Piping

After the suction and discharge nozzles are connected to piping, and
the Client Supervisor informed that all piping work such as
installlation of permanent supports, and hydrotesting, if any, are
completed for the connected piping alignment of the equipment
shall be rechecked as follows:
8.3.1. Prior to connecting the final cold alignment, the suction and
discharge piping shall be disconnected and piping
alignment such as off center, clearance, and
parallelism between the piping and connection
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flanges of the equipment nozzles shall be

checked by visual inspection.
When any misalignment is found in the piping during the above
inspection, the information shall be give to Client
Supervisor.
8.3.2. After the piping alignment check is completed and/or
misalignment of piping is corrected, the suction and
discharge piping shall be connected to the equipment
nozzles making sure proper piping gasket are in place
and the final cold alignment of the equipment shall
be checked with a dial gauge. Misalignment
of piping flanges and rotating machinery flanges shall
be checked by taper gauge before tightening of flanges.
The gap reading shall be taken every 90 degree and
the acceptance value of the parallelism shall be :
Max. Gap - Min. Gap < 1.0 mm
If the shaft alignment move by more than 0.5 mm ( total indicated

run out ) during tightening the flanges the piping shall be redone before
continuing the alignment.
Any offset on the alignment of the equipment found as a result of the piping connections
shall be corrected as follows :
a. Offset value of 0.2 mm or less shall be adjusted by inserting or removing
shims under the lug or saddle of the driver and/or gear box without correcting any
alignment.
b. Offset values exceeding 0.2 mm shall be reduced by correcting the suction
and/or discharge piping by turning or readjusting the pipe supports, and, if
necessary, the suction and/or discharge piping shall be disconnected and be welded again
to correct alignment of the equipment.
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Figure 8.
Vertical lift for Final Alignment
( Vertical Multi Stage Pump )
8.4. Final Check

After completing alignment, the following shall be ascertained :
8.4.1. By revolving the coupling by the hand or a turning device in

the direction of the arrow mark, the equipment should rotate easily.
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8.4.2. The direction of rotation of the driver shall be the same as

indicated by the arrow mark.
8.4.3. After the above, and an instrumental check and a load test of the driver, the
equipment shall be coupled and be capable of being rotated again easily by the hand or
a turning device. If the equipment has any protection device such as a turbine trip
system, it shall be tested before coupling.
8.4.4. The setting of the coupling guard shall be checked.
9 . Inspection and Preparation Before Test Operation
9.1. General
Prior to the test operation of the equipment, the Following confirmation
shall be made under witness of the Client Supervisor and the Vendor.
9.1.1. Oil flushing as specified have been finished.
9.1.2. The equipment can be rotated easily in the direction of the arrow
mark by the hand. After this inspection, the coupling shall be
installed and lubricated properly.
The coupling guard shall be installed firmly.
9.1.3. All rust preventatives, oil grease, etc., used to
protect the equipment during construction shall be
removed using solven 9.1.4. All accessories, such as pressure gauge,
safety valves etc., shall be
installed properly.
9.2. Running Test
After completing the installation work, a running test for each equipment
without shall be done under the witness of the Owner's representative.
If any unusual sound, vibration or oil leakage is found during the running
test,
the operation shall be stopped until the corrective countermeasures are
taken.
10. Inspection Report
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Inspection reports shall be made to assure that all requirements prescribed in para 4
through 10 have been done satisfactory. All inspection and alignment records of the
equipment shall be submitted to Client

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Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

ROTATING EXECUTION PROCEDURE

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

25/10/2005ORIGINATORREVIEWED BYAPPROVED BYBonny Luhur

Site Manager Budi.HK

Project Manager CONTENTS

REVIEWED BYAPPROVED BY02510/2005Issued for

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

(1) Length 150 mm and longer, sensitivy 0.02 mm/m

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

(2) Length 150 mm and longer, sensitive 0.05 mm/m

(1) Length 1,500 mm ( I Beam Type )

(2) Length 500 mm ( I Beam Type )

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

Min. graduation 1/100 mm

(1) Length of leaf 100-150 mm,

(2) Length of leaf 200-300 mm

Right angle rule made of steel

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

Length 200 mm, graduation 5/100 mm

(inner and outer use)

(Cplg gap & shims)

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

Preparation for Installation

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

4.3. Condition and Protection of Equipment

4.3.1. Unpacking shall be performed under witness of the Client Supervisor

5.1. Preparation for Grouting

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MECHANICAL ROTATING EXECUTION PROCEDURE

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MECHANICAL ROTATING EXECUTION PROCEDURE

b. Making pad at side of anchor bolt ( see figure 2 )

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MECHANICAL ROTATING EXECUTION PROCEDURE

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MECHANICAL ROTATING EXECUTION PROCEDURE

5.3 Items to be grouted by Epoxy Grout

5.4. Grouting Procedure

5.4.1 For the grouting work, manufacturer's instruction shall be applied.

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

Epoxy grout details

Installation of equipment shall be executed in accordance with this specification,

Doc No: KI-750503-001

MECHANICAL ROTATING EXECUTION PROCEDURE

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MECHANICAL ROTATING EXECUTION PROCEDURE

Table 2. The dimensions may be modified as necessary for each application.

Doc No: KI-750503-001