METHOD STATEMENT FOR

PUMP INSTALLATION

TABLE OF CONTENTS

1 PURPOSE

2 REFERENCES

3 ABBREVIATION

4 METHOD STATEMENT FOR ERECTION AND INSTALLATION (PUMPS)

4.1 Preliminary survey for the pump foundation

4.2 Preparation of foundation
4.3 Installation of plate leveling pad
4.4 Installation / Erection of equipment / frame
4.5 Centering and positioning
4.6 Grouting of Anchor pockets
4.7 Grouting of equipment base
4.8 Grout filling of equipment base (Frame)

5 INSPECTION

5.1 Cold Alignment of equipments

5.2 Pipe flange parallelism
5.3 Pipe stress measurements

6 No Load Test (Uncoupled)

6.1 Gear coupling

6.2 Final alignment

7 PRESEVATION AND PROTECTION

7.1 Before the installation of the equipment

 7.2 After the installation of the equipment

8 ATTACHMENTS

1. Purpose

This method statement provides minimum requirements for Equipment erection and
installation works at site and shall be read in conjunction with the detailed requirements
of the specification and standards by the project and also a guideline for the personnel
who shall be involved in this activity.

2. References
The terms and definitions used through out this statement shall have the same meaning
related to its project specification and its relevant standards.

12729700-255-0001= GENERAL REQUIREMENTS FOR EQUIPMENT.

12729700-215-0005 =GROUTING
12729700-256-0001 =API 610 CENTRIFUGAL PUMPS FOR GENERAL REFINERY
SERVICE.
12729700-256-0002=ROTATING EQUIPMENT-ANSI HORIZONTAL, END SUCTION
CENTRIFUAGL PUMPS

3. Abbreviation

- SAK : SAUDI ARABIAN KENT

- CS : Construction Superintendent
- QCI : Quality control inspector
- MW - Millwright Fitter

4. Method Statement for Erection and Installation

(Equipments)

4.1 Preliminary survey for the pump foundation

a) A preliminary survey shall be made to ensure the coordinate and elevation of the
foundations is as per the drawing.
b) Ensure that Anchor Bolts / Pockets are constructed / installed as per the drawing and
anchor bolt threads are in good condition.
c) Confirmation of the orientation marks is provided on the foundations prior to
installation.

4.2 Preparation of foundation

a) Visual verification for the roughness and chipping condition of foundation top
surfaces in order to get a minimum grouting clearance of 25MM.
b) The number of jack bolts and location of the jack bolt on the equipment shall be
confirmed.
c) All anchor boxes are verified for its surface roughness and location.
d) Confirmations for no foreign material or grease are present on the foundation and
anchor box.

4.3 Installation of plate leveling pad

a) Leveling plates shall be installed in accordance with the project specification, i.e.
12MM thick 50MM diameter plate in non shrink epoxy grout (Comb extra EP40 by
FOSROC-Proposed)
b) Levelness of the leveling plates shall be maintained to have a minimum tolerance.
(Not more than 2MM)
c) Sufficient time will be provided for curing in accordance with vendor
recommendations after the level plates are mounted.
d) Client shall be invited through an inspection request raised prior to 24 Hrs to have a
cross check on the installation of level plates.
e) A millwright fitter shall do the leveling pad plate fixing.

A typical level plate made out of 12 MM C.S. Plate

4.4 Installation / Erection of equipment or Frame

a) All safety aspects shall be covered during the erection of equipments.

b) Approved, lifting devices shall be made available during erection.
c) Driver unit shall not be installed along with driven unit.
d) The equipment shall be placed over the leveling plate in such a way that the jack
bolts to rest on it

4.5 Centering and positioning

a) Centering and positioning of the equipment / frame to the pre determined marking or
to the elevation by the surveyor.
b) The equipment nozzles, which is mounted to the frame by the vendor shall be
master leveled to have a précised tolerance of 0.05MM in the entire axis by
adjusting jack bolt mounted to the equipment frame.
c) A millwright fitter shall do the centering and positioning.

A Typical Example for Leveling Plates installed in a Foundation

4.6 Grouting of anchor Pockets

a) After the leveling and centering confirmed by the client, anchor boxes shall be air
cleaned to remove all dust and other loose particles.
b) All anchor bolts threaded portion shall be greased and covered with a duct tape to
avoid damage to this portion.
c) Anchor bolts shall be inserted in to the anchor pocket through the holes provided in
the equipment foundation.
d) The protrusion of the anchor bolts shall be maintained as per the drawing by
adjusting the nut provided.
e) Non-shrink epoxy grout will be used and shall be mixed according to the
manufactures data sheets.
f) Curing of the grout shall be done as per manufactures recommendation.
g) No work related to this anchor bolts will not be done until they are cured.
h) All anchor bolts are snug tightened after the foundation pocket grout is fully cured.

4.7 Grouting of equipment base

a) After the leveling and centering confirmed by the client, foundation shall be air
cleaned to remove all dust and other loose particles.
b) Formwork shall be done around the foundation according to the drawing
requirements.
c) Non-shrink epoxy grout will be and shall be mixed according to the manufactures
data sheets.
d) Level of Grout shall be maintained just above the bottom of the lower flange of the
pump base plate or equivalent.
e) Curing of the grout shall be done as per manufactures recommendation.
 4.8 Grout filling of equipment base (Frame)

a) Air cleaning shall be done prior to pre wetting of the pump frame (inside)
b) Wiping of excess water content from the base shall be done with cloth or sponge.
c) Cementations non- shrink grout shall be used for the filling of equipment base.
d) Cementations non- shrink grout (Contexture TS-Proposed) shall be mixed in
accordance with manufactures recommendation.
e) Small concrete vibrators shall be used during filling of grout to make sure filling of
grout takes place all around the frame.
f) Air trapped inside of the frame during grout pouring shall be vented by means of
small wire rope inserted (for shaking as well as spreading) through the grouting
pocket of the equipment frame.
g) Places were wire rope or any other means cannot be implemented for air venting,
additional vent holes shall be drilled.
h) The grouting pocket shall be made a dome shape after the filling to avoid pound of
any medium or rainwater.
i) The dome portion (the grout filling points) shall be painted according to project
specifications and standards.

5. Inspection

5.1 Cold alignments of equipments

a) “Unless otherwise specified, the Reverse Rim (dial) indicator method must be used
for machinery alignment.”
b) The following activity must be performed and confirmed prior to Alignment Check:
- Foundation bolts tightening
- Pump hold down bolts tightening check
- Motor bolts tightening
- Soft foot checks on motor feet.
- All equipment jack bolts to be removed.
- All jack bolts holes to be filled with industrial sealant for preventing further
damage.
c) Before starting the alignment, the equipment shall be disconnected from piping and
conduit as much as possible. All process piping not to be connected to the equipment
until completion of its Hydro test and re-instatement.
d) The initial alignment of the equipment shall be carried out prior to connecting the
piping and after the specified curing period.
e) Tolerances – For Reverse Rim (dial) indicator Method: Maximum out of tolerance is
0.05 mm for both dial gauge reading and unsolved shim calculation.
f) For Rim and Face Alignment Method: Maximum out of tolerance is 0.05mm for radial
and 0.03 mm for axial measurement.
g) All tolerances are related with the target alignment – that means the ambient cold
offset alignment prescribed by vendor, in order to compensate for shafts relative
movement from cold to operating conditions.
h) Distance Between Shaft Ends (DBSE)
i) DBSE must be measured in accordance with the coupling manufacturer instruction.
For flexible-element coupling the DBSE permissible tolerance is +/- 0.4mm unless
specified by vendor.
j) The maximum permissible number of shims under any equipment foot is five (5nos).
 k) Shims – The shims used for alignment are checked for dimensional requirements
and project specifications.

5.2 Pipe flange parallelism

- All supports must be installed and all spring hangers and spring supports must
be locked at cold load setting.
- Pipe flange bolt holes must permit bolts installation without application of
external force
- The machine and piping flange faces must be parallel to less than 0.025mm
per inch of pipe flange external diameter up to a maximum of 0.75 mm.
- For pipe flanges outer diameter smaller than 10 inches the flanges shall be
parallel to 0.25 mm or less.
- Flange face separation must be within the gasket thickness plus or minus
1.5mm.

5.3 Pipe Stress Measurement:

- Before connecting the piping, the dial gauge shall be mounted on the coupling
hub of the driver in vertical and horizontal direction and the pointer shall be
adjusted to zero.
- The pipe connections start with the largest flange.
- The maximum shaft movement shall be less than 0.05 mm in either direction. If
the shafts movement is greater than 0.05 the piping flanges must be
disconnected and corrections made on piping supports or piping flange. Values
greater than 0.05 are permitted during bolts tightening.
- Pipe stress shall be checked while all piping are connected to the machine,
including oil piping, cooling water, or seal system piping.
- Over hung pump support to be loosened and check the shaft movement is
within 0.05mm.

6. No Load Test (Uncoupled)

Prior to the running test of the equipment, the following works shall be carried out:

a) Confirm that the erection of the auxiliary piping and other accessories has been
completed and there after piping shall be flushed with oil.
b) The equipment shafts shall be rotated by hand in the direction of the arrow to ensure
smooth rotation.
c) Rust preventives, oil, grease, etc applied to protect the equipment shall be removed.
d) The correct amount of lubricant, specified in the lubricant list, shall be filled into the
equipment.
e) The pressure gauges, safety valves and other accessories shall be firmly installed.

6.1 Gear Coupling

A thorough visual check shall be done for proper contact of coupling and free of wear.

6.2 Final Alignment

After Hydrostatic test and re-instatement, the Final alignment check must be performed
and the results shall be within the permissible limits as prescribed in preliminary
alignment.
7. Preservation & Protection
7.1 Before the installation of equipment

a) Equipment received shall be stored according to the storage plan agreed in advance
according to the installation schedule and manufactures recommendation.
b) Proper protection shall be provided against wind, rain, dust, corrosion etc.
c) Gauges, Flanges, etc. shall be protected with proper means.
d) Machined parts shall be protected with rust preventives.
e) Ensure all couplings are uncoupled and the coupling elements are clearly marked
with equipment Number, and stored properly.
f) Check that all flanges are properly blinded.

7.2 After the installation of equipment

a) The equipment shall be rotated by turning the coupling in the direction of the arrow,
either by hand or by a turning device, to confirm smooth rotation.
b) The shafts and the machined parts shall be checked for rust and to be coated with
rust – preventives if necessary.
c) Bearing housing shall be filled with the specified lubricant or rust-preventive oil as per
vendor recommendations.
d) All openings on equipment shall be tightly closed.
e) In case foreign materials are expected to fall on the equipment appropriate protective
measures shall be taken.
g) Gauges or other fragile components shall be protected with satisfactory means.

8. Attachments