SECTION 10 - MECHANICAL EQUIPMENT

PT. GLOBAL POWER SERVICES

SECTION 10

MECHANICAL EQUIPMENT

Rev Date/Checked Date/Approved Date/Issued Notes

Oring Original Issue
Rev. A
Rev. B
Rev. C
Rev. D

PT. GLOBAL POWER SERVICES ©DOC2010 Page 1 of 13

SECTION 10 - MECHANICAL EQUIPMENT

PT. GLOBAL POWER SERVICES

SECTION. 10 MECHANICAL EQUIPMENT

Index Page

0.1 DEFINITIONS, CODES & STANDARDS

10.2 CARE OF EQUIPMENT PRIOR TO INSTALLATION

10.3 GENERAL INSTALLATION REQUIREMENTS

10.4 INSTALLATION SEQUENCE

10.5 CARE OF EQUIPMENT AFTER INSTALLATION

10.6 INSTALLATION, CARE AND CHECK-OUT OF SPECIAL EQUIPMENT

PT. GLOBAL POWER SERVICES ©DOC2010 Page 2 of 13

SECTION 10 - MECHANICAL EQUIPMENT

Section 10

MECHANICAL EQUIPMENT

10.1. Definitions, Codes & Standards

10.1.1 In this specification the following words shall have the meanings herein assigned
to them :

Primary equipment shall mean the first item of machinery set into place
whether or not it be a pump, a refiner, or the common drive ofl a multi-vacuum
pump assembly.

Drives shall include turbines, motors, couplings of all types, reducers, sheaves,
sprockets, V-belts and chains.

Equipment shall include both the driven and driver items.

10.1.2 Where Manufacturer's specifications are provided, the assembly installation,

alignment, testing, calibration and lubrication, start-up and test-run shall
conform to the Manufacturer's Specifications.

10.1.3 The following Riau Pulp standards, which are attached hereto, shall form a part
of the specification.

Grout Specification
Equipment Guards
Electrical Installation Specification
Start-up Screens
Calibration, Check-out and Installation of Instruments

10.2. Care of Equipment Prior to Installation

10.2.1 Within 7 days of receiving the equipment, fill bearing housing, gear reducers and
any other oil lubricated parts of equipment with flushing oil consisting of # 10
SAE viscosity oil containing a rust inhibitor.

10.2.2 Inspect all equipment in storage at least once a week.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 3 of 13

SECTION 10 - MECHANICAL EQUIPMENT

10.2.3 Unless specified otherwise, rotating equipment shall be rotated once every two
weeks, whether in storage or on its permanent mounts.

10.2.4 Equipment with openings, such as pumps, fans, refiners, screens and similar
equipment, shall have the inside examined, any foreign matter removed, and defects
reported to the Area Coordinator.

10.2.5 All equipment shall be inspected by the Contractor in the Place of storage to ensure
that it is in good condition, report any damages at defects to the Area
Coordinator prior to transporting the equipment to its prescribed location.

10.3. General Installation Requirements

10.3.1 Washers shall be installed under all nuts and under bolt heads when slotted holes are
encountered.

10.3.2 Beveled washers shall be used on tapered surfaces such as structural steel
flanges.

10.3.3 Equipment bolted to frames and structures shall have the bolt heads on top of the
connecting components so that the bolts will not drop out of the holes in the
event of a nut working loose.

10.3.4 Bolts shall have a minimum of two exposed threads projecting after the nuts have
been tightened down.

10.3.5 Machine bolts, nuts and keys shall be coated with a mixture of molybdenum
disulfide and oil before being assembled, except on stainless steel parts.

10.3.6 Equipment shall not be altered or repaired, and no burning or welding will be
permitted on any parts except by written permission of the Area Coordinator.

10.3.7 Couplings, sheaves and sprockets shall be fitted during stage 1 "Set in Place".
Unless otherwise specified by machinery supplier, they shall be fitted as follows :

- Coupling shall fit flush with the end of shaft.

- Sheaves and sprockets shall have a shaft protrusion of 6 mm..

10.3.7.1 The hubs of couplings, sheaves and sprockets shall have

interference fits with the shafts, all in accordance with ANSI B4.1 or
B4.2. The interference fits shall be recorded in the presence of the
Area Coordinator on a record sheet (see Section 6) The class of fit shall
be as specified. Compression type hubs shall be mounted in accordance
with manufacturers specifications.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 4 of 13

SECTION 10 - MECHANICAL EQUIPMENT

10.3.8 Field mounted bearings shall be fitted following Stage 2 "Leveling of Primary
Equipment and Base plate:. Raceway clearances shall be measured before and
after the bearing is mounted on the 'shaft, and shall agree with manufacturer's
recommendations. The clearances shall be recorded in the presence of the Area
Coordinator on a record sheet (see Section 6).

10.3.9 Field mounted gears shall be fitted following Stage 2, "Leveling of Primary
Equipment and Base plate". The gears shall have a backlash not exceeding the
tolerances set out in the manufacturer's specifications. Clearance shall be recorded
in the presence of the Area Coordinator on a record sheet ( See Section 6 ).

10.3.10 Sealing and cooling water piping discharge from equipment shall be visible.

10.4. Installation Sequence

'
10.4.1 To ensure that each stage of the sequence is completed by the Contractor and
Checked by the Area Coordinator before the next stage commences, the Area
Coordinator shall attach an equipment tag to each piece of primary equipment
(see the sample tag in Section 6).

10.4.2 After the Contractor has completed a stage, he shall advise the Area Coordinator.

10.4.3 When the Area Coordinator is satisfied the stage is complete, he will have the Area
Superintendent initial the card then both the Area Coordinator and the Contractor will
sign the tag.

10.4.4 The Area Coordinator will also maintain a separate record for each piece of
equipment in case a tag is lost or damaged (see the enclosed sample of a record
sheet in Section 6). The Contractor will be required to sign the Area
Coordinator's record for each stage of the installation that has been completed and
for which he has signed the tag. The Area Superintendent will also sign the form
indicating he has accepted that particular phase of erection prior to the Area
Coordinator having accepted it.

10.4.5 On completion of the installation, the Area Coordinator will remove the tag and
will attach a green tag to the primary equipment to signify the completion of the
installation of the equipment.
These tags and the original Acceptance Sheets will be sent to the Documentation
Center.

10.4.6. Stage No. 1 "Set in Place"

10.4.6.1 Equipment on Concrete Pads

Before the equipment is placed, the surface of the foundation that is to

be in contact with grout shall be cleaned of all dirt, oil, grease and

PT. GLOBAL POWER SERVICES ©DOC2010 Page 5 of 13

SECTION 10 - MECHANICAL EQUIPMENT

loose materials and shall be roughened with a brush hammer (see Std.
1S-05.01). When this work is complete the Contractor will notify the
Area Coordinator who will check the foundation prior to setting the
equipment in place.

10.4.6.2 Equipment on Structural Supports br Steel Floors

Before the equipment is placed, all surfaces to be covered shall be finish

coated as per project paint specification.

10.4.6.3 If the equipment is not in good condition or requires modification, the

repairs and modifications shall be done prior to transporting the
equipment to its prescribed location.

10.4.6.4 When the equipment has been set in place, the Area Coordinator will
attach the equipment tag to it, and the Contractor and Area
Coordinator will sign Item 1, "Set in Place".

10.4.7 Stage No.2 "Leveling of Primary Equipment & Base plate"

10.4.7.1 Leveling of equipment shall be done with packing plates and shims to
the exact location and elevation shown on the drawings. Wedges
shall not be used. Jack screws may be used when supplied with the
equipment. The size of the packing and shims shall be approved by the
Area Coordinator and shall be large enough to provide adequate bearing
on the concrete. Solid shims should be used where possible and in no
case shall shims thinner than 30mm be built up to more than 45mm.
Packing and shims shall be placed on both sides of all anchor bolts
within 60mm of the bolt, except where the bolt is mounted in a sleeve,
then the packing and shims shall be placed as close to the bolts as
possible, leaving space however for the introduction of grout into the
anchor bolt sleeves.

10.4.7.2 For large sole plates, additional packing and shims shall be placed
between the anchors where specified by the Area Coordinator.

10.4.7.3 Manufacturer's specifications shall be referred to when leveling and

aligning special equipment.

10.4.7.4 The anchor bolts shall then be tightened down, after which the primary
equipment and base plate shall be level to within 0.10% (1 mm/
1000 mm) when measured longitudinally, transversely and diagonally.

10.4.7.5 Jacking screws used to level the equipment shall be backed off when the
anchor bolts have been tightened.

10.4.7.6 Roughly align the drive assembly to the primary equipment.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 6 of 13

SECTION 10 - MECHANICAL EQUIPMENT

Whenever it is necessary to set the primary equipment on shims, the

shim thickness shall be no more than 30mm.

10.4.7.7 Pumps - Pump suction nozzles shall be grouted into chests or welded
into tanks and the pump suction piping installed at this stage of the
installation. Tanks with a gap between the tank base plate and the
concrete foundation shall be shimmed for 60mm on either side of the
pump suction nozzle on the tank.

10,4.7.8 When the leveling of the primary equipment and base plate is complete
the contractor shall notify the Area Coordinator and they shall both
sign Item 2 "Leveling of Primary Equipment and Base plate".

10.4.8 Stage No.3 "Grouting"

10.4.8.1 After the Area Coordinator has checked Stage 2, grouting shall proceed
as follows :

10.4.8.2 Recheck the concrete surface to ensure it is free from dirt, oil, grease
and loose materials and that it has been roughened with a brush hammer
and blown down with air.

10.4.8.3 Under extreme weather conditions (temperature less than 5°C), of the
grouted area must be protected and heated. (N.A.)

10.4.8.4 The concrete surface area to be grouted shall be saturated with water.
Any free standing water must be removed before placing the grout.
(N.A.)

10.4.8.5 Grout shall be installed so that all voids under a hollow base plate are
filled. Open frame base plates shall be filled with grout to the top of
the frame.

10.4.8.6 When grouting is complete, the Contractor shall notify the Area
Coordinator and they shall both sign Item 3 "Grouting".

10.4.9 Stage No. 4 "Attachments to Equipment"

10.4.9.1 Install all piping, chutes and other attachments and temporarily connect
them to the equipment.

10.4.9.2 During the installation of the piping, start-up screens shall be installed
without gaskets in pump suctions and equipment inlets that cannot
be visually inspected. When the start-up screen is removed after the
flushing operation it shall be replaced with a gasket.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 7 of 13

SECTION 10 - MECHANICAL EQUIPMENT

10.4.9.3 When the piping or chutes are complete, disconnect them from the
equipment. Any misalignment between them and the equipment
shall be adjusted in the piping or chute so that no strain is placed on
the equipment when they are permanently connected in Stage 5.

10.4.10 Stage No. 5 "Alignment"

10.4.10.1 The alignment of drives to equipment shall be done with dial

indicators as illustrated on the form in Section 6 or by laser
alignment.

10.4.10.2 During alignment, the equipment shall be free from all attachments
that can apply external loads and forces.

10.4.10.3 The angular and parallel alignment shall be within the tolerances
specified on the form in Section 6 when both halves of the coupling
are rotated together in the same relative position.

10.4.10.4 When the alignment of the equipment and drive is complete the
Contractor shall notify the Area Coordinator who will read and
record the dial indicators on the form shown in Section 6.

10.4.10.5 Following the readings, the dial indicators shall be left on the
coupling halves, while the attachments to the equipment are made
that could apply external loads and forces and in turn cause
misalignment (e.g. piping, chutes).

10.4.10.6 If the attachments cause misalignment from the recorded dial

indicator readings, the attachments shall be adjusted in order to
eliminate the force.

10.4.10.7 Sprockets and sheaves shall be in line and parallel to one another.

10.4.10.8 Roller chain shall be installed with a minimum of slack. Offset chain
links shall not be used unless the Contractor receives written
permission from the Area Coordinator.

10.4.10.9 Do not connect couplings, sheaves and sprockets to motors at this

stage.

10.4.10.10 When alignment of the equipment and drive is complete, the

Contractor shall notify the Area Coordinator and they shall both
sign Item 5 "Alignment".

PT. GLOBAL POWER SERVICES ©DOC2010 Page 8 of 13

SECTION 10 - MECHANICAL EQUIPMENT

10.4.11 Stage No.6. "Lubrication"

10.4.11.1 Remove flushing oil from equipment and install the permanent
lubricants which shall be according to specifications supplied by the
Area Coordinator or Vendor.

10.4.11.2 When lubrication is complete the Contractor shall notify the Area
Coordinator and they shall both sign Item 6 "Lubrication". Process
Maintenance Supervisor responsible for lubrication will initial the card
prior to the Area Coordinator signing the card.

10.4.12 Stage No.7 "Electrical Check-out"

10.4.12.1 Complete the electrical installation of the equipment according to

"Electrical Installation Specification".

10.4.12.2 Before connecting the motor to the equipment check the motor rotation.

10.4.12.3 Test run the motor for 15 minutes in the presence of the Area
Coordinator. Check motor bearings at frequent intervals for
overheating. Preventative Maintenance Department to conduct a
"vibration analysis" on motor at this time and record this value for
future reference and compare it to the manufacturers guarantee.
Preventative Maintenance Supervisor to initial the card prior to the Area
Coordinator signing the card.

10.4.12.4 Take ammeter and voltmeter reading on the motor without load and record
on the tag shown in Section 6.

10.4.12.5 When electrical checkout is corhplete the Contractor shall notify the
Area Coordinator and they shall both sign Item 7 "Electrical Check-
out". The Process Electrical Supervisor is to initial the card prior to the
Area Coordinator signing the card.

10.4.13 Stage No.8 "Equipment Guards"

10.4.13.1 Connect the drive to the equipment.

10.4.13.2 Lubricate coupling when applicable; check level in hydraulic couplings.

10.4.13.3 Install equipment guards in accordance with design standard .

10.4.13.4 When installation of the guards is complete the Contractor shall notify the
Area Coordinator and they shall both sign Item 8 "Equipment Guards".

PT. GLOBAL POWER SERVICES ©DOC2010 Page 9 of 13

SECTION 10 - MECHANICAL EQUIPMENT

10.4.14 Stage No.9 "Test Run"

10.4.14.1 Before starting-up equipment the Contractor shall obtain a release

from the Area Coordinator and the Vendors Representative (if
supervision is in their scope as the Vendor still has full
responsibility for the equipment) in writing and shall obtain any
special instructions relating to the start-up of the equipment from the
Area Coordinator.

10.4.14.2 Vessels that are attached to equipment shall have all incoming pipe
lines flushed before a test run is made. Following the flush, the
vessel shall be drained, cleaned and inspected in the presence of the
Area Coordinator.

10.4.14.3 Prior to filling a vessel for a test run, inspect pump suctions in the
following manner:

- Visually inspect open pump suctions that allow sight into the
impeller.
- Make sure blind pump suctions have start-up screens.

10.4.14.4 Prior to starting equipment, rotate all moving parts (by hand where
practical) to see if they rotate freely.

10.4.14.5 Recheck the lubrication, notify all personnel in the area and check
for physical obstructions.

10.4.14.6 Check all service piping to be assured it is piped to the right

connections on the equipment.

10.4.14.7 ALL PUMPS SHALL BE STARTED AGAINST A CLOSED

VALVE

10.4.14.8 Test run the equipment in the presence of the Area Coordinator for
the required length of the time to check-out the complete operating
system. Preventative Maintenance Department to conduct a
"vibration analysis" on the pump and record this value for future
reference.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 10 of 13

SECTION 10 - MECHANICAL EQUIPMENT

10.4.14.9 During the test run check all bearings at frequent intervals for
overheating.

10.4.14.10 Take ammeter and voltmeter readings on the motor with load and
record on the tag shown in Section 6.

10.4.14.11 When the test run is complete, the contractor shall notify the Area
Coordinator and they shall both sign Item 9 "Test Run".

10.4.15 Stage No. 10 "Instrumentation Check-out"

10.4.15.1 Prior to stage No.9 "Test Run", instrumentation that is an integral

part of the equipment operation according to "Calibration, check-out
and installation of Instruments" must be complete.

10.4.15.2 During Stage No.9 "Test Run" complete the final calibration and
check-out of the instruments.

10.4.15.3 When the instrumentation check-out is complete, the Contractor shall

notify the Area Coordinator and they shall both sign Item 10.
Process Instrumentation Supervisor shall initial the card prior to the
Area Coordinator signing the card.

10.4.16 Stage No.l 1 "Alignment Re-check"

10.4.16.1 After the test run and flush out, disconnect the couplings and recheck
the alignment in the presence of the Area Coordinator.
Re-check the tightness of any tapered bushing.

10.4.16.2 Correct any misalignment, reconnect the drive and replace the guards.

10.4.16.3 When the re-check is complete, the Contractor shall notify the Area
Coordinator and they shall both sign Item 11.

10.4.17 Stage No. 12 "Dowels or Lugs"

10.4.17.1 The following items shall be doweled :

- Primary equipment
- Gear reducers
- Motor and Eddy current couplings 15 HP and larger.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 11 of 13

SECTION 10 - MECHANICAL EQUIPMENT

10.4.17.2 The following items shall have steel block lugs, with jacking
screws:

- Conveyor head shafts, tail shafts and bearing blocks.

10.4.17.3 "Dowels" shall be standard tapered dowel pins with jacking nuts. Two
dowels shall be used on each item and they shall be located at
diagonally opposite corners.

10.4.17.4 Dowel diameters shall be as follows :

- 1/2 the hold down bolt diameter for coupling connected
equipment.
- The hold down bSlt diameter for V-belt and chain connected
equipment.

10.4.17.5 Dowel length shall be such that it extends a minimum of 3 diameters into
the equipment base. The hole shall be deep enough to prevent bottoming
of the dowel.

10.4.17.6 Dowel holes shall be reamed with a taper ream equal to the diameter of
the dowel.

10.4.17.7 Dowels shall be painted with a mixture of molybdenum disulfide and oil
before installation.

10.4.17.8 All equipment items shall be match-marked with metal stamping.

10.4.18 Stage No. 14 "Installation Complete-"

10.4.18.1 When the above 13 items are complete, the Area Coordinator will
attach a green tag to the equipment and the Contractor will sign Item 14.

10.5. Care of Equipment After Installation

10.5.1 Rotating equipment shall be rotated once every two weeks by hand or driven.

10.5.2 Lubrication shall be checked once a week.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 12 of 13

SECTION 10 - MECHANICAL EQUIPMENT

10.6. Installation, Care and Check-out of Special Equipment

10.6.1 Turbines

10.6.4.1 Turbines normally have an attached gear box and shall be leveled
as described in Stage No.2 - "Leveling of Primary Equipment and
Base plate".

10.6.4.2 Turbines shall be aligned to allow for expansion as per the turbine
manufacturer's instructions.

10.6.4.3 Turbine covers shall be lifted so the inside can be inspected and cleaned if
necessary.

10.6.4.4 In checking out a turbine drive the contractor is required to make two
running checks.
1. Run the turbine and gear reducer (uncoupled from the driven
equipment).

2. Run the turbine, gear reducer and equipment as a system.

10.6.2 Reciprocating Compressors

10.6.5.1 Following Stage No.2 - "Leveling of Primary Equipment and Base

plate", reciprocating compressors shall be checked for crankshaft
misalignment. The crankshaft deflections shall be checked in the
presence of the Area Coordinator and recorded on the "Alignment
Check List for Couplings".

10.6.3 Sulfur Burner

10.6.6.1 Install the sulfur burner, primary and secondary coolers and the
interconnecting piping prior to the installation of the refractory lining.
Shims with a thickness of the permanent gaskets shall be used for the
initial installation.

10.6.6.2 When the above items are all aligned and marked, dismantle the
interconnecting piping so that the refractory can be installed on the
ground.

10.6.6.3 On completion of the refractory lining, reinstall the piping with the
permanent gaskets.

10.6.4 Absorption Towers

10.6.7.1 Gas absorption towers shall be set plumb. The plumbing tolerance
shall be ± 2mm in 3 meters of height.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 13 of 13