Eng ETS 619

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Stanlow Engineering Procedures Eng-ETS-619

No
Title: Installation Of Static Mechanical
Equipment Page 1 of 15 Rev C
Installation Of Static Mechanical Equipment
REV DESCRIPTION DATE AUTHORISER SIGN
C Issued on New Format Jul 2016 Paul Smith
Next Review date Jul 2020
Name Title
Authoriser Paul Smith Manufacturing Support Manager
Technical Approver Lee Donnelly Project & Construction Manager
Custodian Mike Wilde Mechanical & Reliability Manager
Controller Steve Overend Quality Management Focal Point
DISTRIBUTION: Held as an electronic document as part of the Engineering Quality System and is
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Template Reference Only - Eng- QMSGEN-T001 - Rev A

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DATE Rev Document Revision Log

Sept 2002 O New ETS. Revised and updated from ETS101, which is hereby
deemed to be defunct.
July 2011 A Updated and revised in-line with latest DEP’S
Nov 2011 A1 Section 5.1.1 and 5.2.1 amended to capture learning from previous
instances of under tightened flanged joints. Authoriser amended as
per AMS requirements.
Document Reformatted.
Gavin Beevers.
Jun 2015 B Issued onto new format
July 2016 C Section 5.5.3 updated to include reference to finfans.
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Contents
1.0 INTRODUCTION ....................................................................................................... 4

2.0 SCOPE ..................................................................................................................... 4
3.0 REFERENCES ............................................................................................................ 4
4.0 DEFINITIONS ............................................................................................................ 5
5.0 PROCEDURES ........................................................................................................... 5
6.0 RECORDS ............................................................................................................... 13
7.0 APPENDIX .............................................................................................................. 14
1.0 INTRODUCTION
This document specifies the minimum technical requirements for the mechanical
installation of all static mechanical equipment. It is intended to supplement, and in those
cases where it is more stringent, to replace the equipment manufacturer’s
recommendations, unless otherwise agreed by the Principal. It supersedes previous
Engineering Technical Specification ETS 101 ‘Mechanical Equipment - Installation of
Rotating and Static Equipment’. Installation of all rotating equipment has been excluded
from the requirements of this specification. Reference may be made however to
Engineering Technical Specification ETS 502 – ‘Installation and Commissioning of Rotating
Equipment’.
2.0 SCOPE
This document is specific to Stanlow and its requirements are to be satisfied irrespective of
the separate requirements of UK DEP’s, Group DEP’s or National Codes and Standards. As
a rule, the requirements of this document shall be adhered to wherever it is more stringent
than other standards and Vendor recommendations. However, National and/or local
regulations may exist in which certain specific requirements are more stringent. In the
event of conflict the Principal shall be consulted. Deviation from the requirements of this
specification shall only be made with the express consent of the Principal.
This specification does not apply to all equipment that could be included under the
collective heading of Static Equipment. It covers the activities associated with the more
usual static equipment encountered at Stanlow, e.g. vessels, columns, reactors, modules or
skid units and heat exchangers. Specialist equipment items would normally be the subject
of a contract that would include supervision and installation by the equipment supplier.
Although primarily intended for new construction projects, this document may also be used for
maintenance works involving the installation of static mechanical equipment.
3.0 REFERENCES
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1.1 DEP’S
70.10.70.11 - Gen The preservation of old and new equipment and piping standing
idle.
1.2 ENGINEERING TECHNICAL SPECIFICATIONS

ENG-ETS-102 Quality Control - Mechanical Construction
ENG-ETS-205 Structural Concrete Work
ENG-ETS-502 Installation and Commissioning of Rotating Equipment
ENG-ETS-616 Pressure Testing
ENG-ETS-617 Bolt Tightening & Joint Making
1.3 ENGINEERING PROCEDURES AND WORK INSTRUCTIONS

ENG-Mech-100 Control of Mobile Crane Lifting Operations
1.4 STANDARD DRAWINGS

00 454801 Anchor Bolts with Sleeves for Concrete Foundations and
Structures - Stanlow Standard Drg.
4.0 DEFINITIONS
For the purpose of this document, the following definitions shall hold:
Shall and Should - the word ‘shall’ is to be understood as mandatory and the word ‘should’
as strongly recommended to comply with the requirements of this document.
The Principal is the party which initiates the project and ultimately pays for its design and
construction.
The Principal will generally specify the technical requirements.
The Principal may also include an agent or consultant, authorised to act for the Principal.
The Contractor is the party which carries out all or part of the design, engineering,
procurement, construction and commissioning for the project. The Principal may
sometimes undertake all or part of the duties of the Contractor.
The Purchaser is the party which buys the equipment and its auxiliaries for its own use or
as agent for the owner.
The Vendor is considered to be synonymous with the Manufacturer/Supplier defined
above.
5.0 PROCEDURES
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5.1 GENERAL REQUIREMENTS

5.1.1 Purchase Specification
All equipment shall have been the subject of a Purchase Specification raised by the
Principal. Such equipment will have been designed , fabricated, pressure tested and
inspected to the appropriate specifications. Normally the equipment will be delivered to
the Principals Stores. Although arrangements can be made to deliver direct to site.
When it is the intent that equipment be supplied fully assembled and tested from the
vendor ready for service, the purchase specification shall make specific reference to the
final bolt stress target values that shall be used, as per ETS617. Confirmation of this
requirement shall also be part of quality plan agreed with the vendor .
5.1.2 Quality Control

The Contractor shall comply with the requirements of Engineering Technical Specification
ETS 102 – ‘Quality Control – Mechanical Construction’.
At an early stage of the project, the Contractor and the Principal shall agree on a proposal
for quality control of static equipment covering all aspects of installation, inspection and
pre-commissioning. Quality control should be maintained by an independent function
within the Contractor’s organisation or Inspection Department which reports to the
Contractor’s Management. The Contractor shall inform the Principal on any deviations
from the requirements of this document. Each individual item of equipment shall have its
own checklist covering all aspects of its installation, inspection and pre-commissioning.
Where a managing contractor is employed the checklist format shall be mutually agreed
with the Principal. In other cases checklist document Q-19-B as indicated in Engineering
Technical Specification – ETS 102 shall be used. Such checklists shall ultimately be signed by
the Principal or its representative and shall be included within the documentation of the
handover procedure.
5.1.3 Construction Tools/Special Tools

It is the Contractor’s responsibility to ensure that the proper tools are available and are
used for the proper installation of the equipment (i.e. correct-size spanners and keys,
certified slings and chain hoists, torque wrenches, calibrated engineering spirit levels etc.).
Generally, adjustable spanners shall not be used on any equipment.
Abnormal wear and tear of parts of the equipment through the use of improper tools
during assembly is not acceptable. At handover, equipment shall be in ‘as-new’ condition.
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At an early stage during the construction a check should be made on the availability of
special tools that shall be supplied by the equipment manufacturer. Such special tools as
provided shall be used by the Contractor as and when required, but the Contractor remains
responsible for the handover of these tools to the Principal in as-new condition.
Throughout the project, preservation of special tools should therefore be maintained.
5.1.4 Installation and Operating Manuals

Manufacturer’s Installation and Operating Manuals (IOM) shall be available at site prior to
installation of the equipment. The instructions contained therein shall be adhered to,
unless superseded by more stringent requirements of this Specification.
The Vendor shall be responsible for supplying as-built data requisition sheets within the
final IOM. During installation and commissioning, the Contractor shall record any changes
that are made to the equipment in order that the information in the data sheets may be
amended accordingly.
5.1.5 Storage of Equipment Prior to Installation

See also DEP 70.10.70.11-Gen. ‘The Preservation of Old and New Equipment and Piping
Standing Idle’.
At a very early stage of the project it should be verified that, where necessary, there will be
an adequate quantity of rust preventatives and/or Desiccant in bags at site by the time
equipment is received.
On receipt, the equipment shall be checked against the shipping manifest and inspected for
any damage. Shop preservation shall be checked. Where necessary, damage to
preservation shall be rectified without delay.
Shop-applied protection is usually sufficient for the shipment period or 6 months only. The
Contractor shall take all necessary actions to restore the preservation, when the protection
period expires.
At all times, manufacturer’s recommendations on extended storage (indoor and outdoor)
shall be adhered to.
5.2 INSTALLATION
5.2.1 General
The Contractor shall be responsible for providing all supervision, skilled labour; installation
equipment and lifting tackle to comply with this specification.
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The Contractor shall check the installation position (i.e. the concrete foundation or steel
structure) for accuracy of size, location and its condition to receive equipment.
Concrete foundations will have holding down (HD) bolts provided by Civil Contractor,
together with sliding plates where required. The Contractor shall be responsible for
installing and levelling such sliding plates, for grouting by Civil Contractor.
Steelwork supports will have special HD bolts that are to be specified and provided by the
Principal (free issue). The Contractor shall ensure that the specified grade and length are
installed.
Equipment supplied from the vendor “ready for service” with pre-jointed flanges shall have
quality documentation confirming that the correct process specification gasket is installed
and that the bolting has been lubricated and tightened in accordance with ETS617. If this
cannot be confirmed then the Principal must establish this by other means which may
include sample torque or tension checks by the contractor.
5.2.2 Method Statement

The Contractor shall prepare and submit a method statement, for the
installation of all equipment, for approval by the Principal. As a minimum the
method statement shall include the following:
• A full but brief description of the task to be completed with an outline programme and
relevant drawings.
• The size, weight and orientation of the equipment item.
• Details of the route/movements of the equipment transport and cranes within the
operating units and at the job site.
• A lifting study.
• The Engineering Procedure ‘ENG/M/SITE/100’ – Control of Mobile Crane Lifting
Operations’.
• A ‘Stanlow Mobile Crane Planning and Risk Assessment Sheet’.
5.2.3 Pre-installation Visual Inspection

Before withdrawing the equipment from stores, or before offloading from direct delivery
transport, the Contractor shall carry out a thorough visual inspection. Any damage
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discovered at this stage is to be reported immediately to the Principal who will advise the
necessary course of action.
5.2.4 Handling of Equipment

Equipment shall be either drawn from Company Stores or be off-loaded from
transportation at the work site. Lifting shall be carried out with certified lifting slings and
shall be by the use of lifting lugs or trunnions where provided or by lifting at specified
positions. If no lifting position is identified then the Contractor shall consult the Principal
before proceeding further.
The method of lifting, transporting and supporting shall ensure that the equipment is at all
times protected from damage and distortion.
Existing steelwork, structures, lifting beams etc. shall not be used for lifting purposes
without specific approval of the Principal.
Any steelwork, flooring, hand railing etc. which is removed to facilitate equipment
installation, is to be properly reinstated immediately after the equipment has been
installed.
5.2.5 Unpacking
Ensure that all items in the packing lists have been received and that packing materials and
protective devices used during transportation are removed. Check that no temporary plugs
have been left in the pressure retaining part of the equipment.
5.2.6 Identification
Identify each item of equipment from its nameplate and establish its installed location from
the appropriate Contract drawings.
5.2.7 Equipment Movement

Where an item of equipment is designed to move, due to thermal expansion or other
requirements, the sliding or rolling elements are to be installed and set to the required
level/position prior to the equipment installation.
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5.2.8 Dressing
Where equipment is to be partly or completely dressed prior to erection, this will be clearly
specified in the Contract Scope of Work. The Contractor shall ensure that such work will not
interfere with subsequent installation activities.
5.2.9 Attachments
Platforms, ladders and other attachments that are to be fitted on the equipment after
erection shall be installed in accordance with the Contract Scope of Work and the
appropriate Contract drawings.
5.2.10 Hot work

Under no circumstances shall hot work be permitted on any equipment without the specific
written approval of the Principal.
5.2.11 Orientation
Establish the orientation requirements for each item and check that both the equipment
and its foundation carries appropriate orientation marks.
5.2.12 Levelling
Refer to section 5.3.3 below.
5.2.13 Post Installation Visual Inspection

Carry out a visual inspection of equipment after installation to ensure that no damage has
been sustained during the installation. Any damage found shall be reported immediately to
the Principal.
5.2.14 Pressure Tests

Normally, pressure containing equipment will have been tested at the manufacturers works
in accordance with the requirements of the applicable design codes and the purchase
requisition. Usually there is no requirement for further pressure tests post installation. If
circumstances exist where an on-site pressure test is required, then this work will be
carried out in accordance with the requirements of Engineering Technical Specification ETS
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616 ‘Pressure Testing’ or in accordance with an alternative specification issued by the

Principal.
In the event that a hydrostatic test is required, it is important to establish that the
additional static loads imposed by the weight of the test medium have been accounted for
in the design of the vessel supports and foundation.
5.3 FOUNDATIONS
5.3.1 General
An allowance shall be made between the rough surface of the concrete and the underside
of the base plate for grouting (5.3.4).
If fixed points and sliding supports have been provided for in the bedplate, they shall be
sufficiently rigid and properly cast in and/or grouted to the foundation.
Distortion of the base plate of the equipment shall be prevented during installation.
5.3.2 Foundation Bolts

To allow for slight differences in dimensions between the holes in the baseplate and the
bolts in the foundation, foundation bolts shall be installed according to Stanlow Standard
Drawing 454801. Alternative holding bolt down arrangements shall be subject to approval
by the Principal.
5.3.3 Levelling
When equipment is placed on its foundation it shall be levelled using carbon steel packing
and stainless steel shims that straddle the holding-down bolts (See Appendix 1). The total
number of shims shall be minimised by using shims of adequate thickness. No more than
three shims in any shim pack shall be used.
Vertical equipment shall be checked for correct verticality in two 90 degree planes by use
of a theodolite. The maximum deviation from the vertical in either plane shall be 1mm per
metre for vessels up to 5 metres high and 1mm per 3 metres for vessels greater than 5
metres high.
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Equipment supported within a structure shall be aligned within the structure with all guides
and sliding plates properly located.
Any special levelling instructions of the Manufacturer shall be followed.
5.3.4 Grouting
Refer to the grouting procedure in Appendix 1 of this specification.
5.4 PIPING ASSOCIATED WITH EQUIPMENT

5.4.1 Piping Installation
After levelling and grouting, the equipment is normally available for the installation of
piping (including piping related with instrument connections). During this period the
equipment shall remain preserved and protected. For preservation refer to DEP
70.10.70.11-Gen, ‘The Preservation of Old and New Equipment and Piping Standing Idle’.
To prevent ingress of dirt and foreign matter the Contractor shall ensure that all routes
and openings into equipment are properly blinded off or sealed and remain so until pipe
work is connected.
5.4.2 Connections to Equipment

During construction, piping should never be firmly connected to the equipment, unless pipe
supports are installed.
Piping installation work should never commence from equipment nozzles. Piping upstream
and downstream of the equipment should be erected from the nearest anchor away. No
uncontrolled strain shall be imposed on the equipment.
5.5 EQUIPMENT INTERNALS

5.5.1 Vessel, Columns, Reactors and their Internals
Where equipment has been delivered to site with internals already fitted, the Contractor
will open up the equipment to allow inspection by the Principal.
Where equipment is to be fitted with internals on site, the Contract Scope of Work will
specify the requirements. The Contractor will install internals in accordance with the
Principals or Vendor data; possibly under the direction of a Vendor Engineer.
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The Contractor shall withdraw materials from Stores and check against the packing lists.
Any shortages are to be reported to the Principal. Trial assembly, e.g. column trays, before
insertion into the equipment is recommended.
The Contractor is to ensure that equipment internals are installed in the correct location
and orientation e.g. correct trays in correct sections of a column.
Particular attention is to be paid to establishing correct tray levels, weir heights,
downcomer clearances, seal pans, draw-off trays, position of spiders, feed devices and
correct fastenings, packings and bolts. Beams are to be fastened to ensure that one end is
free to move. The Principal reserves the right to inspect the installation at any point.
5.5.2 Housekeeping
Before boxing up, equipment shall be cleared of all rubbish and debris to the satisfaction of
the Principal.
5.5.3 Heat Exchangers
Shell and tube heat exchangers are normally installed as delivered, with no further
requirement to remove covers for internal inspections. Finfans may require shipping bolts
to be removed from the sliding end – consult equipment drawing for instructions.
5.6 REPAIRS / MODIFICATIONS

Repairs and modifications to static equipment can broadly be categorized into: 1) those
repairs that affect the pressure retaining parts of the equipment (e.g. a new nozzle in a
pressure vessel) and 2) those repairs that do not affect the pressure retaining parts of the
equipment (e.g. install new trays in a column).
The extent of repair/modification will be fully specified in the Contract Scope of Work,
including pressure test requirements. The various activities involved in the work will be
included in the Contractors Quality Plan and will cover such essential items as weld
procedures, welder qualification, non-destructive examination, heat treatment, hydro
testing, sub contract activities etc.
6.0 RECORDS
Records of inspections, checks and tests outlined in 5.1.2, shall be signed by the Contractor
and Principal’s representatives. A copy of the signed checklists shall be retained by the
Principal.
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7.0 APPENDIX
Appendix 1 - Equipment installation and grouting procedure.
Installation of equipment on reinforced concrete foundations with foundation bolts and sleeves
designed in accordance with Stanlow Drg. No. 454801 shall be as follows:-
1) The surface of the foundation shall be scarified and brushed to remove the weak upper layer
of concrete from a 200mm minimum width perimeter central to the foundation bolts, (see
Fig.1). For proper bonding, the baseplate shall be clean, free of rust, oil and/or grease.
When using epoxy resin, the baseplate bottom face may have to be specially treated.
Instructions of the resin supplier shall be followed.
2) Prior to grouting, the prepared areas shall be thoroughly saturated with fresh water for 24
hours, so as not to remove the water from the grout. Free water on the foundation top
when grouting, is not allowed. Necessary steps shall be taken to prevent grouting from
drying too quickly as per Supplier’s instructions. Grout material (non-shrink mortar, resin
base mortar, epoxy resin, high-temperature application etc.) shall comply with the
equipment Manufacturer’s requirements or as a minimum be as specified below. Epoxy
grout shall be used only with the agreement of the Principal.
3) The prepared areas adjacent to the foundation bolts shall be completely covered with 3mm
minimum thickness of Pagel V1 grout (or approved equivalent). Bolt sleeves shall be sealed
off at the top to prevent ingress of grout.
4) 25mm thick carbon steel packing pieces shall be placed on the fresh grout on either side of
each bolt hole, (see Fig.1).
5) The packers shall be levelled relative to each other across and along the foundation.
6) The packers shall be left undisturbed for a minimum of 24 hours to allow the grout to cure
and reach a working compressive strength.
7) After the grout has cured, the equipment shall be lowered onto the packers and checked for
level and verticality. Any further adjustments necessary shall be done by placing stainless
steel shims, of the same area as the packing pieces, between the packing pieces and
underside of the baseplate. When the equipment is level and vertical, tightening of the bolts
shall commence with the level/verticality being continuously checked until all bolts are
tightened and the equipment is secure.
8) Sleeve sealing shall be removed and the foundation bolt sleeves filled with Pagel V1 (or
approved equivalent) grout On completion of the sleeve filling activities the 25mm gap
around the baseplate shall be sealed with Pagel V1 grout (or approved equivalent) to leave a
smooth neat finish to the foundation.
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9) After grouting, the baseplate shall be checked for the presence of any voids. Epoxy pressure
grouting techniques shall be used to fill any voids. After a 7 day period, bolt tightness shall
be checked.
APPENDIX 1 FIG. 1
200mm (MIN)
200mm
PLAN OF FOUNDATION
(HATCHING DENOTES SCARIFIED SURFACE)
= =
P.P.1
25mm THICK PACKING PIECE
100mm TO 150mm LONG x
50mm to 75mm WIDE, TO
3mm
INSIDE EDGE OF SCARIFIED SURFACE
SUIT BASEPLATE SIDE

BEAM WIDTH.
PERIMETER OF FOUNDATION
75mm
MINIMUM
BOLT CONCRETE
COVER FROM
SLEEVE WALL
3mm
SLEEVE CAST
IN FOUNDATION
P.P.2 =
P.P.1
= =
TO EDGE OF
100mm FOUNDATION
SCARIFIED SURFACE 200mm MIN. WIDTH
C
L
OF BOLT
TYPICAL ARRANGEMENT SHOWING SCARIFIED

SURFACE, SIZE AND POSITION OF
25mm THICK PACKING PIECES.
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Stanlow Engineering Procedures Eng-ETS-619

Installation Of Static Mechanical Equipment

REV DESCRIPTION DATE AUTHORISER SIGN

C Issued on New Format Jul 2016 Paul Smith

Next Review date Jul 2020

Template Reference Only - Eng- QMSGEN-T001 - Rev A

DATE Rev Document Revision Log

Template Reference Only - Eng- QMSGEN-T001 - Rev A

Rollout of Procedure / Work Instruction

Affected Departments All Engineering / Engineering ETS distribution

Method of Communicating Roll Out of Document

Please enter R in tick column against methods to be used

 Method Person / Department Responsible for Rollout

Template Reference Only - Eng- QMSGEN-T001 - Rev A

1.0 INTRODUCTION ....................................................................................................... 4

Template Reference Only - Eng- QMSGEN-T001 - Rev A

1.2 ENGINEERING TECHNICAL SPECIFICATIONS

ENG-ETS-205 Structural Concrete Work

ENG-ETS-502 Installation and Commissioning of Rotating Equipment

ENG-ETS-616 Pressure Testing

ENG-ETS-617 Bolt Tightening & Joint Making

1.3 ENGINEERING PROCEDURES AND WORK INSTRUCTIONS

1.4 STANDARD DRAWINGS

Template Reference Only - Eng- QMSGEN-T001 - Rev A

5.1 GENERAL REQUIREMENTS

5.1.2 Quality Control

5.1.3 Construction Tools/Special Tools

Template Reference Only - Eng- QMSGEN-T001 - Rev A

5.1.4 Installation and Operating Manuals

5.1.5 Storage of Equipment Prior to Installation

Template Reference Only - Eng- QMSGEN-T001 - Rev A

5.2.2 Method Statement

5.2.3 Pre-installation Visual Inspection

Template Reference Only - Eng- QMSGEN-T001 - Rev A

5.2.4 Handling of Equipment

5.2.7 Equipment Movement

Template Reference Only - Eng- QMSGEN-T001 - Rev A

5.2.10 Hot work

5.2.13 Post Installation Visual Inspection

5.2.14 Pressure Tests

Template Reference Only - Eng- QMSGEN-T001 - Rev A

616 ‘Pressure Testing’ or in accordance with an alternative specification issued by the

5.3.2 Foundation Bolts

Template Reference Only - Eng- QMSGEN-T001 - Rev A

5.4 PIPING ASSOCIATED WITH EQUIPMENT

5.4.2 Connections to Equipment

5.5 EQUIPMENT INTERNALS

Template Reference Only - Eng- QMSGEN-T001 - Rev A

5.6 REPAIRS / MODIFICATIONS

Template Reference Only - Eng- QMSGEN-T001 - Rev A

Template Reference Only - Eng- QMSGEN-T001 - Rev A

SUIT BASEPLATE SIDE

SCARIFIED SURFACE 200mm MIN. WIDTH

TYPICAL ARRANGEMENT SHOWING SCARIFIED

Template Reference Only - Eng- QMSGEN-T001 - Rev A

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