ROTATING EQUIPMENT INSTALLATION

PROCEDURE | METHOD STATEMENT

 TABLE OF CONTENTS

1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITIES
5. MATERIALS
6. WORK METHODOLOGY
7. QUALITY CONTROL
8. SAFETY INSTRUCTIONS & PRECAUTIONS
9. ATTACHMENT
1. 1. PURPOSE
The purpose of this Method Statement for Rotating Equipment is to ensure that the
work activities such as material handling, equipment installation and test &
inspection shall be carried out safely, efficiently and in accordance with the project
requirements in plants and refineries.

2. SCOPE
The scope of works covers under this method statement applies to all installation of
rotating equipment covered under in plants and refineries.

3. REFERENCE
SAES-K-402 Centrifugal Compressor
SAES-K-403 Reciprocating Compressor
SAES-K-511 Diesel Engines
SAES-G-005 Centrifugal Pumps
SAES-G-006 Positive Displacement Pumps
SAES-G-115 Lubrication, Shaft Sealing and Control Oil Systems
SAES-G-116 Cleanliness Standards for Lube/Seal Oil and Fluid Power Systems
31-SAMMS-001 Axial and Centrifugal Compressors and Expander-Compressors
31-SAMMS-003 Reciprocating Compressors for Process Air or Gas Service
31-SAMMS-004 Centrifugal Pumps
31-SAMMS-009 Positive Displacement Pumps – Controlled Volume
31-SAMMS-012 Shaft Sealing Systems for Centrifugal and Rotary Pumps
API 686 Recommended Practices for Machinery Installation and Installation Design
S-000-3150-002 Construction Procedure for Installation of Rotary Equipment
01-SAMMS-017 Auxiliary Piping for Mechanical Equipment
SAES-Q-010 Cement Based, Non-Shrink Grout for Structural and Equipment
Grouting
SAES-Q-011  Epoxy Grout for Machinery Support
PIP-STS03600 Non-shrink Cementitious Grout Specification
PIP-STS03601 Epoxy Grout Specification

4. RESPONSIBILITIES
Site Manager
Ensure full implementation of this Method Statement and identifies the work and
safety requirements including add on resources for the effective accomplishment of
the Mechanical Work.
Mechanical Supervisor
Ensure full work and safety compliance by all foremen, erectors and helpers regarding
the execution of the work in accordance with the project specification and
requirements. Confirm the availability of all materials, tools, equipment and required
personnel who will carry out the work.

Quality Control Manager

Ensure full implementation of the required quality control procedures and maintain
the required documentation as per the approved inspection test plan for the final
acceptance and handover of the system.

Quality Control Inspector

Conducts daily surveillance and inspections in accordance with this procedure and
prepares quality control records and final acceptance of documents when required for
final handover.

Construction Manager
Check the work areas and monitor from time to time in the implementation of safety
procedure and assuring that all safety equipment and tools are present at site and in
proper good condition.

Safety Officer
Check the work areas and monitor from time to time in the implementation of safety
procedure and assuring that all safety equipment and tools are present at site and in
good working condition.

5. MATERIALS
5.1 Provision
All Mechanical Equipment and miscellaneous are to be supplied by Contractor /
Company and in accordance with the specification of Schedule “Q” and SAMMS.

5.2 Material Handling and Storage

5.2.1 Upon receipt of the materials, visual inspection shall be performed for any
damages during the transport and if there is any defect found, it shall be reported to
JGC/DAEWOO.
5.2.2 All materials shall be unloaded, stored and handled in a manner that will
prevent distortion, deterioration and damages. Materials shall be kept free of dirt,
grease and other foreign materials.
5.2.3 All materials shall be verified and match to the number and markings of all the
components against packing list and AFC drawings.
5.2.4 Vendor instructions necessary to preserve the integrity of the storage
preparation for equipment at the jobsite and before start up are provided and applied.
6. WORK METHODOLOGY
6.1 General
6.1.1 Check all construction drawings are of latest revision and have “AFC”.
6.1.2 All necessary permits shall be obtained prior to start of work activities. All safety
measures and precautions are visible in the work area.
6.1.3 Check foundation and other connection point to confirm their locations,
coordinates and elevation.
6.1.4 Any damage components of the mechanical caused during erection shall be
reported to Contractor / Company and an approved corrective measure shall be
applied to rectify it.
6.1.5 Loose timbers, metal sheeting, bolt buckles, tools, debris and temporary
scaffolding shall be kept restrained or removed from work areas. The erector shall be
responsible in securing the equipment and materials in his custody including its
control during erection operation.
6.1.6 The erector shall maintain the job site in a clean and safe condition at all times
and shall properly dispose of all crating and waste materials that are accumulated as a
result of the erection activities.

6.2 Chipping and Pad Plate Elevation

6.2.1 Concrete surface to be grouted shall be prepared for chipping using chipping
hammer, grit blasting or high pressure water jetting whichever is applicable in order
to leave a rough textured. Use of bush hammering or any similar method that can
fracture or damage the integrity of the surface and foundation is not permitted.
6.2.2 Chipping should cover the full extent of the surface intended to be in contact
with grout. This will enable the grout to have a strong adhesion to the chipped surface
of the concrete.
6.2.3 The height of chipped concrete under the base plate shall be at least 25mm
unless otherwise specified by vendor.
6.2.4 Surface of the chipped concrete, base plates and holding down bolts, etc. shall be
cleaned and free from any oil, dust, dirt, paint and any residual curing compound that
can cause bond impairment.
6.2.5 Padding plate material shall be in accordance with ASTM A283 Gr. C or
equivalent. It shall be hot dip galvanized in accordance with ASTM A123 or coated
with zinc rich epoxy primer in APCS-1C of SAES-H-101.
6.2.6 Padding plate shall be set so that the elevation of the base of the equipment is
within the specified height.
6.2.7 Padding elevation tolerance is ±3mm.
6.2.8 Liners and wedges shall be located on both sides and closer to each anchor bolts.
When the distance between anchor bolts is larger than 800mm, extra liners and
wedges shall be located between to prevent bending of the base plate.

6.3 Setting, Centering (Equipment) and Leveling of Machine Skid

6.3.1 A final check shall be made to ensure that the center of the equipment matches
the center line marked on the foundation. Centering shall conform to client inspection
standards corresponding to the type of the equipment being installed.
6.3.2 Where the liners are used in multi layers, it shall be intermittently welded to
each other after completion of the centering of the equipment. Position shall be
measured on the basis of flange within ±3mm.
6.3.3 Leveling shall be performed using appropriate and accepted instrument on the
machined surface of the driver base plate or on the suction/discharge flange of the
vertical nozzle on top of the equipment unless otherwise specified.
6.3.4 Leveling shall be adjusted by inserting and/or removing the liners. When jack
bolts are provided on the equipment base frame, liners and/or wedges are not
required.
6.3.5 The leveling tolerance is within ±0.2mm/m for API pumps and to within
±0.4mm/m for general purpose equipment (API 686)
6.3.6 Sole plate installation and levelling as per API 686.

6.4 Grouting and Anchor Bolt Tightening

6.4.1 Grouting for the base plate shall be done after completion of the shaft pre-
alignment and leveling inspection of the equipment. The top surface of the foundation
shall be cleaned and blown with compressed air. All contaminants shall be removed.
For epoxy resin grout, the surface must be completely dry before application of the
grout. Grouting materials application and procedure shall be performed in accordance
with the approved Method Statement for Grouting.

6.4.2 For pocket type anchor bolts, it shall be set to the base of the equipment. Check
and adjust the anchor bolt before pouring the appropriate quantity of mortar.
6.4.3 Curing time of the grout mortar shall be checked prior to commencing the
anchor bolt torquing.

6.4.4 Anchor bolts shall be set to a minimum three threads protusion from the lock
nut.
6.4.5 Anchor bolts shall be adequately protected to prevent threaded parts from being
covered with mortar.

6.5 Shaft Alignment

6.5.1 General

6.5.1.1 After curing grout and before piping Works, the driver and speed change gear
shall be adjusted for shaft alignment and the machinery without piping connection to
suction and discharge nozzle shall be aligned.
6.5.1.2 Alignment shall be adjusted by fixator or inserting (0.1 ~ 0.5mm) thick shim
plates made of brass or stainless steel.
6.5.1.3 On completion of piping system installation and testing, final alignment shall
be carried out and checked in accordance with vendor’s recommendations.
6.5.1.4 Following points shall be checked prior to the final alignment of the equipment
:
– Alignment shall all for potential movements such as thermal growth, hydraulic
loading, gears with rising pinions, etc. Manufacturer’r recommendations shall be
followed.
– Check that coupling hubs are correctly installed.
– Check and record the distance between shaft ends and/or distance between hubs
(axial float, pre-stress, etc.)
– Confirm that the equipment has been shimmed correctly with stainless steel shims.
– Confirm that no soft feet (maximum dial movement value follows Manufacturer’s
recommendation.
– Axial and transverse keys are properly located and secured.
– Level and alignment adjustment screws/jack screws are removed.
– Bolting shall be checked by using torque wrench.
– On base plate mounted equipment, a dial gauge attach to the coupling hub shall be
used during the tightening of anchor bolts, to detect any deformation.

6.5.2 Requirement
6.5.2.1 Final alignment shall not exceed to Manufacturer’s requirement or the
following whichever is more stingent:

6.5.2.2 For all rotating equipment, the preferred method of alignment shall be the
reverse dial indicator method. A graphical plot of the shaft position shall be made as
follows :

– 2 axial dial gauges

– 1 radial dial gauge
– Both shaft turned simultaneously

6.5.2.3 Readings shall be demonstrated to be repeatable. Dial bracket sag shall be

taken into account and shall not be more than 0.05mm.

6.5.2.4 Alignmnent checks shall include :

– Check of the number of shims used underneath each foot or shim point.
– Soft foot check (maximum dial movement 0.03 at the foot and the coupling hub)
– A preliminary check to ensure that alignment is possible with regard to shim
limitations, bolt and bolt holes positions, etc.

6.5.2.5 An alignment check without piping connected to the equipment.

6.5.2.6 An alignment check with bearing brackets support loose (eg. Overhung
pumps)
6.5.2.7 Final alignment check.
– For the final check, the dial indicators should be on the equipment before and
during the tightening of the piping brackets, in order to highlight the cause of any
distortion. The final reading shall be taken with all process piping and auxilliary
piping connected with proper gaskets in place.

6.5.2.8 The alignment shall begin with a single shim of at least 3mm thickness
underneath each foot or shim point. When the alignment is completed, there shall be
no more than 3 single shims under each foot or shim point. One sollid, precision-
machined shim with lapped surfaces shall be used when necessary to replace a larger
shim stack.

6.5.2.9 Final alignment data shall be recorded, filed and handled over to
JGC/DAEWOO Quality Team.

6.5.2.10 Alignment after the connecting pipe

– After the suction and discharge nozzle are connected to piping, the Mechanical
Supervisor shall be informed that all piping works such as installation of permanent
supports and hydro testing, if any, are completed for the connected piping. The
alignment of the equipment shall be checked as follows :

o Prior to commencing the final cold alignment, the suction and discharge piping shall
be disconnected and piping alignment such as off center, clearance and parallelism
between piping and connection flanges of the equipment nozzles shall be checked by
visual inspection.
o If there are misalignment found in the piping during the above inspection, the
information shall be given to the Piping Supervisor.

– Corrections shall be made on any offset on the alignment of the equipment found
due to piping connections.

– After the piping alignment check is completed, the suction and discharge piping
shall be connected to the equipment nozzles and the final cold alignment shall be
checked with a dial gauge.

7.0 QUALITY CONTROL

7.1 Inspection shall be conducted and recorded in accordance with the Job
Specification Inspection and Test Plan.

9.0 SAFETY INSTRUCTIONS AND PRECAUTIONS

9.1 Make sure that all necessary work permits are issued.
9.2 Check all lifting equipment prior to commencing lifting activities.
9.3 Stay away from any suspended load/falling objects.
9.4 Wear full body harness when working at elevated platform.
9.5 Ensure that barricades and warning signs are properly installed.
9.6 Ensure that there are no hazardous or combustible gases present in the work area.
9.7 Install flashing lights to traffic.
9.8 Copy of approved JSA to be maintained at work site by Work Supervisor. Conduct
daily Tool Box Talk and discuss work methodology prior to commencement of work.
9.9 Implement and monitor safety instruction on site.

9.0 ATTACHMENT
9.1 JSA (Job Safety Analysis)
JOB SAFETY INSTALLATION JSA FOR
ROTATING EQUIPMENT INSTALLATION
Required Training for the Job :
Hand and Power Tools, Mobile Equipment Safety, Manual Rigging and Lifting Safety, Working at
Height.

Person at Additional Controls to

Job Steps
Risk Reduce Risk

• Provide guards to sharp edges of all

equipment.
• Secure appropriate work permit prior to
start of work.
• Install barricade tapes provide warning signs
on sharp materials to make it visible for all
employees present in the work site.
• Provide proper personal protective
equipment i.e., hard hat, safety shoes, safety
glass and working gloves.
• Personnel in the area should be aware of
1.1 Sharp edges of potential
tools and equipment hazards.
that are not easily • All heavy equipment Shall be inspected and
Activity: approved by HSE Department.
spotted.
Installation of Rotating • TSTI shall be carried out by the job
Equipment 1.2 Extreme hot supervisor emphasizing the hazards identified
1.Preparation and hauling temperature. stated on the permit.• TSTI ensure must be
of tools and equipment 1.3 Poor manual understand by all workers
prior to start of work. handling techniques. • Personnel assigned to the tasks shall be
experienced workers.
 
• Improve staggered working  hours.
Include substitution of workforce to allow
sufficient rest in between employees.
• Provision of cool drinking water and
shaded rest
place.

• Supervisor shall monitor their work force

by looking for signs of dehydration.
• Maintain proper back posture and body
position
during manual lifting of materials.
Position body
 where less effort is exerted and less strain.
• Use crane, forklift, or manual lifters for
heavy loads.
• Divide load weight between co-workers.
• Assign additional person at the trailer
bed to assist for
loading/arranging small bore pipe spool.

• Assign sufficient numbers of personnel who

could sustain the load when doing manual
handling.
• Observed proper communication between
coworkers
during execution of specified task.
• Personnel in the area should be aware of
potential hazards.
1.4 Poor practices on • Heavy equipment operators/drivers must
maneuvering heavy undergo competency training and
equipment. certification before operation/driving heavy
equipment.
• All Equipment’s operators shall be certified
by Saudi Aramco and record shall be
submitted to HSE Department for approval.
• Personnel in the area should be aware of
potential hazards.
• Equipment should have blinker light/sound. 
• Provide PWAS to equipment.

• Check wind velocity prior to lifting and

ground stability for outriggers. Fully extend
outriggers with wood matting prior to lifting.
• Provide an approved lifting plan prior to
lifting. Observed  existing structure on the
2.1 Unstable swing radius of crane.
grounds/strong • Conduct daily and visual inspection to all
winds. rigging hardware and crane parts prior to
2. Loading and unloading of lifting.
Rotating equipment / 2.3 Improper • Routine check for the competency of
materials. handling of material riggers.
resulting injury or • Personnel in the area should be aware of
health risks potential hazards.
• Equipment shall be lifted and supported
only at the designed lifting eye.
• Ensure load was placed steady and securely
on the
back of the trailer truck. Use of sling to hold
off the load
 will be advised.
• Handle all material with care and arranged
properly
• Ensure equipment will be inspected by HSE
Department and set properly.
• Use appropriate hand, face, feet, and body
protection equipment.
• Static Equipment material to be kept in
proper place.
• Ensure all material kept out to prevent
unnecessary tripping hazard.

• Check wind velocity prior to lifting and

ground stability for outriggers. Fully extend
outriggers with wood matting prior to lifting.
• Conduct daily and visual inspection to all
rigging hardware and crane parts prior to
lifting.
• Secure load by competent rigger and use
appropriate rigging tackles with visible SWL
and has 3rd party certified.
• Inspect rigging tackles before each use for
3.1 Unstable wear & tear and make sure has color code for
grounds / strong the current month.
winds. • Observed double choked for long load to
3.2 Unsecured loads prevent slips and use tag lines to properly
during lifting. hold a nd control the load.
3. Installation of Rotating • Test lift prior to lifting avoid lifting a load
3.3 Poor crane lifting
Equipment. that exceeds the capacity of the crane and
practices.3.4 Contact
Installation setting and with Equipment over reaching of load.
alignment of Rotating 3.5 Fall of tools, • Avoid swinging of loads on a high speed
Equipment. equipment and manner. Use tag lines to control loads.
materials. • Any personnel are not allowed to ride on a
load.
3.6 Improper • Crane’s swinging radius must be barricaded.
installation of Install warning signs Danger Lifting in
Rotating equipment progress.
• Use proper personal protective equipment
(PPE) like gloves, Safety Glass, safety shoes &
Hard hats.
• Provide fully physical
warning signs on the barricade and
corresponding equipment to avoid
unauthorized entry.
• Ensure shall be use material bags secured
with structure or scaffolding platform to avoid
falling material from height.
• Provide caution tape, hard barricade around
 the working area for to control unauthorized
persons.
• Full body Harness shall be strictly required
when working at height and 100+ tie off. •
Tools shall be secured with retaining strings,
Secure equipment on a permanent
• Use proper personal protective equipment
(PPE) like gloves, safety glass, safety shoes &
Hard hats.
• Personnel in the area should be aware of
potential  hazards.
• Rotating equipment 
Installation areas shall be barricaded and
secured.
Only authorized personnel shall be permitted
inside the barricaded area. Warning signs
“DANGER ROTATING EQUIPMENT
INSTALLATION ON PROGRESS- KEEP AWAY”
shall be in place.
• Competent technician will be perform
Rotating Equipment installation activity.
• equipment installation in strictly accordance
with manufacturer’s instructions.
• Equipment shall not be left unattended at
any time during the work.

• All belts, pulleys, gears, shafts shall be

guarded in accordance with specific
requirements.
• Equipment designed for a fixed location
shall be securely anchored to prevent moving.
• Equipment guarding shall be provided to
protect the operator and other employees in
3.7 Unsafe practices the area from rotating hazards.
during the job • Keep hands, hair and loose clothing clear
execution  / personnel from all moving parts.
injury fall from • Workers assigned on  elevated area with a
heights. height of 1.8m. (6 ft) or greater shall be
equipped with an inspected and color coded
full body harness.
• Full body Harness shall be strictly required
when working at height and 100+ tie off.
• Keep body parts out of pinch points. Use
required proper personal protective
equipment.