TABLE OF CONTENTS

1.13.3 Static Equipment

1.13.3.1 General
1.13.3.2 Main construction sequences for static equipment construction
1.13.3.3 Construction preparation
1.13.3.4 Equipment installation
1.13.3.5 Installation of towers
1.13.3.6 Installation of the Vessel Equipment and the Reactors and Dryers
1.13.3.7 Works Delivery and Acceptance

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1.13.3 Static Equipment
1.13.3.1General
This stationary machinery installation plan is commonly used for the Missan Oil Field
Development Project in Missan Province, Iraq.
There are totally 305 sets of stationary equipments such as industrial , vessels, skids, dome
roof tanks , Water bath heating,flare, dehydrator equipments and towers etc. the total weight
of which is about 4519 ton.
The main work activities of stationary equipment installation shall include removal of the existing
equipment and the installation of new equipment. The removal work of the existing equipment
include the shut down, separation, emptying, safety inspection, dismantlement, transportation
and hand over. The main work activities of new equipment installation shall include the
equipment open package inspection, lifting and positioning, alignment, pressure test, equipment
internals loading, corrosion proofing and insulation; while the flare stack skid shall also include
the site assembling and welding.
The installation of the stationary equipment shall be carried out with cranes of 50 tons to 150
tons according to the condition of equipment foundations and equipment frames. The
installation shall also match the requirements of the overall progress schedule and the lifting
schedule of large-scale equipments. The lifting methods of the large-scale equipments please
see the Method Statement for Large-scale Equipment Construction herein.
Static equipment installation works mainly consist of unpacking and inspection, lifting in position
and alignment, internals installation and painting and insulation; Air cooler installation works
also consist of support assembly lifting, the wing plate lifting, the windows shade installation and
fan installation.
For static equipments installation works, utilize 50 tons to 400 tons crane to carry out integrity
lifting and put in place so as to meet the general process schedule and heavy lifting schedule,
according to handover conditions of equipment foundation or frame.
1.13.3.2 Main construction sequences for static equipment construction
Main construction sequences for static equipment installation

Item activities Description or breakdown

No.
1 Get familiar with
drawing Get acquaintance with the structure, quality, material and technical
requirements of the equipments
compiling Supporting material budget shall be prepared by the construction quota
2 material budget of our company;
The machinery, tools and measures material budget shall be compiled
according to the actual situation of our company and the requirement of
the project.

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 Preparing Compiling basis: equipment drawing, construction organization design,
3 construction standards, specifications and construction method.
procedure Contents: project introduction, construction sequence and
requirements, quality standards, safety measures, progress schedule,
construction organization, machinery, tools and material required, and
the handover technical documents.
Review and approval: project chief engineer shall approve the
construction method statement for static equipments; and the
documents shall be submitted to owner and supervision company for
review and approval.
procurement and Material procurement plan shall be prepared according to the budget
4 supply of the and material inventory
material for Place the purchase order with qualified sub-supplier, receive, inspect
equipment the material at the places specified in the contract, and transport the
installation qualified material to site according to the construction schedule.
Inspect the equipment foundations for appearance, external
5 foundation dimensions, positions according to the construction drawing and the
acceptance construction records provided by construction company together with
the representatives of project company and the supervision engineer
(or his representative)
Countersign the construction sequence handover records if inspection
shows the foundation is qualified.
6 Open package Check the document accompanied with the equipments
inspection of the Visual inspection of the equipments
equipment Inspection of the equipment specification and the quantity of parts
7 Technical Prepare written technical clarification
clarification Construction captain shall organize, representatives from quality and
safety departments shall participate the technical clarification for
construction teams (including quality, safety clarification).
8 Fabrication of Discipline technical superintendent shall calculate the shims
shims specifications and quantities required for each equipment;
Construction team fabricate plain shims, and part of which shall be sent
to machining team to process tilted shim.
9 foundation Top surface of the foundation shall be chiseled to proper elevation;
treatment Prepare place for shim installation (it is not necessary when bolt holes
are reserved)
Roughen the surface
10 equipment lifting Equipment lifting and positioning,
and shim placing
The shims shall be installed at the right places on the foundation before
equipment lifting and positioning.
11 equipment Align the equipment according to the allowance specified in the
alignment and
leveling specification (preliminary alignment and leveling is necessary if bolt
holes are reserved on the foundation, and it is shall be finally aligned
and leveled after grouting the bolt holes).

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 12 joint inspection Inspect the equipment installation derivation and the shim installation
together with supervision engineer (or his representatives);
Sign the equipment installation records and shim concealing works
records.
13 installation of the Install the ladders and platforms attached to the equipment according to
attached ladders the steel structure construction procedure and requirements.
and platforms
14 secondary After the equipments are installed and inspected as qualified, the
grouting installation work team shall entrust the construction work team to
perform the secondary grouting.
Construction work team performs the secondary grouting for
equipment.
15 Pressure test of The heat exchanging equipments and site assembled and welded
the equipment equipments shall be pressure tested at site according to the
requirements of design and construction specification. Equipments with
different structure shall be tested with different methods.
Temporary facilities shall be prepared for pressure test.
Perform the joint inspection of the equipments; pressure test records
shall be countersigned if the inspection shows the equipments are
qualified.
16 installation of Determine the equipments in which the internals shall be installed
internals (if any) according to the documents provided by project company or the
equipment supplying contract.
Install the internals according to the equipment drawing
17 Cleaning, Remove the dust, rubbishes and rust inside the equipments.
inspection and Inspect the inside of the equipments together with supervision company
closing of the (equipment with internals installed at site shall have the internals
inside of installation inspected), manholes shall be closed if the equipments is
equipments inspected as qualified.
Countersign the concealing works records.
18 corrosion Remove the rust on equipment surface, and apply the primary paint.
proofing and Apply the surface paint or install the insulation layer.
insulation
19 handover and Perform the overall inspection and confirmation of the project.
acceptance Sign the handover acceptance certificate
20 assistance for Assist the operating personnel of the client to inspect the equipment
start-up condition, repair the problem such as damage and leakage timely.
21 Prepare Prepare the construction records and inspection and test reports.
handover Prepare the as-built drawing.
technical
documents

1.13.3.3 Construction preparation

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 Technical preparation
Organize all construction personnel to study and get familiar with the equipment
installation technical documents, including equipment manufacturing and assembling
drawing, equipment installation description, manuals for special tools, process
installation drawing, packing list and quality certificates etc.
Prepare all construction material, supporting material, tools and machinery, and
construction machinery for equipment installation;
Organize the relevant management personnel (technical, quality, safety) to perform the
technical clarification for all construction personnel before each construction sequence,
to acquaint them with all situations and construction procedure and requirements, as
well as the quality and safety requirements for equipment installation.
Foundation acceptance and treatment
Foundation acceptance and sequence handover
After the foundation construction is completed, they shall be handed over to the equipment
installation team by foundation construction team according to the requirements of design
specification in a timely manner.
Foundation treatment
The foundation surface which grouting is necessary shall be roughened to a depth not less than
10mm, and there shall be three to five bug holes each square decimeter, the surface contacting
with bolts shall be neat and clean.
The foundation surface shall be chiseled flat around the place where the shim is installed to
assure the contact between shim and foundation. The level derivation allowance of the flattened
part shall be 2mm/m;
The rubbish and dust in the reserved anchor bolts holes shall be removed.
The oil-contaminated concrete shall be removed before equipment installation.
Open package inspection of the equipments
The open package inspection shall be performed after the equipment arrived according to the
requirement of specification. Construction Company together with the Contractor shall carry out
the open package inspection.
Material supplying department shall organize technical department, quality department
and the construction team together with supervision engineer to carry out the open
package inspection after the equipment arrived: verify the package number and quantity
of packages, inspect the description, type, specification, quantity and appearance quality
of the equipment and parts. Verify the dimension of the equipments, connection
specification, nozzle direction according to the equipment assembling drawing, and
check the completeness of the documents and special tools. Any shortage and damage
shall be recorded, and solved with the assistance of the supervision company.

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 The equipment and parts shall be identified with labels after being inspected, and placed
in a clean and ventilated place. Small parts shall be placed on the wooden shelf and
carefully stored to avoid being lost.
Fabrication of shims for equipment

c
L a

h
h
L

b
Plain shim Tilting shim

Figure 1.13.3-1 shims for equipment installation

Shims for equipment shall be processed with carbon steel, the specification and dimension shall
be as illustrated in figure 1.13.3-1, and shall be checked against specification.
Shims can be cut with torch or machining, and the edges shall be grinded with grinding wheel
after being cut.
1.13.3.4 Equipment installation
Equipments lifting and placing of the shims
The equipment shall be lifted and positioned with cranes; Mechanics shall place the
shims and mark the installation orientation on the equipment before lifting. During the
equipment positioning, fitters shall closely cooperate with lifting workers to complete the
equipment lifting work safely and accurately.
The shim surface flatness shall be checked before installed, and there shall be free of oil
contamination. One set of shims shall be installed beside each anchor bolts as closer as
possible, and the distance between adjacent shims sets shall not exceed 500mm. For
the equipment with stiffener on the pedestal, shims shall be place under the stiffener.
The number of shims in each set shall not exceed four pieces, and no thin shims shall
be used. The thickest shall be placed at the bottom, and thinnest shall be placed in the
middle. The height of the shims sets for medium and small-scale equipment shall be 30
60mm, and that for large-scale equipment shall be 50100mm.

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 L

l3L/ 3
4
F
i
g
.
Tilting shims shall be installed in pairs, the overlapping length shall not less than 3/4 of
1
the total length, and the tilting angle shall not exceed 3 (See the fig. 1.13.3-2). Plain2
.
shims shall be installed below the tilting shims. 3
After the equipment alignment, the plain shims shall project out from equipment pedestal3.
at least 1020mm, and the tilted shims shall be at least 10mm longer than plain shims.2-
The shim length under equipment shall exceed the position of anchor bolts as shown in
the drawing. I
n
10~20mm
s
t
a
l
l
a
t
i
o
n
o
After the alignment of equipment and shims, a 0.25kg hammer shall be used to checkf
the shim sets without looseness. After joint inspection as qualified, the shims within eacht
group shall be welded. i
l
After the alignment of the equipment installed on metal structure, shims shall be weldedt
i
with the metal structure. n
g
When the anchor bolts are installed in the reserved holes, the setting of anchor bolts
s
shall satisfy with the follow requirements: h
i
Vertical derivation of the anchor bolts shall not exceed 5 of the bolts length. m
s
Clearance between anchor bolt and hole sides shall not exceed 20mm, and that
between the bolts and hole bottoms shall not exceed 80mm.
Grouting position shall be free of rust and oil contamination, and the bolts threads shall
be greased.
Nuts and washers shall be closely contacted with equipment pedestals, and two circles
of bolt threads shall be exposed above the nuts.
For the horizontal equipment that shall be expanded and contracted under operation

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 temperature, the anchor bolts at the sliding side shall be first fixed, after the equipment
installation and pipe connection is completed, the nuts shall be loosened to reserve a
clearance about 0.51mm, and then the nuts shall be retightened. The sliding surface
of the sliding pedestal shall be cleaned and greased.
Alignment and leveling of the equipment
The reference for equipment alignment and leveling shall be as follows:
The bottom elevation of the
Equipment basic survey
equipment support shall be station
based on the elevation .
reference line on the Foundation central line

foundation. 300

The equipment central position

shall be based on the Foundation elevation
benchmark point
foundation central line.
The verticalness of vertical equipment shall be based on the reference points at top and
bottom of the equipments.
The levelness of the horizontal equipment shall be based on the central lines at both
sides of the equipments.
Alignment and leveling of the equipment shall fulfill the following requirements:
Alignment and leveling shall be performed at two or more than two right-angled
directions within one plane.
Equipment shall be aligned and leveled with shims according to the requirements,
tightening and loosening the anchor bolts and locally stressing shall be prohibited.
When there are holes reserved in the foundations for anchor bolts, the equipment shall
be preliminarily aligned and leveled and grouted in the reserved holes. The final
alignment and anchor bolts tightening shall be performed after the strength of concrete
reaches 75% of the design strength. If the grouting material is CGM, alignment and
leveling shall be performed 24 hours after the initial setting of grouting material.
Allowable derivation for the equipment installation shall be complied with the API
construction specification.
The requirement for horizontal equipment gradient in design shall be fulfilled, if there is
no such kind of requirement, the equipment shall be tilted to the exhausting direction.
Concealing of the shims for equipment installation
The equipment shims shall be concealed after the completion of the following activities:
The equipment installation precision is inspected as qualified.
Shims of each layer have been welded hard.
The records of concealing work are complete.

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 Joint inspection is qualified, and signatures and procedures are complete.
Installation group and construction group shall cooperate to furnish the secondary
grouting of the equipment foundation, and the requirement for that is as follows:
Installation party entrust construction party to grout, and confirm that the grouting
condition is met;
The grouting position shall be cleaned and wetted with water before the work being
performed.
The grouting work of one set of equipment must be finished once, separate grouting
shall not be allowed.
The grade of the grouting material shall be smashed stone concrete one grade higher
than that of the foundation, or CGM grouting material shall be used (subject to
acceptance of the construction supervision);
When grouting the anchor bolts holes, mechanics of the installation party shall inspect
the precision of bolts or other factors that influences the equipment installation precision.
The out surface of secondary grouting shall be flat, and the top surface shall have
outward gradient, and the height of which shall be slightly lower than that of the top
surface of the out edge of equipment supports.
1.13.3.5 Installation of towers
Installation of equipment
Towers shall be lifted, positioned and aligned with crane. After the installation is qualified, the
tower trays and packing shall be installed according to the requirement of construction drawing
and specification.
Installation of tower trays and other internals
The installation of tower trays shall be in the sequence of from upper part to lower part.
And the tower trays shall be installed after the downcomers and beam bolts are fixed;
cambered plate at both sides shall be firstly assembled, and then the tower tray shall be
assembled from side to center. The tower trays shall be temporarily fixed during
installation, and the final fixation shall be done with clamps and bolts after the
dimensions and clearance of each part has been aligned. A gradienter or U-pipe shall be
used to adjust the level of tower tray after each layer of tower tray being assembled. If
the level of which is qualified, remove the access plate and place it in a stable place on
the tower tray.
Since the volume of works for tower tray installation is considerably big, the tower trays
shall be prearranged before installation to eliminate the difficulty caused by
manufacturing errors and increase the installation quality. Inspect the total errors of the
tower trays to find the potential quality problems and solved them beforehand. Mark the
connection position after the arrangement can match the design requirements. A

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 dedicated place and platform shall be provided and temporary construction facility area
to prearrange and align the tower trays and other internals in order to assure the
implementation of the work.
The inside of the tower shall be properly cleaned according to the inspection result
before construction. Ventilation and illumination facilities shall be provided to assure the
proper air ventilating and illuminating.
The equipment internals and accessories shall be cleaned and inspected according to
the construction drawing and technical documents before installation. The internals and
accessories (tower trays, gasket, bolts, nuts and packing) shall be counted and
inspected. The ex-work certificate shall consist of follows:
Ex-work quality certificate of equipment accessories;
Material substitution order;
Material quality certificate
The installation of tower trays shall include rust removing, alignment, and horizontal
transportation at site etc. The float valve shall be installed on the tower plate before the
float valve tower tray is installed into the tower according to the technical specification.
Install and align the tower tray and the removable parts (downcomers, liquid receiving
plate and etc.).
Install and align other internals (baffles, spray plate, supporting plate and etc.).
Equipment internals and packing shall be installed according to the requirement of
construction drawing and specification.
The supporting parts shall be installed flat and firm; packing shall be clean and free of
dirt, sand and other rubbishes.
Packing shall be loaded evenly.
Packing loading shall be carried out after the pressure test.
Equipment cleaning and closure
The tower internals shall be cleaned after installation to remove the rust, dirt and dust.
For the equipment or special position that cannot cleaned manually can be blown with
steam or air, and moisture must be timely removed after blowing. The equipment that
subject to heat expansion and that working in a low temperature condition shall not be
blown with steam.
The manholes may be closed after the equipment is blown and inspected as qualified.
The equipment cleaning and closure shall be done after the construction supervisor
finishing check.
1.13.3.6 Installation of the Vessel Equipment and the Reactors and Dryers
Upon the satisfactory alignment of the vessel equipment, reactors the internals (e.g. demister),
catalyst and dehydrator shall be installed in accordance with the engineering drawings and the

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construction specifications.
The catalyst and the dehydrator shall be charged through the openings at the top of the
equipment with the help of the feeding hoppers prior to the commissioning of the plant, as
required by the main Contractor.
1.13.3.7 Works Delivery and Acceptance
Upon the completion of the installation for the static equipments, it requires to prepare the
technical documentation for the works delivery, submit the mechanical completion report as per
the requirements specified in the engineering design documents and the construction
specification and hand over, as required, the above documents to the main Contractor.

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