Section 6 — Rotating Equipment

Field Storage and Installation of Rotating Equipment

IPE Engineering Practice IPE-EP-6-8-1

Document number: IPE-EP-6-8-1 · Section: 6 — Rotating Equipment

SCOPE

• (*) The Mechanical Contractor shall receive, store, install, align, and provide pre-commissioning support of all rotating equipment. The Contractor shall develop a plan for storage based on this procedure and each Manufacturer's procedure and submit it to the Owner for Owner approval prior to receipt of any equipment. The duration of storage shall be 6 months.
• An asterisk (*) indicates that a decision by the Owner or Owner's Engineer is required, or that additional information is to be furnished by the Purchaser.
• Conflicting Requirements
• (*) All conflicts between this Practice and the Manufacturer's recommended procedure shall be referred to the Owner's Engineer for clarification. This Practice shall be considered the minimum standard.
• All exceptions to this Practice and/or the Manufacturer's recommended procedure shall be submitted to the Owner prior to the final contractor selection and the contract award.
• Any deviations for this procedure or problems with compliance discovered after the award shall be referred to the Owner's machinery specialist for resolution.
• Any deviation to this Practice must be approved by the procedure described in EP 1-1-3.
• A revision bar indicates all changes made to this Revision.

2.0 REFERENCES

The latest edition of the following standards and publications are referred to herein.

STANDARDS AND PUBLICATIONS

DEFINITIONS

• Contractor - Company or business that agrees to furnish materials or perform specified services at a specified price and/or rate to the Owner.
• Inspector - A Refining Company appointed engineer or inspector.
• Manufacturer - The recipient of a direct or indirect purchase order for materials and/or equipment. In this context, a direct order is one issued to a Manufacturer by a Contractor or the Owner. An indirect order is one issued to a Manufacturer by a vendor (recipient of a direct order) for materials, fabricated components, or subassemblies.
• Owner - Refining Company.
• Owner's Engineer - A Refining Company appointed engineer.

STORAGE

• General

The Contractor shall assume the responsibilities for the inspection upon receipt; cleaning, lubricating, and otherwise protecting rotating equipment from receipt until the movement to the plant site for installation at permanent location. New equipment is to be stored under the direction of the vendor for as long as the warranty is valid. The following are to be considered the minimum requirements:

• Equipment preservation as specified herein is to begin within three (3) days of receipt and continue until equipment is removed from storage for transport to the final installation site.
• All oil lubricated bearing housings shall be filled with a preservative rust inhibiting oil immediately after receipt and/or placing in storage or on base. Acceptable oils are Exxon's Rust Ban 343, Shell VSI 32, Bray Oil's Braycote 154 or equal preservative oil. This oil shall be flushed and replaced every three months. Grease lubricated bearings should be filled by the Manufacturer prior to shipment. This grease shall be replaced every six months with an Owner approved grease. The Manufacturer's instructions shall be given to the person who changes this grease as serious damage to motors can result from improper lubrication.
• Prior to any rotation of equipment shafts appropriate precautions shall be taken. Any rotor position locking mechanisms or blocks shall be removed. Internal plastic film in bearing or desiccant bags, etc. shall be removed. WARNING: Sleeve bearings shall be lubed with STP prior to first rotation.
• All shafts are to be rotated 2-1/4 turns once each week in the direction of normal rotation. This shall be accomplished by attaching a lever bar to the end of the coupling or by using tools such as a "strap wrench" that will not mar machined surfaces or otherwise damage the equipment. This will be done by progressing down each storage row, rotating each shaft in turn until all have been rotated. The equipment will be logged and tagged to show a continuing record of date last run, oil lubricant changed, grease lubricant changed, etc. on the Construction Maintenance Record form provided.
• Exposed machined surfaces, (shafts, flanges, mounting feet, casing split lines, etc.) and couplings shall be coated with a suitable, removable, preservative coating. Acceptable coatings are Rustoleum R-10 or R-9, Shell ENIS, Braycote 202, or Rust Ban 373.
• Equipment shall be stored in a dry sheltered environment. The equipment shall be stored at least one foot above the floor and protected against moisture, dirt, and animal entry.
• Major equipment shall be stored with a positive pressure, dry nitrogen purge. The equipment shall have a gauge to determine purge pressure. The equipment shall be inspected on a weekly basis to insure that purge integrity is maintained.
• Oxygen compression equipment and equipment where hydrocarbons are harmful to the process shall not have any hydrocarbon protective coatings or fluids. The Manufacturer's recommended procedures shall be strictly followed, especially for oxygen and chlorine handling equipment.
• For extended periods of storage, six months or more, EP 14-1-2 shall be followed by the Contractor.
• All new compressors should be mothballed. Refer to EP 14-1-2 for preserving procedures.

• As an alternative to the preservation of oil lubricated bearings per Paragraphs 4.1.2 and 4.1.3 above, the equipment may be connected to an oil mist lubrication system providing a continuous oil purge to the bearing housings and/or casings.
• Electric Motors Not Suitable For Outdoor Storage
• These motors will be stored indoors in a selected area of the warehouse or other suitable covered area.
• If equipped with electric heaters, the electric heaters will be connected to an appropriate power source provided in the storage area. NOTE: Proper warning signs will be installed to prevent injury to personnel or damage to equipment possibly caused by mishandling of "electrically hot" equipment.
• (*) Insulation resistance values of each winding will be measured and recorded within three days of receipt. Every three months thereafter, until installation in the plant, measure and record insulation resistance values of all unit rated at 2300 volts or higher and every six months for all units rated below 2300 volts. If the resistance is low, the Owner's Engineer shall be notified for further action/instructions.
• Couplings and exposed machine surfaces will be coated with a preservative coating per section

4.1.5 of this Practice.

• All Other Rotating Equipment Including Electric Motors Suitable for Sheltered Outdoor Storage
• Electric Motors
• (*) A motor is suitable for outdoor storage if the enclosure type is TEFC, TENV, WPII, or Explosion Proof. If in doubt, contact the Owner's Engineer for direction.
• (*) Obtain/record insulation resistance values for each winding. For equipment with rating of 2300 volts or more, repeat this procedure every three months thereafter until installation in the plant. If the resistance is low, notify the Owner's Engineer for further action/instructions.
• Connect space heaters to an appropriate power source. Install proper warning signs.
• Rotating Equipment Excluding Motors
• Remove rust and clean all exposed machined surfaces with a solvent and then coat with a preservative coating per section 4.1.5 of this Practice.
• Flush bearing housings with solvent until clean. Fill with a preservative oil per section 4.1.2 of this Practice to the level of the bottom of the shaft. Turn the shaft 2-1/4 times each week.
• If shipped with service packing installed, remove this and repack with wicking dipped in preservative oil. DO NOT USE PACKING CONTAINING GRAPHITE!
• If mechanical seals are provided integral with the pump, the entire pump will be filled with a preservative oil per section 4.1.2 of this Practice or purged with oil mist.
• If chain drives are exposed, remove chains, coat the chain with a preservative coating, wrap them with kraft paper, label for identification and store for proper retrieval as needed.
• Additional Requirements For Centrifugal Compressors, Blowers And Gas Turbines
• (*) Consult the Owner's Engineer to determine if additional intermediate rotor shaft supports are required. Provide same as necessary.
• Spare rotating elements will be stored per Manufacturer's specific instructions. Vertical storage is preferred with pressurized containers.

"ON FOUNDATION" CLEANLINESS AND CORROSION PROTECTION

• General
• The Contractor shall provide for cleanliness and corrosion protection of rotating equipment after it has been removed from the storage yard and prior to start-up.
• The Manufacturer's recommended procedures with the following procedures as a minimum will be implemented by the Contractor.
• All shafts are to be rotated 2-1/4 turns each week in direction of normal rotation, using only tools (such as a "strap wrench") that will not mar machined surfaces or otherwise damage the equipment. This is to be recorded by the Contractor on the Construction Maintenance Record form provided. WARNING: Pour a viscous turbine oil (ISO Grade 100 or higher) on all sleeve bearings prior to first rotation. Do NOT use STP.
• Components removed and given special protection during storage are to be reinstalled per the Manufacturer's instructions prior to pre-commissioning work.
• External machined surfaces are to be coated with a preservative coating per 4.1.5 of this Practice. Coating is to be maintained until start-up.
• Equipment exposed to the elements shall be sheltered by plastic sheeting to prevent rain and dust from entering the equipment.
• All oil lubricated bearing housings shall be filled with a preservative rust inhibiting oil such as Shell VSI 32 or Owner approved equals.
• If oil mist lubrication is used/provided for the unit, the oil mist shall be immediately connected after installation of the equipment.
• Electric Motors
• Determine (at time of setting the equipment on foundation) if the insulation resistance values have been obtained in storage during the last two months.
• If so, establish/execute plans to measurements taken within one month if voltage rating is 2300 volts or more, within four months if less than 2300 volts and
• If not, obtain readings at the time of setting.
• (*) Repeat measurement of resistance values on three month (2300 volts and greater) and six month (less than 2300 volts) intervals. If readings are low, notify the Owner's Engineer.
• Connect all space heaters as soon as possible. Utilize the appropriate temporary power source until a permanent source can be/is connected. Attach the appropriate warning sign.
• Small Pumps and Turbines
• Fill pump or turbine housing with a preservative oil per 4.1.2 of this Practice.
• Fill oil lubricated bearing housings to the top of the housing with preservative oil if the oil seal will hold the oil. If the seal will not hold, fill to the bottom of the shaft and open the housing once each week and spray the internals with preservative oil.
• Temporary suction and discharge flange covers are to be removed once each week and internals sprayed with preservative, if housings can't be filled with preservative oil.
• Where double or tandem seals are used, the seal pot shall be filled with oil. Where single seals are used, and when the case has not been filled with preservative, open the vent plug and spray internals with preservative oil once each week.

• The presence of preservative oil shall be tagged on the outside of each housing.
• On vertical pumps with lubrication lines, a zerk fitting shall be installed and grease pumped (six strokes) from a grease gun into the fitting once each week.
• Coat couplings and exposed machined surfaces with a preservative coating per 4.1.5 of this Practice.
• As an alternative to 5.3.1, the equipment may be connected to an oil mist lubrication system providing a continuous oil purge to the bearing housing and/or casing.

5.4 Major Equipment

The Manufacturer's recommendations for storage shall be strictly adhered to. Nitrogen purge bottles and gauges shall be field installed, if necessary.

INSTALLATION AND ALIGNMENT

• General
• (*) The Mechanical Contractor is to perform the necessary mechanical effort and advise the Owner's machinery specialist when the equipment is ready for inspection. An installation record in the form of a sign off sheet for required items is to be provided for each equipment. The Mechanical Contractor shall consult with the Owner's machinery specialist to establish mutually the installation requirements for each type of equipment, up front.
• (*) Level will be checked on machined foot pads. If this is not possible, the Owners machinery specialist shall be contacted to determine acceptable alternate locations or procedures. Between the baseplate and the foundation one shim pack is required on at each anchor bolt.
• (*) All leveling is to be done using a precision machinist's level, Starrett 98 series level or equal. Unless otherwise approved by the Owner, Starrett master precision level shall be used where the maximum allowable unlevelness is 0.0005 inches per foot.
• All equipment shims shall be U-shaped stainless steel and, unless specifically approved by the Owner's Engineer, no more than six (6) shims are to be used under each equipment foot in one stack. Tapered (stepped) shims are not permitted.
• Foundation bolts shall not be reduced in diameter nor offset to facilitate baseplate positioning and alignment.
• All equipment shall be grouted in place before any process piping is attached.
• The equipment shall be completely installed with all process piping, auxiliary and utility piping connected, and the unit lubricated with permanent lubricants.
• At equipment turnover, the Contractor shall turn over to the Owner the complete file including installation documentation, drawings and instruction manuals.
• Preparing, Setting and Leveling Baseplates and Soleplates
• Preparations
• The foundation shall be adequately prepared and free of oil, scale and dirt.
• New foundation shall have the surface chipped to remove all laitance and to expose the concrete aggregate for proper grout adhesion.

• Old foundations shall be chipped away until all oil soaked concrete has been removed. The exposed surface should be washed with muratic acid to insure an oil free surface.
• The anchor bolts shall be checked for proper positioning. This is especially critical for soleplates.
• The baseplates or soleplates surface to be in contact with the grout shall be clean of oil, dirt, and rust. Epoxy primer shall be applied if epoxy grout is to be used. If the primer was applied by the Manufacturer, the Contractor shall clean the surface and repair the primer coat as required. Note: Special instructions pertain to StayThru baseplates that have been pre-filled with epoxy grout material. Coordinate details with the Owner's Engineer.
• Anchor bolt sleeves shall be packed to prevent the entrance of dirt and water.
• (*) Holes and vents for the grout pour shall be reviewed and approved by the Owner's machinery specialist. Additional openings shall be cut as required.
• Setting
• Unless pre-filled per StayThru practices, the baseplates and soleplates shall be set, leveled, and grouted in place alone, without the equipment mounted, for all installations over 20 HP. Installations under 20 HP may be set, leveled, and grouted with the equipment mounted.
• Contractors will rough level the equipment on the foundation to the correct elevation and centerline using mild steel blocks free of burrs or flame-cut slag.
• The underside of the base must be clean and shim blocks must be installed adjacent to anchor bolts, cut clear of sleeves. Baseplate distortion can result if hold down bolting and shimming is not properly carried out.
• (*) Minor modifications required to set the baseplates (i.e. enlarging an anchor bolt hole) shall be within the Contractor's scope of work. Modifications shall receive prior approval from the Owner's equipment specialist.
• Leveling
• (*) The maximum allowable unlevelness of the equipment shall be 0.002 inches per foot on small centrifugal pumps and 0.0005 inches per foot on larger equipment. Leveling is to be done by millwrights using precision levels with results witnessed by the Owner's machinery specialist.
• (*) Level readings shall be taken on the machined foot pads in both directions wherever possible. Foot pads for each piece of equipment shall be in the same plane within 0.002 inches per foot of distance between the pads. On small equipment, the suction and discharge flanges can be used to check the levelness instead of the foot pads. For fans, level readings shall also be taken on the shaft. Readings shall be witnessed by the Owner's machinery specialist.
• The baseplates or soleplates shall be adequately supported, anchor bolts hand tightened, and the assembly readied for grout prior to inspection and approval. Shims shall be under the base or soleplate on both sides of each anchor bolt to prevent warpage. All soleplates shall be located in the same plane within 0.001 inch per foot of distance separating plates.
• Grouting
• Pre-Grout Checkout
• After leveling and prior to grouting, a preliminary shaft alignment shall be made.
• All bearings shall be prepared for rotating the shaft, especially journal bearings.
• Check the shaft end gap with motor on mechanical center or the shaft in normal running axial position.

• Shafts shall be rough aligned using the reverse indicator method to insure that the equipment is not bolt bound. Rough alignment shall be within 0.015 inches TIR.
• (*) Subcontractor must notify the Owner's machinery specialist prior to grouting for a level and position check.
• Prior to grouting, pipe connections or flanges shall not be touching the equipment.
• Review the baseplate bracing details to avoid structural members from restricting the grout flow. If required, cut additional holes in any isolated area of the base and provide vent holes.
• Erect a form around the baseplates. Forms should be waxed or sprayed with a release agent and should be braced and sealed against leakage.
• Anchor bolts and sleeves shall be packed and sealed to prevent grout filling/contact.
• (*) For cementitious grout, the foundation shall be water wetted for at least 24 hours prior to the pour. The foundation shall be dry for epoxy grouts.
• Grouting
• Mix the grout, following the Manufacturer's recommendations, mixing enough for one base at a time. Mixing of the grout is to continue while the grout is being poured.
• Pour the grout into the largest opening first. As the grout flows under the baseplate, it will boil up through the vent holes. Grout shall not be vibrated to make it move. Only steel rodding can be used to help move the grout, but only when a head of grout is present and only on cementitious grout.
• After grout has come out of all of the holes, cleanup can begin. For cementitious grout, clean with water, margin trowel and rags. Exposed grout shall be covered with wet rags or burlap as per Manufacturer's recommendations.
• After the grout has stiffened, the top layer of unconfined grout outside of the baseplate can be removed and then finished off, to the bottom side of the baseplate (This reduces spalling due to baseplate expansion). A beveled edge is to be formed as the forms are removed.
• After the grout has cured 3 to 7 days, the Contractor may tighten all anchor bolts. A hammer (ring) test of the baseplate should be done to assure no voids. Any voids shall be filled with fluid epoxy grout. Care shall be taken to avoid overpressure and buckling of the baseplate while filling.
• Prior to setting the equipment on the baseplate, the level shall be re-checked. Baseplates or soleplates which have settled shall be regrouted.
• Equipment can be set on baseplates or soleplates after two days for epoxy grouts and seven days for cementitious grout.
• Piping Fit Up
• Prior to bolting the piping, the piping should be checked for cleanliness and completeness. All piping and vessels upstream of the equipment shall be checked for dirt, sand, and foreign material. All chemical cleaning and/or flushing should be completed. The equipment should be checked against the P&I drawings to insure completeness. Temporary strainers, drain lines, vent lines, and any other significant items should be checked. The piping to and from the equipment should be checked for completeness including confirming the existence of all pipe supports indicated on the piping isometric drawings. Final alignment readings shall only be taken after all piping is connected.

• Extreme care is to be exercised at all times to maintain fluid passages of rotating equipment free from dirt, foreign objects and other contamination. The rotating equipment should be kept free from all stresses during all phases of construction. Any piping attached to the equipment, even temporarily, must be supported as required to insure that no loads are placed on the equipment.
• The system shall be hydrotested prior to the final bolt-up of the piping to the equipment. The system will be hydrotested with all "stops" in place in all spring supports. Height adjustments should be made without modifying or changing the pre-set cold setting.
• Flushing and hydrotest shall not be conducted through the rotating equipment. The Contractor shall isolate the equipment with blinds. All hydrotesting shall be complete before final witnessed pipe attachment.
• The flanges shall be aligned to the equipment per Section 6.4.10 of this Practice. The equipment shall be aligned per Section 6.5 of this Practice and the shaft gap set prior to the piping hook up. The piping shall be fitted to the equipment. Movement of the equipment shall be limited to 0.002 inches. Piping should be freely supported with proper contact at the supports and hangers. All liquid piping should have the "stops" for all spring supports installed during the alignment of the piping to the equipment. Steam and gas piping should be aligned with the spring stops removed.
• Temporary supports for piping alignment are not allowed during the final alignment readings and bolt-up.
• (*) If flange alignment is to be accomplished by "Ring Heat" using a Rose-Bud torch or a similar method, the procedure should be approved by the Owner's welding engineer for each type of piping.
• All piping attaching to rotating equipment is to be aligned in such a manner as to minimize the piping loads imposed on the equipment. In general, the Manufacturers' recommendation shall be followed with the following criteria serving as the minimum standard.
• Flange face separation must be within the gasket thickness ±1/8 inch.
• Bolt hole alignment must be within 1/16 inch maximum offset from center.
• Flange face parallelism must be within 0.002 inch per inch of NPS diameter. Readings are to be taken at least four positions 90° apart. For raised face flanges, feeler gauge readings are to be taken at the raised face.
• Line joint alignment must be within ±1/16 inch parallel misalignment.
• For spared equipment and for equipment with a common header, alignment readings should be taken on all of the equipment at the same time. Additionally, all of the equipment should be bolted up at the same time with indicator readings taken on each shaft simultaneously.
• Once the above criteria have been met, piping can be bolted to equipment and spring hanger/supports activated. Next:
• Dial indicators are to be mounted to the equipment's shaft to monitor both vertical and horizontal movement as the piping is bolted to the equipment. Spared equipment or equipment on the same header shall be monitored simultaneously.
• Bolt-up should start with the largest flanges first. Bolt-up must be completed in a continuous effort without disturbing the dial indicators.

• Shaft movement is not to exceed ± 0.002 inches during the bolt up. Usually this can only be done by selective tightening of all of the flange bolts until they are all tight to bring the pipe flange to the equipment evenly. If indicator movement does exceed 0.002 inches, the flange must be loosened and the procedure repeated. Spiral wound gaskets may not be re-used. Once the bolts are tight, indicator readings on all equipment shall be recorded on the Alignment Data Sheet.
• If an installation cannot meet the above criteria, re-alignment of the flange faces will be necessary.
• (*) Any work carried out on the piping after the equipment has been bolted up, even though several feet away, may cause strains on the equipment nozzle flanges. This work may void the acceptance of the systems. If work is done on equipment, driver, or piping, the system shall be rechecked and re-aligned as necessary per the Owner's discretion.
• Shaft Alignment
• (*) The Owner's machinery specialist is to be consulted for the desired "theoretical perfect cold alignment" and the designation of "sacred" (non-adjustable) and alignable equipment. Typically, pumps are considered "sacred" and are not to be shimmed or moved; therefore, drivers are to be shimmed and moved to align to the pump shaft.
• Shafts are to be aligned using the double reverse indicator or laser alignment methods. The permissible amount of misalignment from theoretical perfect cold alignment will vary by type of equipment. Misalignment shall not exceed the Manufacturer's recommendations or the tolerances given in Table 1.
• All indicator brackets over 6 inches long are to be tested for sag, and the results used to determine the actual shaft alignment. Magnetic brackets are not permitted for shaft alignment.
• A permanent record of every alignment and alignment check shall be made and included in the equipment's file. The Alignment Record Form is included for this purpose. The alignment form should be completely filled out.
• (*) Unless otherwise instructed by the Owner's machinery specialist and/or recommended by the equipment Manufacturer, each piece of rotating equipment shall have the following alignment made as a minimum.
• Preliminary Alignment: To be done prior to the grouting after setting and leveling. Notification shall be given to the Owner.
• Piping Alignment: The piping fit up to the equipment prior to final attachment shall be inspected as per Section 6.4 of this Practice.
• (*) Final Alignment: To be done after piping is complete. It is to be witnessed by the Owner and a vendor's representative (as required) and signed off on the equipment alignment sheet.
• The shafts are to be turned in one direction only (the direction of rotation) while taking alignment readings. A strap wrench, clamp-on fixture, or other suitable means shall be used to rotate the shafts without marring the equipment (Do not use the indicator brackets for rotation). Both shafts shall be rotated together to eliminate false readings due to surface irregularities or run- out.
• Two identical sets of readings shall be taken prior to acceptance. Non-repeating readings are unacceptable.

• Alignment readings shall be taken with all of the equipment feet tightly bolted down.
• (*) Minor modifications to achieve alignment (i.e. enlarging foot bolt holes) require prior approval by the Owner's machinery specialist. Such modifications are within the Contractor's scope of work.
• "Soft Foot" Check
• During final alignment verification, a check shall be made for equipment soft foot according to the following procedure.
• Equipment feet shall have been tightly bolted down prior to the final alignment check.
• Dial indicators shall be installed at each foot to measure vertical distortion.
• Only one-foot bolt at a time shall be loosened. The distortion reading shall be recorded on the equipment installation sheet.
• The bolt shall be re-tightened. If the indicator does not return to zero, reading shall be retaken.
• (*) All of the feet are to be witnessed, one at a time, by the Owner's machinery specialist.
• Use the laser alignment equipment for this check if it was used to originally align the equipment.
• Readings will be considered acceptable if the difference between any two readings at any foot is less than 0.003 inches.
• A reading of 0.004 inches or greater at any equipment foot is unacceptable. The presence of more than three shims or dirt and oil can produce a spring-like effect under the feet.
• (*) Readings may be taken at the shaft coupling with the approval of the Owner's machinery specialist.
• Couplings
• The Contractor shall assure the cleanliness of the couplings.
• The coupling gap shall be measured and recorded on the installation sheet.
• All gap readings shall be taken with a micrometer.
• On equipment with thrust bearings or close clearances, the coupling gap shall be within

0.002 inches of the specified gap. The coupling shall be checked to insure parallel faces.

• On equipment without thrust bearings, the reading shall be taken with the shaft at the operating center (magnetic center for motors). The magnetic or operating center shall be verified at run-in of the particular equipment. The coupling gap shall be within 0.025 inches of the specified gap, unless a closer tolerance is requested by the equipment vendor.
• All couplings are to be installed per the Manufacturer's instructions. Bolts are to be torqued to the Manufacturer's specified value.
• (*) Heat shrunk couplings are to be installed and removed by a method approved by the Owner's machinery specialist. Heating with a rosebud touch is NOT an approved method.
• Hydraulically fit couplings shall be installed with the proper equipment according to the Manufacturer's instructions and within the specified tolerances. Extreme care shall be taken to prevent any damage to the shaft or coupling surfaces. Ring and plug gauges shall be used to check for proper fit.

• (*) Coupling hub radial runout shall be checked at the preliminary alignment. If runout exceeds

0.003 inches TIR, the Owner's machinery specialist shall be notified.

• Coupling spacers shall not be installed until after all final alignment checks and after the driver run-in (see Section 7.4 of this Practice) and overspeed trip testing (see Section 7.5 of this Practice).
• Coupling Guards

The Contractor shall install the Manufacturer's coupling guard such that it shall not touch any rotating parts. It shall completely enclose the coupling and shaft. Any minor modifications shall be within the Contractor's scope of work.

• Miscellaneous

The Contractor shall be responsible for enclosing large equipment "on foundation," as required, with a temporary shelter. Specifically, equipment requiring field assembly and installation free from environmental effects of rain, dust, cold, and possibly direct sunlight shall require shelter.

PRECOMMISSIONING SUPPORT

• Lubrication
• Grease Lubricated Bearing, Gears, and Couplings.
• The Contractor shall inspect all "pre-greased" bearings, gears, and couplings to insure the presence of the manufacturer's lubricant initial charge. If the grease is insufficient, the Contractor shall add the recommended grease per the Manufacturer's instructions.
• The Contractor shall add the initial grease charge to all other equipment per the equipment manufacturer's instructions.
• Unless Zerk fittings and manufacturer-selected spent grease escape piping have been supplied by the equipment manufacturer, the Contractor shall supply and install "Zerk" grease fittings and reliefs on all equipment grease injection ports. These fittings facilitate easy, dirt-free injection. For fittings inaccessible during operation, the Contractor shall supply extension tubing and mount the grease fittings in an accessible location.
• Extension tubing shall be of small diameter.
• (*) The Owner shall supply the recommended grease, or equal, to the Contractor for the initial charge.
• (*) The Contractor is responsible for the removal of any surface contamination, surface rust, or preservative coating prior to the installation of the initial charge. The Owner's machinery specialist shall be notified of any damage.
• If the bearings, gears, and couplings have been greased during storage, the Contractor shall remove all grease that has accumulated on the outside of the equipment housings.
• Non-Pressurized Oil Lubrication Sealed Bearings, Gears and Couplings.
• (*) The Contractor is responsible for insuring the integrity of protective coatings and preservative oils per Sections 4.1.2 and 4.1.5 of this Practice until the pre-commissioning phase. Upon removal or drainage, the Contractor shall notify the Owner's machinery specialist of the presence of water, rust or contaminants in the preservative.
• Prior to the initial oil charge, the Contractor shall flush the bearings at least twice. The primary flush shall be with an evaporating solvent (Varsol, Stoddard R-66 or equal) until the equipment is water and contaminant free. The secondary flush shall be with the recommended lubricating oil.

• Following the flush, the Contractor shall install the initial charge of lubricant per the Owner's Equipment Lubrication List.
• The Contractor shall be responsible for the proper installation of constant level oilers, sight glasses, pressure relief connections, vents, fittings, and other required appurtenances. Trico type lubricator level bars shall be set to the proper level for the bearing housing.
• (*) shall supply the solvent and lubricating oil.
• Additional measures recommended by the Manufacturer (i.e. removal and re-installation of bearing caps and journals for inspecting and cleaning) are part of the Contractor's scope of work.
• Pressurized Lube/Seal Oil Systems
• Small lube oil systems that have been sealed since factory testing shall remain undisturbed. Any oil in the system shall be drained and a fresh initial charge installed by the Contractor just prior to start up.
• (*) Larger lube oil systems or those that require field assembly will be flushed completely. The system shall be flushed under the direction of the Owner's machinery specialist. Stainless steel wire screen, with a minimum 100 mesh, shall be installed at the inlet to all bearings, seals, etc. in horizontal sections prior to flushing. The system will be considered clean when the screen collects no particles for a minimum of two days running.
• The Contractor shall provide all craft support for the oil system's flush. This support shall include changing filters, strainers, 100 mesh test screens as required, implement minor piping modifications, draining flush charge, cleaning any accumulated debris from the reservoir, etc.
• (*) The Contractor shall install the initial oil charge following acceptance of system cleanliness by the Owner's machinery specialist.
• (*) The Owner shall supply the flush oil charge, the initial oil charge, and replacement filters.
• Steam Line Blow-Down (Also Applies To Fuel Lines To Gas Turbines)
• Contractors Scope of Work
• The Contractor shall supply the necessary craft support for steam line blow-down on all steam lines to steam-driven rotating equipment.
• (*) The Contractor shall disconnect the inlet steam line to each steam turbine. The inlet shall then be directed to discharge in a safe direction as determined by the Owner's machinery specialist.
• Following acceptance of the blow-down targets, the Contractor shall reconnect the steam turbine inlet according to the procedure stated in Section 6.4.
• Owner's Scope of Work
• Blow high velocity steam through the line until the temperature is within 20oF of the normal operating temperature. Hold for 5 minutes and the let line cool to within 50oF of ambient. Repeat procedure until the line looks clean.
• Firmly bolt polished test targets to the inlet pipe flange.
• High velocity steam (at least 2-3 times normal velocity) shall be exhausted for a minimum of one half hour against the polished targets.
• The lines shall be considered clean after two targets in a row have no pits and all scratches are in the outer 20% of the pipe diameter.

• Leak Repair
• The Contractor shall provide the craft support required to leak check any associated auxiliary systems (i.e. lube oil, seal gas, refrigeration, etc.).
• The Contractor shall provide the necessary craft support to repair any leaks detected prior to start-up.
• Leak checking shall take place prior to the installation of insulation and after the mechanical completion of the system to be checked.
• Driver Run-In
• (*) All motors will be run-in for a minimum of four hours uncoupled after rotation check. The Mechanical Contractor shall monitor the run-in, taking temperature and vibration data every hour. Any unusual sounds, high temperatures, and high vibrations shall prompt shut down of the driver and notification of the Owner's machinery specialist. If it is not known what grease was initially used or if the grease used is not compatible with the grease to be used for normal operation, then grease shall be purged from the bearings during the four-hour run.
• Steam turbine drivers are to be run-in in accordance with the Manufacturer's instructions for a minimum of four hours. The Mechanical Contractor shall monitor the run-in taking vibration data every hour. The Manufacturer's representative should be present to supervise the run-in. The turbine shall be warmed up and gradually brought up to operating speed, while checking for unusual noises, leaks, high vibration and governor operation. Special procedures, approved by the Owner's Engineer, shall be used for proper run-in of carbon ring seals.
• Gas turbines drivers and engines shall be run-in in accordance with the Manufacturer's recommendation and under the supervision of the Manufacturer's representative. The run-in shall have a four-hour duration while uncoupled.
• Overspeed Trip Test
• Steam turbines, expanders, gas turbines, and engines shall all be tested for proper operation of the overspeed trip devices. The Manufacturer's representative shall supervise the test.
• After the equipment is brought up to operating speed, during the run-in preferably, the machine should be brought up to trip speed. A speed of 115% of the Maximum Continuous Speed should not be exceeded (indicates a faulty trip switch).
• Three successful trips in the specified range constitute a successful test. If the trip speed is inconsistent or out of the range the cause should be investigated, corrected, and the procedure repeated.
• After the first trip, the equipment shall be observed on coast down until it stops. The machine should come to a gradual stop.
• The trip lever mechanism should never be reset until the equipment comes to a dead stop.
• Hot Alignment
• (*) The Mechanical Contractor shall supply the necessary labor involved in installing tooling balls or other miscellaneous equipment. The Owner will provide all hot alignment equipment and personnel.

• Hot alignment shall be performed under conditions as close to the normal operating conditions (particularly in regards to temperature) as possible.
• (*) All large trains shall undergo a hot alignment check. Smaller units shall be hot alignment checked at the discretion of the Owner's machinery specialist.
• Doweling
• (*) The Mechanical Contractor shall dowel all equipment as required. Typically, equipment larger than 300 HP shall be doweled. Smaller equipment shall be doweled at the discretion of the Owner's machinery specialist.
• Dowels shall be tapered with threaded ends for easy removal. The Owner or the equipment vendor shall supply dowels and tapered bits.
• "Sacred" non-moving equipment can be doweled after all of the piping is bolted up and final alignment is complete. Alignable equipment should be doweled after hot alignment if possible.

INSPECTION

(*) The equipment installation and alignment shall be inspected and approved per EP 6-8-1IR by the Owner's machinery specialist. Mandatory inspection points are noted below:

• Pre-grout level, shaft and coupling runout, position and preliminary coupling alignment check
• Post-grout hammer test and post-grout level check
• Alignment and bolting of pipe to equipment
• Motor run in
• Soft foot, coupling gap check and final alignment
• Lube oil flush/seal system flush
• Steam line blowdown
• Uncoupled run-in (and overspeed) test of the driver
• Final acceptance of the package
• Removal of rust preventative
• Removal of spring support stop and verification of spring travel.

9.0 TABLES

TABLE 1

TOLERANCES FOR SHAFT ALIGNMENT - SHORT COUPLED UP TO 48 INCHES

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