TABLE OF CONTENTS

1.

General.....................................................................................................................16

2.
2.1
2.2

Applicable documents ............................................................................................16

Specification and Procedures ................................................................................16
Codes and Standards..............................................................................................16

3.

Definitions................................................................................................................17

4.

HSE and QA/QC.......................................................................................................17

5.

Packing, Delivery and Storage ...............................................................................17

6.

Preparation for installation.....................................................................................17

7.
7.1
7.2
7.3
7.4
7.5

Liners........................................................................................................................18
Materials ..................................................................................................................18
Position and Number Required .............................................................................18
Shape .......................................................................................................................19
Finishing...................................................................................................................19
Setting of Liners ......................................................................................................19

8.

Installation ...............................................................................................................20

9.
9.1
9.2
9.3

Grouting ...................................................................................................................20
Types of grout and materials .................................................................................20
Mixing.......................................................................................................................21
Application...............................................................................................................21

10.
10.1
10.2
10.3
10.4

Alignment Tolerances.............................................................................................22
Position ....................................................................................................................22
Elevation ..................................................................................................................22
Perpendicular ..........................................................................................................22
Levelness .................................................................................................................22

11.

Assembly of Accessories........................................................................................23

12.

Assembly of Piping .................................................................................................23

13.

Internals for Equipment ..........................................................................................23

14.

Removal of Lifting Lugs..........................................................................................23

15.

Documentation........................................................................................................24

RO-EP-QA-SPC-001-01-B
Pag. 15 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1

1. General
This specification covers the minimum requirements for the equipment installation, such as
reactors, columns, drums, heat exchangers, packaged equipment, equipment modules,
miscellaneous equipment and miscellaneous machinery which have been provided as per
requirements of the project specifications.
In the case of any discrepancies between this specification and vendors instructions, in
principle, this specification shall prevail over vendors instructions unless otherwise decided by
CONTRACTOR and approved by CLIENT.
Dress-up assembly shall be performed in accordance with relevant specifications and drawings.

2. Applicable documents
2.1 Specification and Procedures
The following documents are complied with this Specification :
Company Construction HSE Plan
Vendor / Contractor Procedures for Heavy/Awkward Lifting Operation
Company Quality Control Plan
Vendor Site ITP for Static Equipment Erection
RO-EP-QA-SPC-004-01-B Philosophy of Civil Works Onshore
RO-EP-QA-SPC-006-01-B Protection and Preservation of Equipment and Material
Related Vendors Installation and maintenance manuals and/or specifications
2.2 Codes and Standards
ISCIR PT C 4/1-2009 Technical requirements regarding the assemblage, installation, operation,
overhaul and inspection of the fixed, under pressure metallic recipients
ISCIR PT C 4/2-2009 Guide book for the design, construction, assemblage and overhaul of fixed,
metallic pressure vessels
SR EN 12620

Aggregates for concrete

SR EN 13139

Aggregates for mortar

SR EN 206

Concrete- Specification, performance, conformity

SR EN 480

Admixtures for concrete, mortar and grout

SR EN 1008
Mixing water for concrete - Specification for sampling, testing and
assessing the suitability of water, including water recovered from processes in the concrete
industry, as mixing water for concrete
SR EN 1008:2003
Mixing water for concrete - Specification for sampling, testing and
assessing the suitability of water, including water recovered from processes in the concrete
industry, as mixing water for concrete
RO-EP-QA-SPC-001-01-B
Pag. 16 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1

ASTM C33

Standard Specification for Concrete Aggregates

ASTM C39

Standard Test Method for Compressive Strength of Cylindrical Concrete

Specimens

ASTM C595

Standard Specification for Blended Hydraulic Cements

ASTM C597

Standard Test Method for Pulse Velocity Through Concrete

ASTM C1107

Standard Specification for Packaged Dry, Hydraulic-Cement Grout

(Nonshrink)

3. Definitions
Company

the party who is the owner/end user of the vessels that will be installed
under this speciifcation

Contractor

the party who is responsible for the erection of vessels to be installed

under this specification

Equipment/Vessel

as defined in this specification, shall be used to define either reactors,

columns, drums, heat exchangers, packaged equipment, equipment
modules, miscellaneous static equipment

HSE

Health Safety and Environment

ITP

Inspection and Test Plan

4. HSE and QA/QC

All activities performed by the Contractor on the construction site shall comply with all OMV
Petrom norms, standards or instructions as well as with Romanian legislation regarding HSE
and QA/QC requirements.
Before commencement of the works, the contractor shall send to Client for approval the
Inspection and Test Plan (ITP) and the Quality Control Plan (QCP).
The QA/QC checks and tests shall be defined in accordance with OMV Petrom Quality
Inspection plan and QA Manual.

5. Packing, Delivery and Storage

The equipment shall be packed and delivered as required by the project specifications.
The equipment shall be kept in the conditions as required by the Vendor recommendations and
by following the precautions stated in the Specification for Protection and Preservation of
Equipment and Materials until the time of installation.
The equipment shall be checked whether there are any Non-Conformity reports associated with
any of the items to be installed. The equipment with associated non-conformity reports can not
be installed until the report is cleared.

6. Preparation for installation

When released, the foundation the following points shall be checked with the latest relevant
drawings :
RO-EP-QA-SPC-001-01-B
Pag. 17 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1

Distinct position (centre) marking and height (level) marking on the foundation, it will be
referred for alignment work of level and position.

Size and numbers of anchor bolt and nuts, position of anchor bolts with projection. They
will be checked with respect to the General arrangement of the equipment as well as the
foundation drawing.

Existence of damage and rust of threaded parts of buried anchor bolts and cleanliness
Anchor bolts shall be protected properly to avoid damage during chipping/padding work
and keep it up to the equipment erection.

Laitance shall be removed from the surface of foundations and anchor boxes by chipping to
ensure good adherence of padding and grout materials to the said surface. The foundation
concrete shall be at least 7 days old before surface preparation.
Padding using liners and grout shall be performed in accordance with the methods specification
in Para. 7 and Para.9 in this specification.
Prior to installation the following points shall be checked and reconfirmed.
-

Distinct marking on foundations

Level of liners on the chipped surface

Complete freedom from foreign matters on the chipped surface

Proper cleaning of anchor boxes if applicable

The bottom of equipment bases shall be cleaned and free of laitance, loose particles, oil or
grease.
Prior to commencement of the work, lifting and/or movement procedure/method statement
shall be established with COMPANYs approval.
Categories for Lifting Procedure and Movement Procedure are defined as follows.
-

Minor Equipment weight 0 to 10 tons

Medium size Equipment weight 10 to 40 tons

Heavy Equipment weight 40 to 100 tons

Critical Equipment weight exceeding 100 tons and awkward or tandem lifting

Standard lifting/movement procedure identified in the lifting/movement procedure is applicable

for Minor, Medium and Heavy Lift, and the independent detailed procedure is required on each
Critical Lifting and Movement.

7. Liners
7.1 Materials
Liner material shall be carbon steel plate of minimum 380 N/mm2 tensile strength and shall be
free from corrosion.
7.2

Position and Number Required

Liners shall be providing on both sides of anchor bolts, basically.

In general, the interval between liners shall not exceed 800 mm.
If the interval is more than 800mm, an additional liner shall be added between the liners.
RO-EP-QA-SPC-001-01-B
Pag. 18 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1

The load to be supported by liners shall be max. 30 kg/cm2. If the supported load is to exceed 30
kg/cm2, either the width or number of liners or both shall be increased. The load to be
supported shall be calculated in accordance with the equation shown below.
L=W/NxAxB
L : Load supported by liner (kg/cm2)
W : Lifting load of equipment (kg)
N : Number of liners
A : Width of base plate for equipment (cm)
B : Width of liner (cm)

The wedge liners may be applied to Reactors, some Tower and Column, etc, if necessary. The
gradient of the wedge liners shall be generally less than 1/30, and two wedge liners shall be
used in back to back so as to make their top and bottom faces in parallel.
7.3

Shape

The width of liners shall be as shown in Table 7.1 below.

Table 7.1. Width of Liner
Nominal Dia. Of Anchor Bolt
M24 or 1 inch and under
M30 M48 or 1-1/4 inches ~ 2 inches
M56 or 2-1/4 inches and over

Width of Liner (mm)

50
75
100

The length of liners shall be 20 to 30 mm longer than the width of the equipment bases.
The thickness of both taper and straight liners shall be at least 10mm and the minimum
thickness of the tapered ends shall be 2 mm. Adjustment allowance shall be 4 to 6 mm.
7.4

Finishing

Tapered faces only shall be machined to a normal finish. Even other surfaces are under formed
and not so smooth, they need not be finished. Edges, however, shall be bevelled to prevent
injury to personnel.
7.5

Setting of Liners

Prior to the installation of liners and equipment, the liners and grouting portions of foundations
shall be chipped and all concrete laitance shall be removed from grouted portions.
RO-EP-QA-SPC-001-01-B
Pag. 19 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1

Flat liners shall be installed at the level and positions as described in Para. 6 with pads of
cement grout at least three days before equipment installation.
In case that the wedge liners are used, the level of padding with a flat liner need to be adjusted
to meet with the final required equipment elevation.

8. Installation
Prior to the installation work, the equipment shall be checked for the following points:
-

Appearance of equipment, such as damage, rust, etc

Number and appearance of auxiliary systems

Orientation marking

Center of gravity

Sling points

Equipment shall be set and aligned at the proper position, elevation, levelness and
perpendicularity in accordance with the drawing.
The equipment shall not be lifted by its nozzle but only by its lifting lugs or shell parts. Shell
parts shall be protected by wooden blocks, rubber or other material from damage caused by
sling wire.
With regard to horizontal type equipment requiring allowance for thermal expansion, full
attention shall be paid to the position relation between the anchor bolt holes of the place and
the anchor bolts themselves and the nuts for sliding end anchor bolts if any shall be loosen after
curing of grout material.
The alignment of towers and vertical vessels, the height of which is 20 m and longer, shall be
done before dawn or on cloudy days to avoid deviations due to weather or heat.
Upon completion of alignment, the plural liners shall be intermittently welded to each other.
Where sliding plate is used, the sliding surface of the vessel shall be cleaned and plastered with
anti-seizing agent.
Shims used for level alignment shall be as follows.
-

Less than 0.100 (2.5 mm) thick shall be stainless steel.

Shim thicker than 0.100 (2.5 mm) may be carbon steel.

The number of shim used any one hold down bolt shall be limited to 4 (four) basically.

9. Grouting
9.1

Types of grout and materials

Grout for filling under base plates or towers, vessels, structural columns, machinery, etc. shall
be one of the types given below, and shall be specified on the drawings:

For general use - Portland cement and sand in volumetric proportions 1:2.

For bolt sleeves, shear pockets and under base plates of heavy equipment machinery, etc - a
high strength, non-shrink grout, mixed and applied strictly in accordance with the
Manufacturer's instructions.
RO-EP-QA-SPC-001-01-B
Pag. 20 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1

The follwing table provides guidelines for the grout type to be used. This is to be confirmed by
the project drawings and also by the Vendor.
Grout type
Type G1: sandcement grout
Type G2: non-shrnk
cementtous grout
Type G3: non-shrnk
epoxy grout

Note 1:

Mnmum compressve
strength at 7 days (note)
30 N/mm2

Applcaton

Trowable grout: 50 N/mm2

Major steel structures, statonary,

rotatng, and fllng-n of anchor box

Flowable grout: 40 N/mm2

80 N/mm2

Mnor steel structures (see note 2)

Heavy equpment subject to vbraton

specfed on drawngs or by vendor.
(see note 3)

Mnmum compressve strength shall be verfed by :

Type G1 : feld test n accordance wth astm c39.
Type G2 and G3 : manufacturers data sheets and certfcates.

Note 2:
Not assumng structural foundatons such as platforms, walkways, stars and
ladders and the lke
Note 3:
If not specfed, then clear confrmaton from vendor shall be obtaned whch
type of grout to be used
Water for mixing grout materials shall be fresh and clean, and free from injurious amount of oil,
acid, alkali, salt or organic materials.
The grout materials for TYPE G2 and TYPE G3 shall be stored in accordance with manufacturers
recommendation and shelf life shall be confirmed and follow the manufacturers instruction in
use.
9.2

Mixing

(1) TYPE G1 grout shall be mixed cement and fine aggregate (sand) in the proportion of 1:1 by
volume and the weight percent of water and cement shall be 40% or less, and grout shall be
stiff consistency.
(2) Both mixing and pouring of TYPE G2 non-shrink cementations grout shall be in accordance
with the grout manufacturers instructions.
(3) Minimum compressive strength for type G1 grout shall be 30N/mm2 in accordance with
ASTM C39-86.
Test cubes shall be prepared and tested to confirm the requirement.
9.3

Application

(1) The application of TYPE G2 non-shrink cementitious grout and TYPE G3 epoxy grout shall be
coincident with Vendors requirement.
(2) In case TYPE G1 sand cement grout and TYPE G2 non-shrink cementitious grout are used,
after cleaning, water shall be sprinkled over the foundation tops for 24 hours, and padding or
grouting shall be done in a moisture condition. Remaining puddles shall be removed before
padding or grouting.
(3) Grouting of one continuous area shall be completed without interruption.
RO-EP-QA-SPC-001-01-B
Pag. 21 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1

(4) Grouting shall be applied not only under the equipment bases and anchor holes but also the
ejected portion of the liner so that such portion can be perfectly covered with a minimum 40
mm by grouting.
(5) The mounting space of grout shall be in general at arranged of 25 to 50 mm.
(6) Grout shall be carefully placed in between the base plate and the foundation top, and
rammed in and tamped sufficiently with an iron bar or the like to eliminate any air pockets.
(7) Upon completion of padding or grouting, grout shall be properly cured for 7 days or longer
by covering it with continuously wet mats or sprinkling it .
(8) No load shall be applied for at least 10 days after padding or grouting.
(9) A 30 mm W x 25 mmH drain ditch shall be provided. The orientation for drain ditch shall be
provided by Contractor timely.
(10) The surface of grouting shall be finished so as to be smooth by using a steel trowel, etc.

10.

Alignment Tolerances

Equipment shall be aligned within the following tolerances and the results shall be recorded:
10.1

Position

The centreline of the foundation shall be in alignment with that of the equipment in every
direction within the tolerance of 3mm.
10.2

Elevation

At least, one point on the base plate shall be aligned within the tolerance of 3mm.
10.3

Perpendicular

The centre (basic line) of the equipment shall be in alignment with the vertical line within the
tolerance of 6mm for every 10m length of the equipment, in principle, provided that such
tolerance for 20m and longer equipment shall not exceed 12mm.
*(This tolerance is applicable to vertical equipment)
10.4

Levelness

The centre line (basic line) of the equipment shall be alignment with the horizontal line within
the tolerance of 1/1000.
When the slope is specified and taken into account in the fabrication the equipment shall be in
alignment with the base plate line with the tolerance of 1/1000, after alignment the slope shall
be checked at the bottom of shell body.
*(This tolerance is applicable to horizontal equipment)
In the case where an item of equipment is curved and the center line (basic line) thereof is not
within the specified tolerance, the centerline shall be measured at any point close to the base
line of the vessel (tangential line) where it is possible to measure it.
*(This tolerance is applicable to vertical equipment)
RO-EP-QA-SPC-001-01-B
Pag. 22 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1

If there is any interference from other objects in measuring the center line (basic line) of an item
of equipment, measurement shall be taken on both side of the equipment proper from two
directions 90 deg apart and the average value shall be adopted.
*(This tolerance is applicable to vertical equipment)

11.

Assembly of Accessories

Installation of platform, ladders and davit, etc which are attached directly to equipment, shall be
performed in accordance with relevant specifications, drawings and Vendor Installation
procedures or manuals.

12.

Assembly of Piping

Piping and pipe supporting structures should have been designed so that access is provided for
maintenance and removal of valves, in-line instruments, tube bundles and for operational
reasons.
If vessel/equipment flanges deviate from the standard sizes selected from teh piping classes,
the matching pipe flanges should have been ordered witht eh vessel and should have been
used for the fabrication of piping that will be connected to the vessel.
Connection piping shall be fabricated either in the shop or in the field as per the project
drawings.
Before assembly, the piping shall be cleared for welding and NDE.
The following dimensional tolerances shall be applicable, unless otherwise stated:
Lenght
<1.5m
>1.5m

Tolerance
1.5mm
3mm

Flanges shall be positioned in the same plane. The flange facings shall not deviate more than
1mm in the latter plane in the same direction.
If connection to the vessel nozzle shall be performed by welding, then the station welding
specification and the Vendor recommendations shall be followed. Where required, clamps shall
be utilised.

13.

Internals for Equipment

Assembly of internals for equipment shall be performed in accordance with relevant

specifications, drawings, Vendor Installation manuals.

14.

Removal of Lifting Lugs

Lifting lugs and tailing lugs including trunnions may be left welded to equipment unless
removal is specified in the relevant drawings or removal is requested by CONTRACTOR due to
the field conditions.
In case cutting of lugs is specified with the cutting line it shall be followed. If cutting line is not
specified minimum 50mm length of the lug from the equipment surface shall be left to avoid
damage to the equipment material. The cut surface shall be ground smooth.
All exposed parts must be then painted as per the vessel painting system stated in General
Assembling drawing. If equipment is received as completely painted, then paint will be checked
RO-EP-QA-SPC-001-01-B
Specification for Erection of Static Equipment
Valid from: June 2010, Edition: 1
Pag. 23 din 24

for any damage in the paint and required cleaining and repair painting shall be applied as per
project specifications and/or Vendor recommnedations.

15.

Documentation

The installation procedure and/or work method shall be submitted for COMPANY approval prior
to commencement of the work.
(1) Lifting inspection and Maintenance Procedure
(2) Standard Lifting Procedure and Movement Procedure
(3) Critical lifts and Movement Procedure
(4) Detailed work procedure for activities which has risk to health and safety
The procedure shall include the followings but not be limited to:
-

Organization of work with manpower plan

List of construction equipment, measuring tool and instrument

Work procedures, effective execution of the work

Sequence of work and control

Technical requirement and precautions if applicable

Calculation sheet if applicable

Scaffolding plan, where applicable

Inspection result shall be recorded and submitted to CONTRACTOR according to ITP.

The Contractor shall provide the final documentation as defined in OMV Petrom specification
for final documentation, in the quantity and in the time frame specified by the Client during the
tender phase.

RO-EP-QA-SPC-001-01-B
Pag. 24 din 24

Specification for Erection of Static Equipment

Valid from: June 2010, Edition: 1