Method Statement For General Pumps

Method Statement For General Pumps

List of Contents

1. SCOPE OF WORKS

This Scope of Works describes the company system installation & testing of various types of pumps it also establishes the associated responsibilities.

• References

• ISO 9001-2008 CL 7.5.1
• ASME B16 – Pipe Flanges And Flanged Fittings
• UL 448 Pumps for Fire Protection Service
• NEMA-G for motor 15 HP and above
• Manufacturer standard for 15 HP and below motor
• Project specifications Division 21, “Electric-Drive, Centrifugal Fire Pumps & Diesel-Drive, Centrifugal Fire Pumps” for fire pumps, pressure-maintenance pumps, and fire-pump controllers.
• Other relevant codes and standards.
• AWWA C 151 & C111
• NFPA-20

• Responsibilities

• Study department shall select the pump confirming to Division 21 of project specification and submit the technical data, after obtaining approval procurement process shall follow per project quality plan Para 5.
• Site engineer shall be responsible for execution of installation and commissioning.
• Site Mechanical engineer shall have an overall responsibility for execution and monitoring of this procedure and approved manufacturer recommendation.
• QC inspector shall carry out inspection related to this activity in coordination with client inspection team.
• Material receiving inspection shall be performed by QC Inspector and verify the documents as per technical submittal.

• Procedure

• Pump skid, pump, driver, auxiliary piping and other components are free from any physical damage.
• Loose components and materials that were shipped separately match the packing lists and have corrosion resistance metal tags.
• Vendor shall provide the purchaser with the instructions necessary to preserve the integrity of the storage preparation after equipment arrives at the job site and before start-up.
• Nameplate stampings (in units consistent with the data sheet). & In addition to being stamped on nameplate, pump serial number shall be plainly & permanently marked on pump casing.
• Rotation arrows shall be cast in or attached to each major item of rotating equipment at a readily visible location.
• Pump skid’s general arrangement conforms to the Pump P&ID.
• Castings are sound & generally free from porosity, hot tears, shrink holes, blow holes, cracks, scale, blisters, & similar injurious defects per visual requirements of MSS-SP-55, Mold-parting fins & remains of gates and risers shall be chipped, filed or ground flush. Chaplets in pressure castings shall be held to a minimum & shall be clean, corrosion-free with composition compatible with the casting. Chaplets shall not be used in impeller castings.
• For fabricated steel casings and nozzle heads, flanges shall be as per ASME B 16.1.
• Gasket contact surface shall not have mechanical or corrosion damage.
• All vent and drains shall be as per IFC and in accordance with AWWA c-512.
• Typical Requirement – Exposed shafts and shaft couplings shall be wrapped with waterproof, moldable waxed cloth or volatile corrosion inhibitor paper. The seams shall be sealed with oil proof adhesive tape.
• Related Rigging & Lifting of equipment follows manufacturer’s instruction manual.
• All piping components are installed in their respective locations as shown in the P&ID, (i.e.: piping, removable pipe spools, valves, vents, drains, spectacle plates, blinds, flange spacers, etc.
• All in-line equipment & Instruments are installed in their respective locations per P&ID. (i.e.: Strainer,  straightening vanes, flow meter, orifice fitting, Pressure Indicators, Temperature indicators, etc)
• Discharge and Suction piping are stenciled with the following:

a. Flow directional arrows and fluid service

b. Line designation number, size, class and specification

• Support and Support spacing of inlet and outlet piping, conforms to the Support details in their respective IFC drawings.
• Pipe inlet and outlet spools are tested.
• Pipe shall be in full contact with the supports.  Shims shall be provided as required.
• Pressure gages installed are of the same range as shown in the P&ID.
• Flow direction of Control valves, check and globe valves (where applicable) follow the process flow direction.
• Final cold alignment is to manufacturer’s tolerance.
• Lifting equipment was tested by safety officer.
• External coating on piping is complete and conforms to the project coating requirements.
• Package base plates are drain-gutter type, with one or more drain connections.
• The base plates are provided with lifting lugs for at least a four-point lift.

Mounting Plate Installation and Leveling for Pumps

• For all pumps, the base plate pads shall be drilled.
• The Maximum allowable number of shims under any equipment support foot is five.
• All base plates for permanent installation in onshore facilities shall be grouted.
• The vendor shall commercially sand blast, in accordance with SSPC SP 6, all grout contact surfaces of the base plate, and coat those surfaces with inorganic zinc silicate in preparation for epoxy grouting.
• The equipment base plate mounting surfaces are to be leveled longitudinally and transversely to within 400 micrometers per meter (0.005 inches per foot)

Final Alignment of Pump & Driver

• Soft foot check is done with piping disconnected on each equipment foot. Note: Maximum permissible movement is 0.05 millimeter (2 mils) at each foot, or as specified by Manufacturer.
• Alignment is within the Manufacturer’s tolerances before Piping and conduit are attached.  Pipe strain checks are per the manufacturer’s procedures.  Alignment is within the Manufacturer’s tolerances after pipe & conduit attached.
• Final Alignment was performed after Hydro test of piping and

     completion & acceptance of piping supports.

Note: After final piping bolt-up, final shaft alignment shall be verified and all machinery shall be hand rotated to ensure that neither binding nor case distortion has occurred during piping installation.

Piping spring hanger & spring support stops shall be installed during final shaft alignment checks.

• RIW B-QF-057
• Checklist B-QF-017, 23 & 159
• Inspection & test plan AV-ITP-M-002

5.0   Field Quality Control

1. Inspection and Testing

Quality shall be maintained by ensuring the systematic implementation of this procedure and ensure that necessary quality records are generated as

appended formats to this procedure and ITP for Pumps Installation.

• Cleaning

      Clean the Area and remove dirt and debris as work

      progresses.

6.0   Sub-Contractors / Suppliers

7.0   Storage and Handling

  All materials stored on site are monitored by qualified storekeepers that 

  ensure they are in good conditions and safe from environmental

  conditions that might endanger them ( e.g. moisture, heat , dust, friction ) .

  Materials shall be stocked and stored in a safe confined space to prevent

  from deterioration and damage, the delivered material shall be checked to

  conform to the project specifications. As for the handling, workers are

  instructed to carefully treat all equipment and materials with care and

  engineers as well as foremen monitor the material  handling process for

  extra assurance.

8.0   Health and Safety

     Health and Safety International Standards are always implemented on site

    through our experienced health and safety officers and engineers so as to

    prevent danger and maintained safety hazards that might lead to serious

    injuries, it is compulsory to use an approved Personal Protective

    Equipment.

9.0   Environmental Requirements

    All construction related works shall be executed to the highest levels of 

    quality while at the same time avoiding any operation that might 

    endanger the environment . Therefore, materials are carefully chosen to

    be as environment friendly as possible. Any hazardous material is

    carefully stored as mentioned earlier and scrap materials are carefully

    and safely disposed off.

10.0   Attachment

    a. Risk Assessment Sheet