HOISTING FACILITIES AND WEATHER PROTECTION FOR ROTATING EQUIPMENT
DEP 31.25.00.10-Gen. November 2008
DESIGN AND ENGINEERING PRACTICE
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DEP 31.25.00.10-Gen. November 2008 Page 2
PREFACE DEPs (Design and Engineering Practice) publications publications reflect the views, at the time of publication, of: Shell Global Solutions International B.V. (Shell GSI) and/or Shell International Exploration and Production B.V. (SIEP) and/or other Shell Service Companies. They are based on the experience acquired during their involvement with the design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Shell Operating Units. Where appropriate they are based on, or reference is made to, international, regional, regional, national and industry standards. The objective is to set the recommended recommended standard for good design and engineering practice applied by Shell companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by Shell GSI, in most cases under Service Agreements primarily with with Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Service Company. Consequently, three categories of users of DEPs can be distinguished: distinguished: 1)
Operating Units having a Service Agreement with Shell GSI or other Shell Service Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2)
Other parties who are authorized to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise). otherwise).
3)
Contractors/ Contractors/subcontractors subcontractors and Manufacturers/Sup Manufacturers/Suppliers pliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.
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DEP 31.25.00.10-Gen. November 2008 Page 3
TABLE OF CONTENTS 1. 1.1 1.2 1.3 1.4 1.5 1.6
INTRODUCTION ........................................................................................................4 SCOPE........................................................................................................................4 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........4 DEFINITIONS .............................................................................................................4 .............................................................................................................4 CROSS-REFERENCES .............................................................................................4 SUMMARY OF MAIN CHANGES SINCE LAST EDITION .........................................5 COMMENTS ON THIS DEP .......................................................................................5 .......................................................................................5
2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
SELECTION CRITERIA .............................................................................................6 GENERAL...................................................................................................................6 CATEGORY OF ROTATING EQUIPMENT................................................................6 CLIMATIC CONDITIONS............................................................................................7 MAINTENANCE ACTIVITIES AND STRATEGIES.....................................................7 LOCATION OF THE EQUIPMENT ................................................................... .............................................................................7 ..........7 CRANE OPERATIONAL REQUIREMENTS...............................................................8 ECONOMIC CONSIDERATIONS......................................................................... CONSIDERATIONS ...............................................................................9 ......9 OFFSHORE CONSIDERATIONS ..............................................................................9 OTHER CONSIDERATIONS ....................................................................................10 ....................................................................................10
3.
REFERENCES .........................................................................................................11 APPENDICES APPENDICES
A APPENDIX PPENDIX 1
SUMMARY SELECTION GUIDE FOR HOISTING FACILITIES .....................12
1.
INTRODUCTION
1.1
SCOPE
DEP 31.25.00.10-Gen. November 2008 Page 4
This DEP specifies requirements and gives recommendations hoisting facilities and weather protection for rotating equipment. It includes the factors to be taken into account when deciding whether or not to provide hoisting facilities and whether or not to provide weather protection. A summary selection guide is given in Appendix 1. This DEP is a revision of the DEP of the same number dated December 1999; a summary of the main changes is given in (1.5). 1.2
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufcturers/Suppliers nominated by them. This DEP is intended for use in oil refineries, chemical plants, gas plants and exploration and production facilities as well as distribution storage depots and installations. When DEPs are applied, a Management of Change (MOC) process should be implemented, this is of particular importance when existing facilities are to be modified. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic, and legal aspects. In all cases, the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this DEP as closely as possible.
1.3
DEFINITIONS The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project, or operation or maintenance of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal Principal is is the party which initiates specify the project ultimately pays for its design and construction. The Principal will generally the and technical requirements. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal. The word shall shall indicates indicates a requirement. The word should should indicates indicates a recommendation.
1.4
CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced in this DEP are listed in (4).
1.5
DEP 31.25.00.10-Gen. November 2008 Page 5
SUMMARY OF MAIN CHANGES SINCE LAST EDITION Other than editorial changes, the main changes have been as follows: Section
1.6
Change
General
Added US Customary Units; added ISO references.
2.1
First paragraph deleted, reference to Table 1 added.
2.2
For Category APIand/or 617 weight’ references deleted (these ‘size are or in Category 1, 2);3, ‘size criteria to changed weight’.
2.3
Very Cold Climates, comments about weather protection for very cold climates and severe climates added; comments about roof and side walls obstructing mobile crane access deleted (weather protection needs come before hoisting needs).
2.4
Comments about unscheduled shutdown of equipment, and permanent cranes shortening repair time added; comments about preference for mobile crane deleted (the recommendations are in Table 1).
2.5
Second, third and fourth paragraphs deleted.
2.6.1
First, third and fourth paragraphs added.
2.6.2
Reworded.
2.6.3
‘Electrically driven’ changed to ‘electrically or pneumatically (using dry instrument air) driven’; “permanent hoisting” changed to “permanent onshore hoisting”.
2.6.4
New section.
2.6.5
New section.
2.6.6
New section.
2.7
‘whenever an overhead crane and associated structures or building is considered’ changed to ‘whenever a deviation from st th th Table 1 is considered’; comments to the 1 , 4 and 5 bullets added.
2.9
New section.
References
List updated.
Table 1
‘Very Cold Climates’ and requirement for building or enclosure for same added.
COMMENTS ON THIS DEP
[email protected].. Comments on this DEP may be sent to the DEP Administrator at
[email protected] Shell staff may also post comments on this DEP on the Surface Global Network (SGN) under the Standards folder.
2.
SELECTION CRITERIA
2.1
GENERAL
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If a building or structure containing heavy equipment does not have an overhead crane installed, the roof and side walls of the building shall be removable and the area around the equipment shall allow adequate access for mobile cranes. The most important factors affecting a decision on whether to provide permanent roofing, side walls and hoisting facilities above rotating equipment, or to install the equipment in the open air are as follows: (2.2) (2.3) (2.4) (2.5) (2.6) (2.7) (2.8) (2.9)
Category of rotating equipment Climatic conditions Maintenance activities and strategies Location of the equipment Crane operational requirements Economic considerations Offshore considerations Other considerations
The recommended Hoisting and weather protection for the various equipment categories and climactic conditions are summarized in Appendix 1, Table 1. 2.2
CATEGORY OF ROTATING EQUIPMENT The following categories can be distinguished: distinguished: Category 1: 1: Multi-stage turbo machines generally in accordance with ISO 10437 (API 612), API 616 or 617, such as turbo-compressors, turbo-generators, gas-turbine driven compressors, whose power rating is greater than 5 MW (6700 hp) for low pressure applications or 10 MW (13400 hp) for high pressure applications or whose heaviest part has a “maintenance mass” greater than 2000 kg (4400 lb). Normally, the equipment is strategically planned for on-site disassembly when overhauled. As a guideline only, the following equipment is typical of this category:
•
Back pressure steam turbine with a power rating greater than 10 MW (13400 hp). Condensing or extraction steam turbine with a power rating greater than 5 MW (6700 hp). Multi-stage compressor (axially-spilt outer casing) with a power rating greater than 5 MW (6700 hp). Multi-stage compressor (barrel type) with a power rating greater than 10 MW (13400
•
hp). Industrial gas turbine with a power rating greater than 10 MW (13400 hp).
• •
•
Category 2: 2: Multi-stage turbo machines, without an installed spare, built to the same standards as Category 1 but whose power rating is not greater than 5 MW (6700 hp) for low pressure applications or 10 MW (13400 hp) for high pressure applications or whose heaviest part has a “maintenance mass” not greater than 2000 kg (4400 lb). Category 3: • •
• •
Equipment in Category 2 but having an installed spare. Turbo-compressors and turbo-generators driven by steam turbines in accordance with API 611. Reciprocating compressors in accordance with API 618. Diesel/gas-engine-driven compressors, generators, pumps having a power rating not greater than 250 kW (335 hp).
DEP 31.25.00.10-Gen. November 2008 Page 7
Category 4: Auxiliary and general-purpose equipment of types normally falling outside categories 1, 2 and 3, e.g. pumps in accordance with ISO 13709 (API 610) and fire water pumps. 2.3
CLIMATIC CONDITIONS In respect of the degree of protection required for the equipment and the maintenance area in relation to climatic conditions, the following climatic conditions can be distinguished: -
very cold climates (e.g. Canada, Alaska, Russia, China, etc), and climates w with ith high snowfall cold to moderate with periodic wind, wind, rain, frost and snow desert with periodic sand storms tropical with monsoon-type rainfall tropical and dry offshore marine - cold climate offshore marine - tropical climate
Providing a building in very cold climates significantly decreases the cost of weatherproofing, decreases the amount of required maintenance and surveillance of the weatherproofing, improves access for surveillance and maintenance of equipment, and improves overall reliability and safety. Providing weather protection in severe climates (e.g. desert, tropical, cold) decreases the time required to perform maintenance tasks, and improves safety during maintenance activities. 2.4
MAINTENANCE ACTIVITIES AND STRATEGIES For a planned overhaul or internal inspection, the necessary protection and hoisting facilities can be prepared well in advance and sufficient time is also available for restoring the unit to its original weatherproof state for outdoor use. However, experience has shown that equipment in Category 1 and 2 has a greater chance of an unscheduled shutdown, and it is not realistic to assume that time will be available to inspect and maintain neglected overhead cranes, or to arrange for mobile cranes to be made available. The type of hoisting facilities provided (e.g. mobile or permanent cranes) will influence the time required to carry out maintenance activities and thus are linked to the category of the equipment. Permanently available overhead cranes and weather protection shorten the repair time. If rotors have to be installed or removed by a mobile crane, damage to the rotors or labyrinths is more likely to occur, as all movements are less controllable. The weight of the parts to be lifted and whether equipment is to be completely stripped at site shall be taken into account in the selection of the hoisting gear. The following permanent hoisting facilities may be considered: a. b. c. d. e. f.
Electric/pneumatic overhead travelling crane. Overhead travelling crane, chain-driven with electric/pneumatic/chain hoist. Jib crane with an electric/pneumatic hoist. Hoist beam with an electric/pneumatic hoist. Hoist beam with with trolley for a chain block. Special lifting equipment such as special special hoists, jacking equipment, cradles, etc., which may for example be used for the removal/manoeuvring of hot gas generators out of gas turbine enclosures or any other special lifting device required to facilitate maintenance. g. Offshore pedestal crane. 2.5
LOCATION OF THE EQUIPMENT The location of the equipment in the plant and its accessibility for maintenance by mobile cranes shall also be considered in the selection and specification of hoisting facilities.
2.6
CRANE OPERATIONAL REQUIREMENTS
2.6.1
Crane accessibility
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If permanent cranes are not provided and hoisting will be performed by mobile crane(s), each of the pieces of rotating equipment of interest shall be the subject of a lifting study by the Engineering Contractor, to document the access requirements, crane size and rigging requirements, and any other lifting requirements for the maintenance of the equipment. The following shall be taken into account:
-
Lifting operations over live equipment should be avoided wherever possible.
-
Engine-driven mobile cranes will have restricted access to equipment when the plant is operating, due to hazardous area classification.
-
Mobile cranes or main cranes of adequate lifting capacity shall be able to access the equipment in order to lift and lay-down the major assembly or individual driver/driven equipment safely for both normal and irregular maintenance.
-
The operator of a mobile crane shall be able to see the load being lifted, even for mezzanine-mounted equipment.
-
The increased risk to personal safety and risk of equipment damage during lifting.
-
Regardless of whether permanent or mobile cranes are used, if a piece of rotating equipment requires a special lifting device(s), there shall be a purpose-built storage space for the device(s) adjacent to the rotating equipment, to ensure the lifting device(s) is not lost. Also, there shall be a truck-accessible lay-down space, where the crane can set the equipment onto a truck of suitable size, for transport to a workshop.
2.6.2
Crane availability The availability of mobile cranes at short notice (e.g. evenings, weekends, holidays, etc), and during a plant's major overhaul, shall be considered when deciding between permanent and mobile cranes.
2.6.3
Crane characteristics Where permanent onshore hoisting facilities are specified they shall be electrically or pneumatically (using dry instrument air) driven and shall have the following capabilities: a)
hoisting speed, slow
between 0.30 m/min and 0.40 m/min (1 ft/min and 1.3 ft/min), with jog facility
hoisting speed, fast
between 4.5 m/min and 5.5 m/min (14.5 ft/min f t/min and 18 ft/min)
cross-travel speed
between 8 m/min and 10 m/min (26 ft/min and 33 with jog facility
long-travel speed
between 15 m/min and 18 m/min (49 ft/min and 60 ft/min), with jog facility
a) The slow hois hoisting ting speed range shall apply for a lifting mass of 1 15 5 ton or more.
ft/min),
2.6.4
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Crane sizing Once a decision has been taken to install an overhead travelling crane, an appropriately sized crane shall be installed. Previous guidelines to install a crane ‘sized for the heaviest maintenance lift’ have not always resulted in the most suitable selection. Although a smaller crane is less convenient because it requires more disassembly of equipment for lifting, a large crane requires more structural steel and is more expensive. The crane shall be large enough to lift:
•
a radially-split compressor body, without requiring bundle removal; the casing top half (or other heavier component) of an axially-split compressor;
•
a reciprocating compressor crankcase, without requiring removal of the crankshaft;
•
an induction motor driver, without requiring disassembly;
•
•
2.6.5
the heavier of the rotor or stator of a synchronous motor (or the whole motor, if it is not much heavier than the driven equipment).
Crane controls For control of an overhead travelling crane, a remote control unit suitable for the hazardous area classification is preferred to a pendant controller (i.e. a control unit that hangs down from the crane rail on a cable).
2.6.6
Crane maintenance Overhead travelling cranes are only reliable if they are regularly inspected and maintained. If they are not protected from the elements, they will require more frequent inspection and maintenance. Therefore, when permanent cranes are installed they shall have maintenance programmes and any required certification testing entered in the maintenance management system). NOTES:
1. The pr practice actice o off scheduling scheduling the crane for inspection and maintenance maintenance just just prior to schedule scheduled d maintenance of the process equipment is often incorrect and can result in the crane not operating reliably when required for unscheduled maintenance of the process equipment. 2. Local regulations regulations shall be follow followed ed regarding frequ frequency ency of inspection and certification certification..
2.7
ECONOMIC CONSIDERATIONS A Cost Benefit Analysis Analysis for the actual site conditions should be performed whenever a deviation from Appendix 1, Table 1 is considered. Apart from the obvious factors, the analysis should consider the following: Effect on repair times and availability of equipment (if the required on-stream availability is 95 % or greater, overhead travelling crane(s) are recommended). Additional safety measures to mitigate the risk of using mobile and/or temporary lifting facilities. Effect on man-hours and manpower, both of which are higher for temporary lifts; this is probably more significant to cost and safety on an offshore facility. Crane cost recovered during construction (especially for field assembly of reciprocating compressors). Frequency of maintenance (especially for reciprocating compressors, or where multiple units are installed on the same deck). The final selection of the hoisting facilities shall be subject to the approval of the Principal.
•
•
•
•
•
•
2.8
OFFSHORE CONSIDERATIONS The requirements for hoisting equipment are more critical on an offshore facility due to the inherent space limitations. Mechanical handling aspects, including consideration of special lifting/storage containers for offshore use, shall be included as an integral part of a topsides layout and the structural and piping design to ensure adequate access by personnel and mechanical handling equipment. In particular, particular, piping, cable trays, etc., shall be routed so that they do not need to be removed to gain access to equipment requiring maintenance.
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Although equipment installation and maintenance is the main objective of mechanical handling, good layout and design of structural steel and piping within an equipment package can provide a significant contribution to the success of overall platform design and subsequent operation. The relatively high cost and safety risk of installing temporary lifting facilities (including scaffolding) on an offshore platform should be taken into account as part of total life-cycle cost analyses. A permanent facility may provide the lowest total cost option and may be integrated with the equipment package or may be part of the platform structural design. Pedestal cranes on offshore platforms platforms shall be arranged and designed to access all equipment on the top deck. Also, hatches should be utilised to enable the crane to access equipment on lower decks wherever possible. In particular, it is of great benefit to be able to use the cranes to lift seawater and firewater pumps on fixed installations and vertical cargo/ water pumps on Floating Production Storage and Offtakes (FPSOs). Adequate areas shall be provided to enable equipment to be laid down while maintenance activities proceed. 2.9
OTHER CONSIDERATIONS There are other factors affecting a decision on whether to provide a partial or full building or structure, or enclosure for rotating equipment, which will affect the approach to hoisting the equipment. These include: • • • • •
Considerations for fire or blast protection. Considerations for falling object protection. Considerations for near-field or far-field noise reduction. Considerations for mitigation of hot surface risk (e.g. gas turbine hot surfaces). Considerations for hazardous area segregation.
3.
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REFERENCES In this DEP, reference is made to the following publications: NOTES:
1. Unless specifically designated by date, date, the la latest test edition of each publication shall be used, together with any amendments/supplements/revisions amendments/supplements/revisions thereto. 2. The DEPs and most referenced referenced external external standards ar are e available to Shell staff on the S SWW WW (Shell Wide Web) at http://sww.shell.com/standards/. http://sww.shell.com/standards/.
AMERICAN STANDARDS STANDARDS Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries
API Std 610
General-purpose steam turbines for Petroleum, Petrochemical and Natural Gas Industries
API Std 611
Petroleum, Petrochemical and Natural Gas Industries – Steam Turbines – Special Purpose Applications
API Std 612
Gas Turbines for the Petroleum, Chemical, and Gas Industry Services
API Std 616
Axial and Centrifugal Compressors and Expander-compressors for f or
API Std 617
Petroleum, Chemical, and Gas Industry Services Reciprocating compressors for Petroleum, Chemical, and Gas Industry Services
API Std 618
Issued by: American Petroleum Petroleum Institute Publications and Distribution Section 2101 L Street Northwest Washington DC 20037 USA
INTERNATIONAL STANDARDS Petroleum, Petrochemical and Natural Gas Industries – Steam Turbines – Special Purpose Applications
ISO 10437
Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas
ISO 13709
Industries Issued by: International Organisation for Standardisation ISO Central Secretariat 1, ch. de la Voie-Creuse Case Postale 56 CH-1211 Geneva 20 Switzerland Copies can also be obtained from national standards organizations.
