Method Statement for Equipment Preservation_Rev 0

August 10, 2017 | Author: Rachel Flores | Category: Construction Management, Pipe (Fluid Conveyance), Refractory, Hvac, Bearing (Mechanical)
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NGHI SON REFINERY AND PETROCHEMICAL PROJECT Document Title : METHOD STATEMENT FOR SITE PRESERVATIONS WORK FOR MECHANICAL EQUIPMENT

Contractor Doc. No: VV3160-001-C-019

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METHOD STATEMENT FOR WEC’S PRESERVATIONS WORK FOR MECHANICAL EQUIPMENT DOCUMENT CLASS: X

Issue Purpose

0

04 - Nov - 2014

Issue for Approval

Rev.

Date

Description

For Approval

Prepared by

Checked by

Responsible Company

Prepared by:

Checked by:

WEC

Nava

Nava

Approved by Approved by:

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NGHI SON REFINERY AND PETROCHEMICAL PROJECT Document Title : METHOD STATEMENT FOR SITE PRESERVATIONS WORK FOR MECHANICAL EQUIPMENT

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TABLE OF CONTENTS 1.

SCOPE :

3

2.

PURPOSE :

3

3.

REFERENCE DOCUMENTS :

3Error!

Bookmark not defined. 4.

ORGANIZATION AND RESPONSIBILITIES :

Error!

Bookmark not defined.3 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5.

Preservation Manager Field Engineering Manager Material Manager Area construction Manager Discipline Engineer Quality Control Manager Subcontractors

4 4 4 4 4 4 4

PROCEDURE

5

5.1 General Requirement 5.2 General Information of Preservation Materials (Rust Preventive) 5.3 Treatment of Piping Connections for Equipment 5.4-5.10 Protection of Mechanical Equipment 5.11-5.16Protection of Electrical Equipment and Materials 5.17 Protection of Instrument Equipment and Materials 5.18-5.21Protection of Piping Materials 5.22 Protection of Skid Mounted Package Units 5.23 Protection of Steel Structure 5.10 Other Items Requiring Special Treatment 6.

5 6 7 7 15 20 21 23 24

24

ATTACHMENT A-1 A-3 A-4 A-2

International Symbols Inspection & Maintenance Record Card Typical Properties of Rust Preventive Compounds Organization Chart for Preservation Work

26 27 28 29

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1. SCOPE The scope covers all works associated with the protection, cleaning, lubricating, inspecting and reserving of materials, in suitable storage conditions according to Vendor’s and/ or Licenser`s recommendation, from the job site receipt date until materials and equipment are installed and commissioned, and the requirements specified in this procedure shall be applied for all materials and equipment which will be installed in the plant facilities. 2. PURPOSE This Project procedure is to be used to define the requirements for Preservation and Maintenance of Equipment and Material at the Nghi son refinery and petrochemical Project site and to ensure that equipment or materials are adequately protected whilst in storage. 3. REFERENCE DOCUMENTS 3550-8710-SP-0001:

Construction Execution Procedure

S-000-1635-0001V:

Construction Material Control Procedure

S-000-13A0-0002V:

Specification for Rust Prevention

4. ORGANIZATION AND RESPONSIBILITIES The organization of Site Working Group in each Zone for preservation work fundamental is mentioned in to the Attachment-4 and the person's in charge role were specified. WEC shall be totally responsible for implementing preservation and maintenance activities, strictly in accordance with vendor, supplier or manufacturer recommendations, or where applicable, this procedure, once the MIR has been signed / cleared through Client. WEC’s responsibility is from the time of site receipt of free issue materials and equipment through to mechanical completion and turnover of installed materials and equipment to the Client. An each Zone is managing the preservation activities independently, respectively. Each Zone shall assigned the require staff managing of preservation activities seems satisfactorily.

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4.1 Preservation Manager Responsible for ensuring the implementation of this procedure and that equipment is checked and protected in strict accordance with Vendor and/ or Licenser requirements, JGCS specifications, and any associated project specific procedures. 4.2 Field Engineering Manager Responsible for providing technical assistance to Discipline Engineers to carry out adequate preservation 4.3 Material Manager Responsible for monitoring of maintenance procedures and associated records while the materials/ equipment is under his control. This responsibility shall pass to the Area Construction Manager when the materials/ equipment issued to site. 4.4 Area Construction Manager Shall take charge after handover from Material Manager to ensure to meet the preservation requirements during construction/ installation, pre-commissioning until handover to Commissioning Manager. 4.5 Discipline Engineer Shall carry out actual preservation activities, ensure regular surveillance of activities in the field and off-field facilities, and generate surveillance reports in order to document such activities using log sheets. Shall make tag wise check sheet/ log sheet. 4.6 Quality Control Manager Overall responsible to maintain the approved system and ensure all the material, equipment and package managements control in all phase, as per the requirement in this procedure. 4.7 Subcontractors Shall responsible for executing actual preservation work at site, providing the required material and facilities for preservation work, preparing equipment record cards (Log Sheet) for all preservation required items.

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5. PROCEDURE 5.1 GENERAL REQUIREMENT 5.1.1

This Common Procedure specifies the minimum and general required procedure to be used to protect materials and equipment from rust and deterioration during storage and after unpacking at the job site and until the equipment will be commissioned under the circumstances of the jobsite. An each Zone shall prepare the detail procedures for their preservation work.

5.1.2

Additional protective measures specified by the Vendor and/ or Licenser, if any, shall be performed. In the event of conflict between the Vendor’s and/ or Licenser`s requirements and this procedure, Vendor’s and/ or Licenser`s requirement must be followed subject to acceptance by Field Engineering Manager.

5.1.3

After unpacking the materials and the equipment, preventive maintenance and periodical inspections and services shall be performed to monitor the condition of the items and renew or maintain the protective systems in accordance with this procedure or the procedure prepared by the Vendors and/ or Licensers.

5.1.4

An equipment record card (Log Sheet: refer to Attachment-2) shall accompany the related equipment when it is issued to a Subcontractor, which shall also specify maintenance care and service required to be carried out by the site working group and Subcontractor until commissioning.

5.1.5

The preservation requirements defined in the Preservation Log Sheet takes precedence over the requirements listed in this procedure.

5.1.6

The Area Construction Manager with support from the Discipline Engineers shall ensure that the site working group carries out, maintains and documents all equipment protection and preservation requirements.

5.1.7

Handling of the equipment and connecting up, during the construction period, may reduce the effectiveness of the original protection. The Area Construction Manager, with support from the Discipline Engineers, shall ensure that the preservation and maintenance schedule is further reviewed and documented and its requirements implemented through the remaining construction period.

5.1.8

A suitable team appointed to warehousing and to conservation of goods shall be engaged in checking and maintain preservation according to the specific measures recommended by Vendor and/ or Licenser and exercising a normal good judgment in protection of materials. Page 5 of 29

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5.2 GENERAL INFORMATION OF PRESERVATION MATERIALS (Rust Preventive) 5.2.1

The rust preventive materials referred to this procedure shall be compounds specified by U.S Military Specifications or equal. In the event of conflict between the rust preventive materials specified by Vendor and/ or Licenser and this procedure, the materials used must be acceptable by Field Engineering Manager.

5.2.2

If surfaces need to be cleaned before using rust preventive materials, mineral spirits such as VARSOL or any Standard solvent shall be used for cleaning surfaces prior to applying the rust preventive materials.

5.2.3

Type of Rust Preventive Materials

Type

Specification No.

Description

MIL P-2 or Equal

MIL-C-16173 GR.2

Thin Film Preservative, Soft Film

MIL P-10 or Equal

MIL-L-21260 GR.30

Engine Preservative Oil

MIL P-18 or Equal

MIL-L-22110

Vapor Phase Inhibitor

MIL P-19 or Equal

MIL-C-16173 GR. 4

Thin Film Preservative, Transparent, Non Tacky

MIL P-20 or Equal

MIL-P-46002

Lubricating Oil, Contact and Volatile Corrosion Inhibitor Treated

Refer to Attachment-3 “Recommended Rust Preventive Materials” 1. Removal of Rust Preventive Materials (a) Rust preventive materials are not normally removed before operation of equipment, but if they need to be removed, the following removers shall be used MIL P-2, P-10, P-19, P20

:

Petroleum Solvent

0MIL P-18

:

Water or Alcohol Page 6 of 29

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(b) Rust preventive materials applied on beveled weld ends shall be removed before welding, except a type of rust preventive materials such as Deoxy Aluminite (Taset Silver or equal) 5.3 TREATMENT OF PIPING CONNECTIONS FOR EQUIPMENT 5.3.1

Remove flange covers from prefabricated piping, valves, vessels, exchangers and other equipment.

5.3.2

Clean flange faces with solvent and coat them with MIL P-19 or equal.

5.3.3

Replace flange covers, attaching them securely, and renew those if poor condition.

5.3.4

Any open threaded connections shall be plugged or capped after coating the threads with oil MIL P-20 or equal.

5.4 PROTECTION OF MECHANICAL EQUIPMENT 5.4.1

Unpack and check equipment and accessories received, against the requisition and packing lists. Ensure equipment is in good condition, and also protected against rusting/ deterioration/ dust accumulation. Protect piping connections and store.

5.4.2

Protect piping connections in accordance with paragraph 5.3.

5.4.3

In connecting equipment nozzles with piping, shop installed rubber gasket and thin spectacle blind plates.“Dimension of Insert Plate for Preservation” shall remain un-removed or site fabricated sheet gasket shall be installed to isolate the equipment from other equipment and piping system where applicable, so that independent periodic preservation shall be applied to the equipment.

5.4.4

Protective preservation for skid mounted auxiliary equipment and materials e.g. lube oil console for forced lube oil system shall be per paragraph 5.8.

5.4.5

Where feasible, mechanical equipment needing to seal with nitrogen gas at the job site according to the Vendor’s procedure shall be purged with a quantity of dry nitrogen gas equal to 1 to 3 times of the casing volume to be protected prior to establishing the normal gas pressurization level specified in the Vendor’s procedure. Periodical check and maintenance of positive pressure shall be provided.

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5.5 CENTRIFUGAL PUMPS, BLOWERS, GEAR CASES AND OTHER MECHANICAL EQUIPMENT NOT SPECIFIED IN PARAGRAPH THROUGH 5.11 5.5.1

Preventive Maintenance

5.5.1.1 Required preservation preventive treatment will be performed at Vendor shop. Do not open their package unless otherwise instructed by Site representative except checking the conditions of the protective measures after delivery at site. 5.5.1.2 When the equipment is unpacked for installation on its foundation or opened for connecting the piping to the flanged nozzles, it shall be necessary for preventive maintenance instructed by Site representative. 5.5.1.3 The following preventive maintenance shall be performed at site. a. Store coupling with spacer, oiler and orifice plates at connecting flanges in warehouse if removal from the equipment is required. b. Blind it off from the piping using gaskets on nozzle side of the blinds. Do not remove the blinds (insert plates) or insert sheet gasket until after the lines have been cleaned during pre-commissioning. c. Caps or plugs shall not be removed from threaded connections until connecting piping has been cleaned. 5.5.2

Periodic Service

5.5.2.1 Once Weekly a. Check oil level for bearing boxes, gear cases and all oil sumps, and add them with MIL P-20 or equal as necessary. b. Turn shafts 5-1/4 revolutions. Use appropriate tools recommended by working group. Do not use tools that will grip or mar the shafts of equipment. c. After rotation they should come to rest on a different part of the shaft circumference, and checks should be made in the casing(s) for water upon each weekly rotation. 5.5.2.2 Every Two Weeks d. If rust preventative becomes dirty or contaminated, drain flush with solvent and fill with MIL P-20 or equal. 5.5.2.3 Every Four Weeks e. Inspect all exterior machined surfaces and recoat the surfaces with MIL P-19 or equal as necessary. Page 8 of 29

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Inspect lube oil and cooling water systems and consoles to ensure that coatings, etc., are intact.

g. Do not open, leave system under nitrogen seal and follow Vendor’s recommendation, if it has been applied at their shop. 5.5.2.4 Every Three Months h. Spray pump, blower casings, with MIL P-20 or equal through nozzles such as casing drain and vent. 5.6 RECIPROCATING PUMPS 5.6.1

Preventive Maintenance

5.6.1.1 Required preservation preventive treatment will be performed at Vendor shop. Do not open their package unless otherwise instructed by Site representative except checking the conditions of the protective measures after delivery at site. 5.6.1.2 When the equipment is unpacked for installation on its foundation or opened for connecting the piping to the flanged nozzles, it shall be necessary for preventive maintenance instructed by Site representative. 5.6.1.3 The following preventive maintenance shall be performed at site. a. Blind it off from the piping using gaskets on nozzle side of the blinds. Do not remove the blinds (insert plates) until after the lines have been cleaned during pre-commissioning. 5.6.2

Periodical Services

5.6.2.1 Once Weekly a. Check oil level for crank-cases of proportioning, metering and power pumps and add them with MIL P-20 or equal as necessary. b. Turn shafts or proportioning, metering and power pumps 5-1/4 revolutions. Do not use tools that will grip or mar shaft or equipment. c. Check stroke adjustment mechanism works smoothly. 5.6.2.2 Every Two Weeks d. If rust preventative becomes dirty or contaminated, drain, flush with solvent and fill with MIL P-20 or equal. Page 9 of 29

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5.6.2.3 Every Four Weeks e. Inspect all exterior machined surfaces and recoat surfaces with MIL P-19 or equal as necessary. f.

Spray liquid cylinders and valve chambers with MIL P-20 or equal.

5.6.2.4 Every Three Months g. Inspect painted external surfaces of equipment and repair them as necessary. 5.7 CENTRIFUGAL COMPRESSORS AND THEIR TURBINE DRIVERS 5.7.1

Preventive Maintenance

5.7.1.1 Required preservation preventive treatment will be performed at Vendor shop. Do not open their package unless otherwise instructed by Site representative except checking the conditions of the protective measures after delivery at site. 5.7.1.2 When the equipment is unpacked for installation on its foundation or opened for connecting the piping to the flanged nozzles or assembling the internal parts, it shall be necessary for preventive maintenance instructed by Site representative. 5.7.1.3 The following preventive maintenance shall be performed at site. 5.7.1.4 Store spare rotor in container if any, small parts and other spare parts in covered warehouse in accordance with Vendor’s recommendations. 5.7.1.5 Blind it off from the piping using gaskets on nozzle side of the blinds (insert plates). Do not remove blinds or install sheet gasket until after the lines have been cleaned. 5.7.2

Periodical Service

5.7.2.1 Once Weekly a. Check internal pressure for the equipment sealing with nitrogen blanketing system during storage, and maintain the pressure as required by the Vendor’s procedure. Change nitrogen bottle for nitrogen blanketing system when necessary. b. Prior to rotating shaft, spray bearings with MIL P-20 or equal. c. Turn shafts of compressors, lube oil pumps and drivers 5-1/4 revolutions. 5.7.2.2 Every Four Weeks d. Inspect all exterior machined surfaces and recoat the surfaces with MIL. P-19 or equal as necessary. Page 10 of 29

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e. With regard to lube oil and cooling water systems and consoles, inspections shall be conducted to ensure that coatings, etc., shall be protected and serviced in accordance with the requirements as outlined in this procedure or as specified by Vendor. f.

Do not open, leave system under nitrogen seal and follow Vendor’s recommendations, if it has been applied at their shop.

5.7.2.3 Every Three Months g. Inspect painted external surfaces of equipment and repair them as required.

5.8 RECIPROCATING COMPRESSORS A preventive maintenance and periodical services for this class of equipment shall be in accordance with the following procedures unless otherwise specified by the Vendor.

5.8.1

Preventive Maintenance

5.8.1.1 Required preservation preventive treatment will be performed at Vendor shop. Do not open their package unless otherwise instructed by Site representative except checking the conditions of the protective measures after delivery at site. 5.8.1.2 When the equipment is unpacked for installation on its foundation or opened for connecting the piping to the flanged nozzles or assembling the internal parts, it shall be necessary for preventive maintenance instructed by Site representative. 5.8.1.3 The following preventive maintenance shall be performed at site. a. Provide a nitrogen blanketing system, if nitrogen seal at the jobsite is requested by working group's recommended procedure instead of placing the bags filled with MIL P-18 or equal into the cylinders and crankcases. b. Blind it off from the piping using gaskets on nozzle side of the blinds (insert plates). Do not remove the blinds or install sheet gasket until after the lines have been cleaned. c. All components received, such as valves, piston rods, packing, etc., which are packed separately shall be stored indoors. Page 11 of 29

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d. Do not install piston, rings, or rod packing until the compressor is serviced for initial operation. 5.8.2

Periodical Services

5.8.2.1 Once Weekly a. Check oil level for frame oil sump, and add it with MIL P-10 or equal as necessary. b. Turn crank shaft 5-1/4 revolutions by hand lever, supplied by the working group. c. Change nitrogen bottle for nitrogen blanketing system when necessary. 5.8.2.2 Every Two Weeks d. a) Check crankcases and add MIL P-10 or equal to standard oil level. e. If rust preventive becomes dirty or contaminated, drain crankcases, flush with solvent and fill with MIL P-10 or equal. 5.8.2.3 Every Four Weeks f.

Inspect all exterior machined surfaces and recoat the surfaces with MIL P-19 or equal as necessary.

g. With regard to lube oil and cooling water systems and consoles, inspections shall be conducted to ensure that coatings, etc., are intact. Pumps, drivers, etc., shall be protected and serviced in accordance with the requirements as outlined in this procedure or as specified by Vendor. 5.8.2.4 Every Three Months h. Inspect painted external surfaces of equipment and repair them as necessary. 5.9 HOISTS AND MISCELLANEOUS 5.9.1

Preventive Maintenance

5.9.1.1 Required preservation preventive treatment will be performed at Vendor shop. Do not open their package unless otherwise instructed by Site representative except checking the conditions of the protective measures after delivery at site. Page 12 of 29

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5.9.1.2 When the equipment is unpacked for installation on its foundation, it shall be necessary for preventive maintenance instructed by Site representative. 5.9.2

Periodical Services

5.9.2.1 Once Weekly a. Check oil level for oil lubricated bearing boxes, and add them as required with MIL P-20 or equal. b. Turn shafts of oil lubricated equipment 5-1/4 revolutions. Do not use tools that will grip or mar the shafts or equipment. 5.9.2.2 Every Two Weeks c. Check Oil lubricated bearing boxes, and add MIL P-20 or equal to the proper oil level. d. If rust preventive becomes dirty or contaminated, drain, flush with solvent and fill with MIL P-20 or equal. 5.9.2.3 Every Four Weeks e. Inspect all exterior machined surfaces and recoat them with MIL P-19 or equal as necessary. f.

Inspect external surface of rollers chains, wire rope and chain hoists and apply with MIL P-10 or equal as necessary.

g. Inspect exterior surface of sheaves and sprockets and apply grease as required. 5.9.2.4 Every Three Months h. Inspect painted external surfaces of equipment and repair them as necessary. 5.10 PRESSURE VESSEL AND STORAGE TANKS Pressure Vessels, Heat Exchangers, Air Cooled Exchangers, Storage Tanks and Other Equipment. 5.10.1 Preventive Maintenance 5.10.1.1The following preventive maintenance shall be performed as required after checking the conditions of the protective measures which have been provided by the Vendor at shop when the equipment is unpacked for installation on its foundation or opened for connecting the piping to the flanged nozzles or assembling the internal parts. Page 13 of 29

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5.10.1.2Remove porous bags filled with desiccant which have been put into equipment at shop completely, when the interior of the equipment is inspected. 5.10.1.3To minimize a generation of dew condensation on internal surfaces of equipment, minimize opening of flanged nozzles or manholes. 5.10.1.4Care must be taken in the storage of heat exchangers to ensure their stability, especially for double tube exchangers. Flange faces inspected, cleaned with solvent then coated with MIL P-19 or equal if necessary and flange covers replaced or renewed if necessary. 5.10.1.5For equipment such as shell/ tube exchangers and air cooled exchangers for which vapour phase inhibitor (MIL. P-18 or equal) have been applied on internal surface of equipment or nitrogen gas has been filled, shop installed rubber gaskets and thin blind plates shall remain un removed or site fabricated sheet gasket shall be installed, where applicable, even after connecting with pipes to isolate them from other equipment so that independent periodic preservation shall be applied to them. 5.10.1.6Machinery parts of air cooled exchangers require the same protective procedure as mechanical equipment, see paragraph 5.5 5.10.1.7For trays, if shipped separate from column and extended outdoor storage is anticipated, apply MIL P-10 or equal and renew polyethylene sheets as necessary. 5.10.2 Periodical Services 5.10.2.1Every Two Weeks a. For nitrogen sealed equipment for storage, periodical check at two week intervals of filled nitrogen pressure shall be made and add nitrogen gas, if necessary to maintain suitable pressure. 5.10.2.2Every Three Months b. Inspect painted external surfaces of equipment and repair them as necessary. c. Inspect coated bevel weld ends of equipment, repair it with a preservative MIL P-19 or equal. If equipment has been applied with a vapor phase inhibitor, MIL P-18 or equal at the working group shop, spray MIL P-18 or equal additionally into the equipment through the proper nozzles, when the equipment has been passed for one year after shipment from the shop.

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5.11 PROTECTION OF ELECTRICAL EQUIPMENT AND MATERIALS Unpack and check equipment and accessories received against requisitions and packing lists. Clearly mark and identify all items with project service and reference numbers. Identify and mark all loose items and store with equipment package until the equipment is required for installation. Store, as required by Vendor, equipment containing electronic components in dry and air conditioned place where condensation cannot occur. Care shall be taken not to exceed the storage temperature specified by Vendor. Printed circuit boards shall not be taken out of their protective antistatic covers. Electrical equipment shall not be oiled. 5.12 MOTORS 5.12.1 Preventive Maintenance 5.12.1.1Upon receipt of motors and generators at the work site, the insulation resistance of the stator winding is to be measured with a “MEGER” tester and recorded along with temperature and weather condition at the time of reading. Testing shall be done in accordance with project testing specification. 5.12.1.2Remove any lubricators from oil lubricated bearings and install plugs. Fill bearing boxes and gear cases with MIL P-20 or equal, at least to the level of the bottom of the shaft. Turn the shaft of the motors several revolutions to apply the protective film uniformly to the entire shaft and bearings. If the unit has grease lubricated bearings, the bearings do not require any further lubrication until the time prior to start-up. 5.12.1.3Electrical accessories which can be damaged by moisture, such as magnetos, injection nozzles and alternators, shall be stored in a dry, warm place, where condensation due to humidity will not occur. 5.12.1.4All openings such as terminal boxes and ventilation openings shall be sealed to prevent dust accumulation. 5.12.1.5Clean shaft couplings and exposed machined surfaces with solvent and coat them with 5.12.1.6MIL P-19 or equal as necessary. 5.12.1.7If space heaters are furnished, they shall be connected to a suitable continuous supply of power as soon as practicable after unpacking and placing of the equipment on its foundation, unless otherwise recommended by Vendor, and if this meets the requirement under their guarantee 5.12.1.8Do not coat or oil commutators of DC Units. Page 15 of 29

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5.12.2 Periodical Services 5.12.2.1Once Weekly a. Check oil level for oil lubricated bearing boxes, and gear cases, and add to them with MIL P-20 or equal as necessary. b. Turn shafts 5-1/4 revolutions. Do not use tools that will grip or mar the shafts. 5.12.2.2Every Two Weeks c. Check oil lubricated bearing boxes and add MIL P-20 or equal to the proper oil level. d. If rust preventative becomes dirty or contaminated, drain, flush with solvent and fill with MIL P-20 or equal. e. If unit has a drain plug, remove, drain any condensate and replace plug. 5.12.2.3 Every four weeks f.

Inspect exterior machined surfaces, and recoat the surfaces with MIL P-19 or equal as necessary

5.12.2.4Every Two months g. Measure and record winding insulation resistance values of motors rated 400 volts and higher and all generators. Record temperature and weather conditions at the time of reading. h. If resistance is low and cables have been connected, disconnect the cables and repeat the measurements. If resistance reading of winding insulation only is lower than the specified minimum acceptable value of insulation resistance in the project test specification dry out leads in unit’s terminal box by removing the cover and exposing to dry, clear weather, or by placing an electric lamp or heater in the terminal box. i.

If this does not result in acceptable insulation resistance values, dry out the windings by an approved method until acceptable values are obtained.

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5.12.2.5Before Start Up j.

Prior to start-up, measure and record winding insulation resistance values of all motors.Record temperature and weather conditions at the time of reading. If resistance is low, proceed as above “Note” in Preventive Maintenance (5.11)

k. Except “sealed for life” bearings, if grease lubricated units are onsite more than year from the date of shipment from the factory without having been operated, inspect the bearing grease. If there has been any deterioration of the lubricating properties of the grease, clean it out and repack the bearings in accordance with manufacture’s recommendations. l.

Clean Commutators of DC Units, but do not apply any oil or Vaseline. Measure and record insulation resistance values of all units with cables connected. If readings are low, dry out unit by approved method before starting.

m. Remove any sealing from ventilation openings.

5.13 TRANSFORMERS 5.13.1 Inspect transformers tank and radiators for dents, and any signs of oil leakage as soon as transformer arrives on the job site. Any paint damage shall be repaired before outdoor storage. 5.13.2 Transformers intended for outdoor installation may be stored outdoors without protective covering. All other units shall be stored indoors. 5.13.3 Drums of insulating liquid may be stored outdoors without protective covering, if laid on their side with the bungs horizontal. 5.13.4 Do not leave drums in upright position.

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5.13.5 Insulators. Remove protective covers from insulators, or encase if packed separately, and inspect thoroughly for cracks or chips. Replace protective covers, or repack in shipping crates to prevent damage in storage. 5.13.6 Every three months, measure and record insulation resistance of transformer windings in accordance with project testing specification. 5.13.7 If transformer is shipped with main tank filled with insulating liquid, except for expansion space, measure and record level and ambient temperature when unit arrives on site and every three months thereafter. If level falls, search for leaks and add insulating liquid to keep level within tolerances. 5.13.8 If transformer is shipped with main tank filled with insulating liquid, and blanketed with gas under pressure, or filled with gas under pressure, measure and record gas pressure and ambient temperature when unit arrives on the job site, and every three months thereafter. If pressure falls, search for leaks; add gas to keep pressure within tolerance. 5.13.9 If transformers are filled with silica gel absorbers, they shall be inspected weekly and reinhibited as necessary. 5.13.10 Equipment received at the job site filled with insulation oil should be sampled at the job site and crackle tested in accordance with Vendor’s instruction. 5.13.11 All drums of insulating oil for topping or filling of equipment should be similarly tested.

5.14 SWITCHGEAR, STARTERS AND CONTROL EQUIPMENT 5.14.1 Indoor storage of switchgear, starters and control equipment is required. These shall be stored in a dry warm place where condensation due to humidity will not occur.There should be good ventilation within the storage area(s).In humid conditions, it may be necessary to remove the equipment from shipping cases to permit ventilation and to avoid mildew. Air conditioned storage should be arranged if individual equipment specifications demand.

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5.14.2 Free standing metal enclosed equipment, such as switchgear, motor control centres shall be stored in an upright position. 5.14.3 If oil immersed, circuit breakers are shipped dry and cannot be stored indoors, they shall be filled with insulating liquid as soon as received on work site. 5.14.4 After assembling, check insulation resistance of main buses. 5.14.5 When equipment is supplied with space heaters, space heaters shall be energized from continuous source of power once weather proof packing has been removed or damaged. 5.15 CABLES 5.15.1 All cable reels shall be shipped with wood lagging to prevent damage during shipment and storage. 5.15.2 Cable reels shall be stored in upright position and not laid on side. 5.15.3 Upon receipt or during storage, wood lagging and cable shall be inspected for damage. 5.15.4 Cabling shall be capped off on both ends with cap, suitable to withstand UV radiation during storage, capping is also done to prevent moisture ingress. 5.15.5 Continuous checks shall be performed immediately upon receipt and tagged for preservation.

5.16 BATTERIES AND CHARGERS 5.16.1 Batteries and chargers shall be stored in accordance with the Vendor’s instruction, normally in a dry place where condensation will not occur. 5.16.2 Nickel–Cadmium Batteries and Lead-Acid Batteries that have been shipped dry do not require maintenance.

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5.17 PROTECTION OF INSTRUMENTEQUIPMENT AND MATERIALS A preventive maintenance and periodic service for this class of equipment shall be in accordance with the protective procedures specified by the Vendor. In any event protection procedure shall not be less than the follows: 5.17.1 All instrument openings shall remain properly covered or plugged until piped or wired up. 5.17.2 Every four weeks, inspect external machined surfaces of control valves, relief valves, motor operated valves and other instruments, and coat them MIL-P-19 or equal as necessary. 5.17.3 Replace flange covers, renewing those in poor condition.

5.17.4 Apply the same preventive maintenance and periodical services for operators of motor operated valves as specified in paragraph 5.12 5.17.5 No protection is necessary for field mounted instruments unless the equipment is specifically designed with purging or heating to provide protection from the elements. In this event, these systems shall be energized after installation. 5.17.6 Electronic instruments shall be stored in a dry location at temperature less than 500C. 5.17.7 Opening of containers or inclusion of desiccant may be required to prevent mildew and corrosion. Air conditioned storage should be arranged if individual equipment specifications demand. 5.17.8 On completion and satisfactory stage acceptance of the appropriate CCR and FAR locations, these locations should be used as a priority for storage of control equipment, providing air conditioning is operational and buildings are dust free. 5.17.9 Potentiometers shall never be exposed to temperature above 500C. There must also be good ventilation in the instrumentation storage area(s) and dust accumulation shall be prevented. 5.17.10 In humid conditions, it may be necessary to remove instruments from shipping cases to permit ventilation and prevent mildew on electrical insulation.

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5.17.11 Shop assembled control panels shall be retained in the shipping container until moved to the control house. Panels containing sensitive electronic components shall be stored in air conditioned environment. The desiccant included in the panel hermetic enclosure shall be inspected at monthly intervals and renewed when required. 5.17.12 For instruments installed in Waterproof Houses or NEMA 4 local panels with houses or panels that are heated or purged, see paragraph 5.16(5) above. 5.17.13 All drains and vents shall be maintained operable and clear of obstructions and shall be inspected and checked monthly 5.17.14 The distributed control system (DCS) and the like shall be stored in environment as specified by the Vendor. 5.17.15 The handling and placement of the DCS and the like system after arrival at the job site shall be closely co-ordinated with and supervised by Contractor and/ or Vendor’s representatives 5.17.16 All tubing and piping shall remain properly covered or plugged until installed. 5.18 PROTECTION OF PIPING MATERIALS 5.7.1 Pipes 5.18.1 Store austenitic stainless steel pipes outdoor in original packages. Provide sheet covering as required when original package is removed. 5.18.2 Periodically, visually inspect external surfaces of carbon steel and low alloy steel pipes to detect severe general or localized corrosion. Corrective action will be determined by the conditions. 5.18.3 Visually inspect austenitic stainless steel pipes for evidence of pitting corrosion. 5.18.4 Inspect that the end protection of pipes is securely installed, and repair them as required. 5.18.5 Painted and galvanized pipes shall be stored and handled with care to reduce abrasion of the coatings.

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5.18.6 Address issues relating to cement lined pipes (Manner of handling the materials and care of the materials during the storage and after fabrication shall be carried out in accordance with Cement Mortar Protective Lining and Coating for Steel Water Pipe (C205/ American Water Working Association-AWWA) 5.19 PREFABRICATED PIPES 5.19.1 Apply flange surfaces with MIL P-19 or equal, if the preservative material applied at shop has been removed during the prefabrication work. 5.19.2 Protect flange surfaces and bevelled weld ends of prefabricated pipes with wooden covers, Vinyl caps. 5.19.3 Ensure end capping of pipes, pipe spools, pipe fittings, valves, etc. during site storage and erection. 5.19.4 Ensure pipe spool lay down area is properly drained, spools properly supported off the ground in a position not collecting water or flanges touching the soil.

5.20 FITTINGS (Elbows, Tees, Reducers, Flanges) 5.20.1 Store items of 2” and smaller sizes will be kept indoors after unpacking. 5.20.2 Store item of 3” and above sizes will be kept outdoors on hard standing or on pallets. 5.20.3 Apply flange surfaces of carbon steel and low alloy steel with MIL P-19 or equal, if they have not been applied Vendor at shop. 5.20.4 Ensure end capping of pipes, pipe spools, pipe fittings, valves, etc. during site storage and erection. 5.20.5 Protect gasket contact surfaces for spectacle blind (spacer and blank) using hard board and tape in accordance with JGCS specification. 5.21 VALVES, STEAM TRAPS, STRAINERS, MISCELLANEOUS 5.21.1 Store items of 4” Manual operated valves and smaller sizes indoors. Page 22 of 29

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5.21.2 Store item of 6” and above outdoors on hard standing or on pallets, laid on their side or with the valve stem upright. 5.21.3 Inspect valve stems, clean with solvent and coat with grease as necessary. Seal all valves, replace flange covers renewing those in poor condition. Plug any open threaded valves. 5.21.4 Apply flange surfaces of carbon steel and low alloy steel with MIL P-19 or equal, if they have not been applied Vendor at shop. 5.21.5 During storage in warehouse and after the installation, if original grease coating has been partially or fully removed, recoat with grease. 5.21.6 Ensure end capping of valves, etc. during site storage and erection.

5.22 PROTECTION OF SKID MOUNTED PACKAGE UNITS The preventive maintenance and periodical services for the equipment constituting the packaged unit shall be in accordance with the requirements specified in each paragraph in this procedure, and the following further preservation shall be made: 5.22.1 For equipment which is shipped with skid box, the skid box shall not be unpacked until the equipment is installed on its skid or foundation. 5.22.2 In case when the skid mounted packaged equipment is shipped without skid box enclosure the following shall be made during the construction period: 5.22.3 Polyethylene sheets temporarily cover for line mount instruments and electrical and/or instrument panels shall be maintained to protect them from dirt. 5.22.4 For electrical and/ or instrument panels mounted on the skid base, periodic replacement of desiccant with new or reclaimed ones shall be made to maintain dryness inside panel. 5.22.5 All electric and/ or instrument panels which are not mounted on the skid and shipped with separate packing shall be stored in warehouse until they are installed on the skid. During the warehouse storage, panels, for which moisture proof packing have been applied at manufacturer’s shop shall be checked of their tight seal. Page 23 of 29

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5.22.6 If tear on the sealing sheet is found, the sheet shall be removed and desiccant shall be put in the panel boxes subject to periodical replacement of desiccant with new or reclaimed ones. Energize anti-condensation heaters if supplied.For panels for which moisture proof packing are not applied, periodical replacement of desiccant with new or reclaimed ones shall be made. 5.22.7 Shop installed rubber gaskets and thin spectacle blind plates on flanged connection shall remain un-removed or site fabricated sheet gasket shall be installed where applicable even after connecting them with piping at the job site so that independent preservation shall be applied to the equipment by isolating them from other equipment.

5.23 PROTECTION OF STEEL STRUCTURE 5.23.1 Structural Steel Structural steel can be stored on wooden pallets at open areas without cover.

5.23.2 Structural Bolts Structural bolts shall be stored in warehouses on racks in bins with packing or with seal, etc.

5.24 OTHER ITEMS REQUIRING SPECIAL TREATMENT 5.24.1 Refractory Linings Castable refractory lined equipment, such as vessels, piping, fired heaters and exchangers must have refractory protected against condensation until the equipment is placed in service. Refractory cements must be stored strictly in accordance with Vendor’s instructions, including proper ventilation.

5.25 INSULATION MATERIALS Pre-cast insulation and Rockwool blanket shall be palletized and stored under cover and proper ventilation required.

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6. ATTACHMENT Attachment-1: International Symbols Attachment-2: Check Log sheet Sample (for reference). Attachment-3: Recommended Rust Preventive materials. Attachment-4: Organization Chart.

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ATTACHMENT – 1 INTERNATIONAL SYMBOLS

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