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STAR RAFNER, A.. CONTRACT N


AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 2/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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TABLE OF CONTENTS

1. SCOPE 3
2. DEFINITION OF TERMS 3
3. REFERENCE DOCUMENTS 4
3.1 Owner Specifications 4
3.2 Code and Standards 4
3.3 Contractor Specifications and Documents 4
4. GENERAL CHECKS FOR STATIC EQUIPMENT AT WORKSHOP ARRIVAL 4
5. FOUNDATION CHECKS AND PREPARATION 5
6. LEVELING PAD PLATES 7
6.1 Position and Number Required 7
6.2 Shape of Pad plates 7
6.3 Setting 8
7. SHIM PLATES 8
8. INSTALLATION 8
9. ALIGNMENT 9
9.1 Position 9
9.2 Elevation 9
9.3 Perpendicularity 9
10. REMOVAL OF LIFTING LUGS 10
11. GENERAL CHECKS FOR STATIC EQUIPMENT 10
12. ADITIONAL CHECKS ON SPECIFIC EQUIPMENT TYPES 11
12.1 Checks to be done for Vessels, Columns, Reactors and Their Internals 11
12.2 Checks to be done for Furnaces 12
12.3 Checks to be done for Boilers 14
12.4 Checks to be done for Desuperheaters - Steam Temperature Control Equipment 15
12.5 Checks to be done for Shell-And-Tube Heat Exchangers 15
12.6 Checks to be done for Air-Cooled Heat Exchangers 16
13. DOCUMENTATION 17

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 3/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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1. SCOPE

This Specication covers the installation requirements of equipment installation such as reactors,
columns, drums. heat exchangers, and package equipment for the Aegean Refinery Project (ARP).
In case of any discrepancies between this specication and vendors instructions in principle this
specication shall prevail over vendors instructions unless otherwise decided by Contractor.
Dress up assembly and erection shall be performed in accordance with relevant documents.

2. DEFINITION OF TERMS

For the purpose of this procedure, the following definitions shall apply:
PROJECT Aegean0 Refinery Project (ARP) in Aliaa/IZMIR (Turkey), being
executed by CONTRACTOR or its affiliates.
OWNER STAR RAFINERI A.S. (STAR)
PMC Project Management Consultant Amec Foster Wheeler plc
SUBCONTRACTOR Autonomous Construction Company responsible of performing
the activities of the works described on this specification.
CONTRACTOR TSGI Mhendislik naat Limited Company is the entity that will
perform the activities described in this procedure (also called
TSGI MI).
VENDOR Supplier of items or equipment
CONTRACT Contract means the General Conditions together with the
schedules listed in the General Conditions, any Amendments or
Changes, and all drawings, plans and specifications listed herein,
or issued to Subcontractor by Contractor.
WORK Work means all labour, supervision, administration, materials,
transportation, supplies, tools, equipment, temporary facilities,
storage facilities, and such other work and materials necessary to
be performed or supplied for the work required by the Contract.
The work includes any work which is not expressly described in
the Contract but which is nevertheless necessary for the proper
execution of the work.

COMMISSIONING All activities performed after the achievement of ready for


commissioning certificate for each unit /system.

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 4/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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3. REFERENCE DOCUMENTS

3.1 Owner Specifications

STGPS C/D1 Unfired Pressure Vessel


STGPS- C/D2 General Requirements For Tower Trays And Internals
STGPS-E1 Heat Exchangers
STGPS-E2 Shell And Tube Exchangers
STGPS-E3 Air Cooled Heat Exchangers
STGPS-F1 Fired Heaters
STSP-F4 Refractories In Direct Fired Process Equipment And Boilers

3.2 Code and Standards

API 661 Heat Exchangers


ASME VIII Div1 Boilers and Pressure Vessels
97/23/EC(PED) Pressure Equipment Directive
EN 10025 Hot rolled products of structural steels

3.3 Contractor Specifications and Documents

000-A-EE-0190626 Preservation Procedure For Equipment And Materials


000-A-EE-0191008-560 Material Control Procedure
000-A-EE-0190404 Site Material Receiving Inspection Procedure
000-A-EE-0190426 Site QC Static Equipment Plan

4. GENERAL CHECKS FOR STATIC EQUIPMENT AT WORKSHOP ARRIVAL

Contractor shall ensure that all packages in material consignment have been received with all
appropriate documentation including Vendors instruction and prescriptions for preservation and

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 5/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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maintenance of materials from receipt at site until commissioning and start-up. Subcontractor shall
also adhere to procedures 000-A-EE-0191008-560, 000-A-EE-0190404, 000-A-EE-0190426.
For additional checks at workshop refer to Preservation Procedure - 000-A-EE-0190626

5. FOUNDATION CHECKS AND PREPARATION

Check the foundation bolts to make sure that they are straight and vertical and securely
tightened. Shims should be located on either side of each foundation bolt and made in one
piece.
Anchor bolts holes/anchor boxes and bottom of equipment bases shall be cleaned and free of
laitance, loose particles, oil or grease. Any anchor bolts hole and foundation shall be rough
chipped for removal of laitance. Civil drawings shall be checked versus the equipment
fabrication and installation/vendor drawings before equipment erection. The laitance shall be
removed from foundation (back-chipped)
Top of foundation and inside anchor boxes shall be chipped and anchor bolts shall also be
cleaned.
Marking on Foundation used for alignment shall be checked.
In the case of Horizontal equipment location of anchor bolts will be checked to match the
holes on the saddles
On Horizontal equipment check that fixed saddle and sliding saddle are matching design
indication

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 6/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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Sliding Saddle Detail Fixed Saddle Detail


on equipment drawing on equipment drawing
sample sample

Fixed/Sliding Saddle detail on Civil Drawing Sample

Fixed/Sliding Saddle Foundation detail on Civil Drawing Sample

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 7/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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In the case of equipment erected on structure the elevation of the structure will be verified to
be in accordance with design documentation.

6. LEVELING PAD PLATES

Materials of pad plates shall be EN 10025 S235JR or equivalent.

6.1 Position and Number Required

Pad plates shall be provided on both sides of anchor bolts. However, in case of horizontal
equipment, this requirement will be not applied, pad plates shall not be provided on both side of
anchor bolts.
In general, the spacing between pad plates shall not exceed 800 mm. If the spacing exceeds 800
mm, an additional pad plates shall be added.
The load to be supported per pad plates shall be max. 30 kg / cm2. If the supported load is to exceed
30 kg/cm2, either the width or number of pad plates or both shall be increased.
The load to be supported shall be calculated in accordance with the equation shown below:
L= W / (N x A)
L: Load supported by pad plate (kg/cm2)
W: Lifting load of equipment (kg)
N : Numbers of pad plates
A : Area of pad plate (cm2)

6.2 Shape of Pad plates

The width of levelling plates shall be as shown in Table 1 below.


Table 1 - Width of levelling plate

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 8/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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The lengths of levelling plates shall be 20 to 30 mm longer than the width of the equipment bases.
When using pad plates with grout as a levelling plate, the minimum thickness of the pad plate shall
be minimum 10 mm.

6.3 Setting

Prior to the installation of pad plates and equipment, the pad plates and grouting portions of
foundations shall be chipped and all concrete Iaitance shall be removed.
Pad plates shall be installed at the level and positions as described in Para.6.1 by use of cementious
non-shrink grout at least three (3) days before equipment installation.
If the subcontractor has any alternative method other than above mentioned, Subcontractor shall
submit proposal and get acceptance from Contractor before commencement of work.

7. SHIM PLATES

If shim plate shall be used for nal levelling, shall be made out of stainless steel. The width and
length of shim plate shall be same as pad plates as described in Para. 6.2.
Note: In emergency case and for interim alignment, wedge (other than taper plate) can be used
HOWEVER only as a temporary means.

8. INSTALLATION

Before erection of the equipment, cleaning under the base plate of the equipment shall be
checked.
Equipment shall be installed and aligned at the proper position, elevation, levelness and
perpendicular in accordance with the construction and vendor erection drawings.
Scrupulous care shall be taken so as to prevent foundations, anchor bolts, equipment,
structures, underground facilities, etc., from being damaged. If there is any possibility of such
damage occurring, all necessary preventive and protective measures shall be taken as the
circumstances require.
The equipment shall not be lifted by its nozzle or shell parts, unless otherwise specied. Shell
parts shall be protected by wooden blocks, rubber or other materials from damage caused by
sling.
With regard to horizontal type equipment requiring allowance for thermal expansion, full
attention shall be paid to the positional relation between the anchor bolt holes of the base

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 9/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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plate and the anchor bolts themselves. Where slide plates are to be installed, slide plates
shall be set at specied elevations by use of adjusting pad plates.
Installation of any equipment to be stacked shall be done carefully paying attention to avoid
damage to companion anges and levelling to keep necessary clearance between anges,
taking account of bolt tightening and gasket thickness.
Any equipment temporarily placed on foundation shall be supported by adequate means such
as trusses, guy ropes, etc., until it will be securely bolted. Similar precautions shall be taken
against the possibility of storm, etc., when so required.
Upon completion of alignment, each taper pad plates shall be welded by tack (Do not weld to
base plate.). Pad plates or shim plates which project more than 15 mm from the base plates
shall be cut.
In case of horizontal equipment, the nuts of sliding side of anchor bolts shall be loosened to
allow for thermal expansion after hardening of grout. Lock nuts shall be tightened.
Installation of air-cooled heat exchangers and special equipment shall be performed in
accordance with the manufacturers instruction documents. Tube protective covers will be
removed prior to commissioning activities. Temporary xing lugs for header box will be
removed after installation to allow tube expansion.
Fixing rod for expansion joint of heat exchangers shall be loosened after installation in
accordance with instruction by Contractor.

9. ALIGNMENT

Equipment shall be aligned within the following tolerances and the results shall be recorded
according to 000-A-EE-0190426 . Unless otherwise specied, alignment shall be done using either
pad plates, shim plates and lifting device.
9.1 Position

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

At least, one (1) point on the base plate shall be aligned within the tolerances of 3 mm. Pad plate
levelling tolerances shall be 3 mm.
9.3 Perpendicularity

The center (base line) of the equipment shall be in alignment with the vertical line within the tolerance
of 10 mm for every 10 m height of the equipment, provide that such tolerance for 20 m and longer
equipment shall not exceed 20 mm.

This document is the property of TSGI Mhendislik naat Limited Company. Its reproduction without a written permission is strictly forbidden.
STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 10/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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Note: (This tolerance is applicable to vertical equipment)


The center line (base line) of the equipment shall be in alignment with the horizontal line within the
tolerances of L/1000. (L is the length of the equipment). Maximum tolerances shall not exceed the
values specified in Para.9.3
Note: (This tolerance is applicable to horizontal equipment)
For alignment of air-cooled heat exchangers the following, but not limited to items, shall be subjected
to inspection in addition to above.
Structure assembly (plumb, level, and dimension)
Fan ring roundness (clearance with blade)
Tube bundle and n inspection (damage, level)
Ensure oating header box is free to move
Rotation shaft alignment (plumb)
If there is any interference from other objects in measuring the center line (base line) of an item of
equipment, measurement shall be taken on both side of the equipment from two directions 90 apart
and the average value shall be adopted.
Note: (This is applicable to vertical equipment)
Alignment of vertical columns and vessels with height 30 m and over shall be done before dawn or
on cloudy days to avoid deviations due to weather or heat.

10. REMOVAL OF LIFTING LUGS

Lifting lugs and tailing lugs including trunions may be left welded to equipment unless removal is
required in the relevant drawing or removal is requested by Contractor.
In case cutting of lugs is required a minimum 50 mm 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.

11. GENERAL CHECKS FOR STATIC EQUIPMENT

The following points are generally applicable to mechanical equipment. Specific points to particular
types of equipment are included in the subsequent sections.
Check that all packing materials and protective devices used during transport and handling
have been removed from the equipment, such as shock-absorbent materials from machined
faces, blanking plates from orifices, blocking of shafts or rolling bearings and restraining
devices from instruments, safety devices and protective equipment.

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 11/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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Check whether special (maintenance) tools and instruction manuals have been supplied.
Check that the nameplate is properly attached to the equipment in accordance with the
specification. Compare the nameplate rating with the Equipment Record Card and note any
variations.
Check that the insulation and fireproofing have been applied in accordance with the
specification and that precautions have been taken to prevent the ingress of water.
Check and inspect any alterations made during plant construction and erection for
compliance with the design specification, and record any deviations.
Check that specified materials have been used, and that welding, heat treatment, stress
relieving and non-destructive testing have been carried out properly and fully documented.
Check wall thicknesses of shells, heat exchanger and furnace tubes, and nozzles and
compare them with those stated on the Equipment Record Cards. Correct and complete
these cards as necessary.
Check that the nozzle facings, flanges, flange finish, gaskets and stud bolts are in accordance
with specified requirements and the alignment of flanges on process connections is correct.
Check that the applied surface protection system complies with specified requirements.
Check that ladders, stairways, platforms and walkways are correctly installed, with handrails
and flooring properly secured. Check operating platforms for alternative escape routes, which
shall be freely accessible and clearly indicated.
Especially with vacuum equipment, if out-of-roundness, bulges or dents are suspected as a
result of transport, handling, field welding or other cause, check the equipment and report any
such defects. Procedures for rectification of any damage shall be agreed between the Owner
and the Contractor.
A general inspection is required to check personnel hazards (e.g. tripping and headroom)
associated with the accessibility of operating equipment. Hazards shall be removed or
permanently marked and additional access provided as needed.

12. ADITIONAL CHECKS ON SPECIFIC EQUIPMENT TYPES

12.1 Checks to be done for Vessels, Columns, Reactors and Their Internals

Check and inspect equipment internals for correct tray levels, weir heights, down comer
clearances, seal pans, draw-off trays, position of spiders, demisters and correct
fastening, packing and bolts.
Check beam fastening and ensure one end is free to move.
Check the presence of drain holes where required and hole configuration of liquid inlet
devices in relation to the trays below.

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 12/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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Check and inspect the welds of stiffening rings, especially for vacuum equipment.
Check and inspect the strip lining, if applicable, especially at nozzle locations.
Check and inspect the lining of the cylindrical parts of manholes and nozzles, and the
flange surface lining, if fitted.
Check that test holes in reinforcement plates are open.
Check that dewatering holes are located in appropriate positions.
Check the adjacent (steel) structure for interference with nozzles due to expansion/
contraction.

Check the verticality of tall equipment and the correct slope, if any, of horizontal
equipment.

Test for leaks from the draw-off trays. An allowable leakage rate may be stated in the
specification.
Before final boxing-up, a check on proper installation of internals, correct flange finishes
and cleanliness shall be carried out jointly by operational and technical staff.

12.2 Checks to be done for Furnaces

Check the proper position and support of radiant and convection bank tubes. Remove
any temporary bracing installed for transportation.
Check that the furnace tubes are straight and that there is proper clearance between the
tubes; if not, adjust the roof tube supports by installing or removing shims
Check whether tubes have been correctly expanded into fittings, see Appendix 2. Take
readings of original expansion and enter these into the records.

This document is the property of TSGI Mhendislik naat Limited Company. Its reproduction without a written permission is strictly forbidden.
STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 13/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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Check that the return fitting plugs are properly bolted.


Check the fuel supply system, both oil and gas for leakage.
Check expansion joints for free movement (for when becoming hot)
Check the furnace structure and plating for correct bolting/welding, construction and
painting of plates and beams; check roof for rain water draining facilities.
Check the dampers for correct operation. Ensure that the position marker on the outside
coincides with the real position of the damper inside. Ensure that dampers will not close
under the effect of gravity.
Check expansion pieces in ducting for tightness and adequate support near the
expansion pieces.
Check provisions for installation and removal of spade-type blinds in flue gas ducting.
Check the burner installation, the correct position and shape of burner throats, the correct
position of fuel guns in the throats, adjustability of air registers, fuel guns, the correct
position and size of peepholes and observation windows. Record the result of the burner
position measurement and issue a 'burner protocol' to be filled in the inspection
department.
Ensure that burner throats and ignition burner are visible from observation windows.
Ensure that observation windows are not obstructed by furnace tubes.
Inspect the heater access doors. They should move freely and at the angle specified and
should not be obstructed.
Inspect and test the steam to the furnace, i.e. snuffing steam to fire box and header
boxes and steam for soot blowing and burners.
Inspect and test the soot blower equipment for correct working within the full range of
operation.
Check soot blower system and in particular:
- Expansion;
- Purge facilities;
- Self-draining of steam supply piping system;
- Tightness of valves
Test the concrete lining of the ducting for voids by tapping with a very light hammer.
Inspect the lining for cracks wider than 1.5 mm. These cracks shall be cut out in such a
way that a dovetail is obtained for repairs. For further checks on refractory, anchors, etc.
Carry out a tightness test on air preheaters. Cleaning devices of fixed-type preheaters
should be carefully checked. Packing between flanges shall be checked for tightness.
Apply a smoke-bomb test as a final check on the tightness of the firebox, ducting,
dampers, air preheater etc. During this test the flue gas side shall be kept under pressure
with the forced-draught fan.

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 14/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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Hydrostatically test the furnace coils in accordance with the design data sheets. The test
pressure shall be maintained for approximately half an hour plus the time required for
checking on leaks (see Section 3).
After a furnace with horse-shoe type fittings has been closed following a routine cleaning
or inspection shutdown, a tightness test shall be carried out to check that the horse shoe
fittings do not leak. This test may be conducted with medium pressure steam, provided
that the pressure and temperature do not exceed the furnace design conditions. If tubes
or fittings have been repaired, a hydraulic test is required. The set pressure for this
strength test shall be established by the plant inspector in accordance with local rules.
Normally, the test pressure amounts to 1.5 times the design pressure multiplied by a
factor S/S' where S and S' represent the allowable material stress values at ambient
temperature and design temperature respectively.
Check proper installation of skin thermocouples (if applicable); see Standard drawing
Check operation of observation windows and the functioning of the air purge to the
windows on the radiant cell.
Check that the locking pin of any spring hanger support is removed and the pointer within
the operation range. Note the position in the cold, and later in the hot, condition.

12.3 Checks to be done for Boilers

Check the boiler structure and plating for correct bolting/welding, construction/
conservation plates, beams and painting.
Check that the air and flue gas ducts are adequately supported and that sufficient
allowance has been made for expansion.
Check the fuel oil and gas supply system for leakage.
Check that the internals of the steam drum are in the correct position, properly fastened
and free of debris. Check the down comer and riser tubes, if possible.
Check the air preheater, if any.
Check that the intermittent blowdown lines are adequately supported and clamped. Make
sure that the line size is not smaller than the blow-down connection.
Check that the blowdown valves are fail to close and check that continuous blowdown
lines have position indicators (from 0 - 100% with intervals of 10%).
Check that statutory requirements have been satisfied.
Check the proper position of observation doors. Ensure that the burner throats burner
tips, side wall tubes, rear end tubes and superheater tubes are clearly visible.
Inspect the burner installation, the correct position and shape of burner throats, the
correct position of the fuel guns in the throat, the adjustability of air registers, fuel guns, if
applicable and the cleanliness of the fuel gun nozzles. Record the results of the burner
position measurements.

This document is the property of TSGI Mhendislik naat Limited Company. Its reproduction without a written permission is strictly forbidden.
STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 15/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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Inspect and test the soot blower equipment for correct working within the full range of
operations. Pay attention to purge facilities and steam shut-off valves.
Pressures test the boiler in accordance with the code or regulation under which it is
designed. Boiler feed water shall be used as a testing medium.
Apply a smoke-bomb test as a final check on the tightness of the firebox, ducting,
dampers, etc. During this test the flue gas side is kept under pressure with the forced
draught fan.
After starting up the boiler, the set pressure, maximum relief and the reseating pressure
of the safety valves shall be checked at working temperature and adjusted if necessary.

12.4 Checks to be done for Desuperheaters - Steam Temperature Control Equipment

Check that the direction of injection is correct.


Check the size of the injection nozzle and Venturi.
Check that the bolts are in accordance with specified requirements.
Check that the forces and movements on flange connections are within acceptable limits
and the equipment is adequately supported.
Check whether associated valves, instrumentation, and straight lengths of piping
upstream and downstream of the injector are in accordance with the specification.
Check for proper installation of the low-alloy carbon steel inner tube, if fitted.

12.5 Checks to be done for Shell-And-Tube Heat Exchangers

Check that the correct material has been used for drain/vent plugs.
Check whether anodes/sacrificial plates have been installed where specified.
Check that test holes in reinforcement plates are open and that dewatering holes are
located in appropriate positions.
Check that threaded holes for pulling eyes in contact with the fluid are plugged off with
dummy bolts.
Check that impingement protection, if provided, is properly installed.
Check that the extended bolt ends for bolt tensioning (external as well as internal) are
properly protected.
Check that the test flange or test ring is present and properly stored.
Check the verticality of vertical heat exchangers and correct slope, if any, of horizontal
heat exchangers.

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STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 16/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

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New heat exchangers which have been tested at the Manufacturer's works in accordance
with the design test pressures need not be retested after installation, unless required by
local regulations. It is good practice, however, to test the tightness of the floating head
and channel flanges. Pneumatic testing at a pressure of 1 bar (g) is normally sufficient.
Whenever a shell cover, channel or floating head cover has been removed for cleaning
or repair purposes, the heat exchanger shall be subject to a hydrostatic pressure test not
exceeding 110% of the design pressure.
Re-tubed replacement bundles shall be subjected to a full pressure test in situ to prove
the tightness of the tube-to-tube sheet connections.
In cases where the heat exchanger design is based on differential pressure, care should
be taken not to overload the tube sheets. Special care shall be taken if bellows are
installed.
Heat exchangers provided with sheet gaskets which have been idle for more than three
months after the date of hydrostatic testing at Manufacturer's works may be opened on a
spot-check basis to check for deterioration of the gaskets.

12.6 Checks to be done for Air-Cooled Heat Exchangers

Check the clearance between blade tips and fan ring and check for equal and proper
pitch angle setting of all fan blades.
Check whether fins of the cooler tubes have been damaged during transport or handling.
Damaged fins may be straightened if practicable, otherwise damaged tubes shall be
replaced.
Check that the correct material has been used for drain/vent plugs.
Check the sliding supports of the header box for free and unobstructed moving.
Check the proper operation of the louvre adjustment mechanism, if fitted.
Bearings of fans and drives shall be inspected for cleanliness and proper lubrication.
The correct fan rotation and blade setting shall be checked.
Sections of heat exchangers of the air-cooled type are normally tested at the
Manufacturer's works. After assembly the sections shall be tested together with the
associated piping in accordance with the relevant codes.
It is essential to remove the test water by air blowing and drying, see (3).
In case of automatic adjustable fan blade pitch, check:
- that the motor capacity is sufficient over the full pitch range;
- the correct positioning of fan blades in case of air failure.
A general check of the construction should include:
- the sealing between cooler bundles;

This document is the property of TSGI Mhendislik naat Limited Company. Its reproduction without a written permission is strictly forbidden.
STAR RAFNER, A.. CONTRACT N
AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
2248-000-A-EE-0020014 17/17
CONSTRUCTION SPECIFICATION FOR STAR DOCUMENT No.
STATIC EQUIPMENT ERECTION 000-A-EE-0020014

REV 0 1

- the correct sloping of the horizontal parts of the air plenum and tube bundles;
- alignment of belt pulleys;
- rigidity of fan and belt guards;
- proper tension of belt drives;
- tube vibration check at maximum air flow;
- guards protecting personnel from hot surfaces;
- proper alignment of process piping to headers to ensure no excessive nozzle loading;
- full priming of grease lines between grease nipple and bearing house;
- tightness of fan blade securing bolts;
- vibration of fan and motor as a baseline for further degradation of bearings.
New heat exchangers which have been tested at the Manufacturer's works in accordance
with the design test pressures need not be retested after installation, unless required by
local regulations. It is good practice, however, to test the tightness of the bundle.
Pneumatic testing at 1 bar (g) is normally sufficient.

13. DOCUMENTATION

The installation procedure/ method statement shall be submitted for Contractors approval prior to the
commencement of work. It shall include the following items. (But not be limited to):
List of construction equipment.
Organization of work.
Rigging/lifting study.
Scaffolding plan, if necessary.

This document is the property of TSGI Mhendislik naat Limited Company. Its reproduction without a written permission is strictly forbidden.

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