The document discusses Shell's experience installing 251 centrifugal pumps for its Scotford Upgrader Expansion 1 project. It summarizes Shell's quality program aimed at achieving flawless start-up of projects. Specifically, it discusses lessons learned from previous projects that were incorporated into specifications for the pumps. It also outlines the procurement process, construction including installation, and commissioning of the pumps. The goal of the presentation is to discuss installation of the pumps and topics from each phase of the project from design to start-up.
This document summarizes a parametric study evaluating design parameters for pulsation dampeners on plunger pumps. The study uses a pulsation model to examine the effects of:
1) Pump system configuration, finding that complex piping can significantly impact pulsations compared to just the pump package.
2) Dampener location, finding pulsations generally increase as the dampener moves farther from the pump, and are still high when located next to the pump due to quarter-wave resonances.
3) Dampener neck geometry, finding pulsations decrease with a larger neck diameter and shorter neck length to maximize the dampener's effect.
The study also examines the impacts of fluid compressibility and
This document discusses pumps, including their function, principle of operation, types, selection criteria, and engineering design process. The main types of pumps covered are centrifugal pumps and positive displacement pumps. Key factors in pump selection include the nature of the fluid being pumped, system requirements, environmental conditions, and cost. Pump performance is characterized using curves showing head, flow rate, and efficiency. Proper pump sizing and installation are important to avoid issues like cavitation.
This document provides an overview of different pump types, including their key components and applications. It discusses the main categories of pumps as either dynamic (centrifugal) or positive displacement. Within centrifugal pumps, it describes the main components of a single-stage pump and different designs such as single-stage, multi-stage, vertical, horizontal, and submersible configurations. The document also discusses pump classifications according to API 610 standards and provides examples of pump types that fall under different classifications such as between bearings pumps, overhung pumps, and vertically suspended pumps. Key industries where different pump types are used such as oil and gas, power generation, and water treatment are also outlined.
This document provides an overview of early sizing considerations for pressure safety valves (PSVs). It discusses important terminologies, types of PSVs, sizing basis, applicable standards, and the early sizing procedure. The procedure involves selecting possible orifice areas to meet capacity requirements. The objectives of early sizing are to remove holds in piping and instrumentation diagrams and allow early release of piping designs. The document also discusses inter-discipline interfaces, lessons learned, and quality management system documents related to PSV sizing.
This document provides information on the design of pressure vessels. It defines pressure vessels as containers designed to operate above 15 Psi and discusses why proper design is important to prevent failure. The document outlines various codes used for pressure vessel design and stresses that vessels experience from internal pressure, weight, and other loads. It also describes common pressure vessel components like shells, heads, nozzles, and supports, and provides formulas for calculating thicknesses of different vessel components.
For all the Gas Turbine lovers, the following presentation is aimed to cover the Major Inspection of the Gas Turbine (GE, Fr-9E). It is weaved with all of the major activities involved in MI, tools and tactics with addition of the reference values. Each activity is described with aid of pictures for detailed understanding.
Blowout preventers are critical well control equipment used to seal the wellbore. They consist of valves attached to the wellhead that can seal around drill pipes or close the wellbore entirely. The document discusses the types of blowout preventers, criteria for selection, specifications including sizes and pressure ratings, components like ram and annular blowout preventers, and testing procedures to ensure proper operation. Function tests are performed weekly to verify components can close and seal within specified time limits using stored accumulator pressure.
This document outlines technical requirements for positive displacement pumps used in the petroleum, chemical, and gas industries according to API 675 standards. It covers hydraulic diaphragm and packed plunger pump designs, excluding rotary pumps. Requirements include materials of construction, pressure containment, liquid end connections, flanges, check valves, diaphragms, relief valves, gears, bearings, lubrication, capacity control, and accessories like drivers, motors, couplings and guards.
This document summarizes a parametric study evaluating design parameters for pulsation dampeners on plunger pumps. The study uses a pulsation model to examine the effects of:
1) Pump system configuration, finding that complex piping can significantly impact pulsations compared to just the pump package.
2) Dampener location, finding pulsations generally increase as the dampener moves farther from the pump, and are still high when located next to the pump due to quarter-wave resonances.
3) Dampener neck geometry, finding pulsations decrease with a larger neck diameter and shorter neck length to maximize the dampener's effect.
The study also examines the impacts of fluid compressibility and
This document discusses pumps, including their function, principle of operation, types, selection criteria, and engineering design process. The main types of pumps covered are centrifugal pumps and positive displacement pumps. Key factors in pump selection include the nature of the fluid being pumped, system requirements, environmental conditions, and cost. Pump performance is characterized using curves showing head, flow rate, and efficiency. Proper pump sizing and installation are important to avoid issues like cavitation.
This document provides an overview of different pump types, including their key components and applications. It discusses the main categories of pumps as either dynamic (centrifugal) or positive displacement. Within centrifugal pumps, it describes the main components of a single-stage pump and different designs such as single-stage, multi-stage, vertical, horizontal, and submersible configurations. The document also discusses pump classifications according to API 610 standards and provides examples of pump types that fall under different classifications such as between bearings pumps, overhung pumps, and vertically suspended pumps. Key industries where different pump types are used such as oil and gas, power generation, and water treatment are also outlined.
This document provides an overview of early sizing considerations for pressure safety valves (PSVs). It discusses important terminologies, types of PSVs, sizing basis, applicable standards, and the early sizing procedure. The procedure involves selecting possible orifice areas to meet capacity requirements. The objectives of early sizing are to remove holds in piping and instrumentation diagrams and allow early release of piping designs. The document also discusses inter-discipline interfaces, lessons learned, and quality management system documents related to PSV sizing.
This document provides information on the design of pressure vessels. It defines pressure vessels as containers designed to operate above 15 Psi and discusses why proper design is important to prevent failure. The document outlines various codes used for pressure vessel design and stresses that vessels experience from internal pressure, weight, and other loads. It also describes common pressure vessel components like shells, heads, nozzles, and supports, and provides formulas for calculating thicknesses of different vessel components.
For all the Gas Turbine lovers, the following presentation is aimed to cover the Major Inspection of the Gas Turbine (GE, Fr-9E). It is weaved with all of the major activities involved in MI, tools and tactics with addition of the reference values. Each activity is described with aid of pictures for detailed understanding.
Blowout preventers are critical well control equipment used to seal the wellbore. They consist of valves attached to the wellhead that can seal around drill pipes or close the wellbore entirely. The document discusses the types of blowout preventers, criteria for selection, specifications including sizes and pressure ratings, components like ram and annular blowout preventers, and testing procedures to ensure proper operation. Function tests are performed weekly to verify components can close and seal within specified time limits using stored accumulator pressure.
This document outlines technical requirements for positive displacement pumps used in the petroleum, chemical, and gas industries according to API 675 standards. It covers hydraulic diaphragm and packed plunger pump designs, excluding rotary pumps. Requirements include materials of construction, pressure containment, liquid end connections, flanges, check valves, diaphragms, relief valves, gears, bearings, lubrication, capacity control, and accessories like drivers, motors, couplings and guards.
This document provides information about heat exchangers, including:
- Heat exchangers transfer energy between fluids at different temperatures through conduction, convection and radiation.
- They have advantages like being economical, having high efficiency and being easy to modify.
- Heat exchangers can be classified by their flow configuration, transfer process, construction and heat transfer mechanism.
- Common types include shell and tube, plate, double pipe, and condensers, evaporators and boilers.
- Maintenance includes hydrotesting to detect leaks and plugging leaking tubes temporarily or permanently.
The document discusses the design of storage tanks. It covers general considerations for tank design codes, types of tanks, selection of tanks, material specifications, and design of various tank components like shells, bottoms, roofs, foundations. It also discusses seismic analysis, anchorage requirements, venting, and floating roof tank accessories. Key aspects covered include allowable stresses and corrosion allowances for materials, thickness calculations using different methods, wind girder design, and anchorage design considering uplift forces.
This document summarizes the key components and operation of a gas turbine located at the Panipat Refinery. It includes 5 gas turbines made by BHEL/GE that are MS 6000 single shaft design units with a base load capacity of 30.77 MW each. The major components discussed include the compressor, combustors, turbine section, casings, bearings, and cooling/sealing systems. It also provides details on the basic principles of how a gas turbine works by continuously drawing in air, compressing it, adding fuel to increase its energy, directing the high pressure gas to expand through a turbine, and exhausting the low pressure gas.
The document discusses gas turbines used at an NFL power plant in Vijaipur. It provides details on the models, ratings, and loads of three gas turbine generators (GTGs). It then discusses heavy duty gas turbines from GE in terms of their configurations, frame sizes, speeds, and applications. The rest of the document goes into extensive technical details about the components, workings, inspections, and factors that influence gas turbines, including compressors, combustion systems, turbines, bearings, and more.
All valves require proper care and maintenance,as does other more complex equipment, to ensure theyare kept in optimum working order. The principledifficulties encountered with valves are leakage pastthe seat and disk, leakage at the stuffing box, stickingvalve stems, and loose valve disks.
Pressure Safety Valve Sizing - API 520/521/526Vijay Sarathy
No chemical process facility is immune to the risk of overpressure to avoid dictating the necessity for overpressure protection. For every situation that demands safe containment of process gas, it becomes an obligation for engineers to equally provide pressure relieving and flaring provisions wherever necessary. The levels of protection are hierarchical, starting with designing an inherently safe process to avoid overpressure followed by providing alarms for operators to intervene and Emergency Shutdown provisions through ESD and SIL rated instrumentation. Beyond these design and instrument based protection measures, the philosophy of containment and abatement steps such as pressure relieving devices, flares, physical dikes and Emergency Response Services is employed
Excel sheet Download Link: https://www.scribd.com/document/385945712/PSV-Sizing-Tool-API-Based-Calc-Sheets
PSV Sizing for Blocked Liquid Discharge Condition
PSV Sizing for Blocked Gas Discharge Condition
PSV Sizing for Fire Case of Liquid Filled Vessel
PSV Sizing for Control Valve Fail Open Case
Relief Valve Sizing for Thermal Expansion
Restriction Orifice Sizing for Gas Flow
Restriction Orifice Sizing for Liquid Flow
Single Phase Flow Line Sizing Tool
Gas Control Valve Sizing Tool
This document is a piping material specification for a project located in Padur. It includes 3 pages of content listing abbreviations, a table of contents, an index of piping classes and materials, and 4 sheets providing details on pipe sizes, materials, and fitting types for Pipe Class A13A. The document specifies material types, standards, and notes for a 150# carbon steel piping system conveying corrosive hydrocarbons.
The document discusses factors related to casing design, including:
1) The design factor is the minimum acceptable safety factor, which is the ratio of the load applied to the pipe's rating.
2) The axial strength of the pipe is determined by an equation using the pipe's minimum yield strength, outer diameter, and inner diameter.
3) A triaxial stress criterion using three stress components - axial, tangential, and radial - is presented for evaluating combined loading conditions. Loads falling within the resulting design envelope meet the design criteria.
Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies the efficient transport of fluid
Industrial process piping (and accompanying in-line components) can be manufactured from wood, fiberglass, glass, steel, aluminum, plastic, copper, and concrete. The in-line components, known as fittings, valves, and other devices, typically sense and control the pressure, flow rate and temperature of the transmitted fluid, and usually are included in the field of Piping Design (or Piping Engineering). Piping systems are documented in piping and instrumentation diagrams (P&IDs). If necessary, pipes can be cleaned by the tube cleaning process.
"Piping" sometimes refers to Piping Design, the detailed specification of the physical piping layout within a process plant or commercial building. In earlier days, this was sometimes called Drafting, Technical drawing, Engineering Drawing, and Design but is today commonly performed by Designers who have learned to use automated Computer Aided Drawing / Computer Aided Design (CAD) software
John Crane gas seals provide maximum reliability through ensuring a clean and dry seal environment. Key factors include filtering the gas to 1 micron, using coalescing filters to remove liquids, heating the gas above hydrate and liquid formation points, and using an SEPro system to provide heated filtered gas to the seals during shutdown periods. It is also important to properly monitor the outer barrier seal, ensure adequate separation from bearing oil, and have the OEM test the job seal system to validate performance matches duty conditions.
The document is a presentation about industrial compressors used in processing plants. It discusses the main types of compressors, including positive displacement and dynamic compressors. It describes methods of capacity control for different compressor types and flow capacities at varying discharge pressures. Standard speed and flow capacity ranges for compressor drives are also covered. The presentation focuses in detail on centrifugal compressors, explaining their operation and key components like impellers and diffusers. Contact information is provided for questions.
Performance Pulsation Control specializes in the engineering, design, and manufacture of maintenance free and gas charged pulsation control devices for oil and gas, well service and industrial applications. This presentation explains the benefits of discharge dampeners for pulsation control.
Rotating equipment maintenance.
PUMPS
COMPRESSORS
AGITATORS
FANS / BLOWERS
TURBINES
VACUUM PUMPS
VALVES
Type of Seals
Stuffing
SINGLE MECHANICAL SEAL Pusher Type
Bellows Mechanical Seal
Double Mechanical Seal
The document defines mechanical completion and commissioning. Mechanical completion involves checking equipment is installed correctly and ready for commissioning. Commissioning verifies systems function as intended. Key activities for mechanical completion include inspections, testing, and documentation. Commissioning activities include system testing, instrumentation calibration, and verifying equipment and systems meet objectives. The document provides details on planning, executing, and documenting mechanical completion and commissioning.
This document provides guidance on pump maintenance and troubleshooting. It discusses different types of maintenance including fix-on-failure, scheduled, preventive, and predictive maintenance. The document then covers mechanical and hydraulic pump problems, whether internal or external to the pump. Specific issues that could cause problems are identified. The importance of qualitative measurements like sounds and smells is emphasized. Case studies using gauge readings to troubleshoot issues are presented. Maintaining pumps is important to avoid downtime and costs.
This document provides information on gas lift valve mechanics, including the three basic types of gas lift valves, how they operate, and the forces involved in opening and closing them. It discusses unloading valves, orifice valves, and how gas lift valves close in sequence from the bottom of the well upward. Diagrams show the components of different gas lift valve designs and the formulas used to calculate valve opening and closing pressures.
This document provides standards for piping design, layout, and stress analysis. It covers topics such as design and layout considerations including numbering systems, safety, clearance, pipe routing, valves, equipment piping, and stress analysis criteria. The standards are intended to replace individual company specifications and be used in existing and future offshore oil and gas developments. It references other NORSOK and international standards and does not cover all instrument control piping, risers, sanitary piping, or GRP piping.
The document discusses the fundamentals of mechanical seals used in pumps. It describes how mechanical seals work to prevent leaks by creating a close fit between a stationary and rotating seal surface. It covers the basic components of mechanical seals including primary sealing elements, secondary sealing elements, and hardware. It also discusses seal face materials, designs, installation, operation, and ways to control the seal environment through flushing, cooling, and heating.
The document summarizes Shell's experience installing 251 centrifugal pumps for its Scotford Upgrader Expansion 1 project. Key lessons learned are discussed from the design, procurement, construction, and startup phases. During construction, over 1000 deficiencies were found and over 300 non-conformance reports were issued. Strict adherence to standards like API 686 was important for successful leveling, alignment and grouting of pumps. Continuous temperature control and cleaning were also essential for preservation and installation.
Ehsan Nazeer is a design and estimation engineer with over 5 years of experience in HVAC. He has a bachelor's degree in mechanical engineering. His experience includes working as an HVAC engineer for Naser M. Al-Baddah & Partner General Trading & Contracting Co. in Kuwait where he was responsible for HVAC installation, maintenance, and commissioning on various projects. He has also worked as a design and estimation engineer where he performed HVAC design calculations and prepared cost estimates and tender documents.
This document provides information about heat exchangers, including:
- Heat exchangers transfer energy between fluids at different temperatures through conduction, convection and radiation.
- They have advantages like being economical, having high efficiency and being easy to modify.
- Heat exchangers can be classified by their flow configuration, transfer process, construction and heat transfer mechanism.
- Common types include shell and tube, plate, double pipe, and condensers, evaporators and boilers.
- Maintenance includes hydrotesting to detect leaks and plugging leaking tubes temporarily or permanently.
The document discusses the design of storage tanks. It covers general considerations for tank design codes, types of tanks, selection of tanks, material specifications, and design of various tank components like shells, bottoms, roofs, foundations. It also discusses seismic analysis, anchorage requirements, venting, and floating roof tank accessories. Key aspects covered include allowable stresses and corrosion allowances for materials, thickness calculations using different methods, wind girder design, and anchorage design considering uplift forces.
This document summarizes the key components and operation of a gas turbine located at the Panipat Refinery. It includes 5 gas turbines made by BHEL/GE that are MS 6000 single shaft design units with a base load capacity of 30.77 MW each. The major components discussed include the compressor, combustors, turbine section, casings, bearings, and cooling/sealing systems. It also provides details on the basic principles of how a gas turbine works by continuously drawing in air, compressing it, adding fuel to increase its energy, directing the high pressure gas to expand through a turbine, and exhausting the low pressure gas.
The document discusses gas turbines used at an NFL power plant in Vijaipur. It provides details on the models, ratings, and loads of three gas turbine generators (GTGs). It then discusses heavy duty gas turbines from GE in terms of their configurations, frame sizes, speeds, and applications. The rest of the document goes into extensive technical details about the components, workings, inspections, and factors that influence gas turbines, including compressors, combustion systems, turbines, bearings, and more.
All valves require proper care and maintenance,as does other more complex equipment, to ensure theyare kept in optimum working order. The principledifficulties encountered with valves are leakage pastthe seat and disk, leakage at the stuffing box, stickingvalve stems, and loose valve disks.
Pressure Safety Valve Sizing - API 520/521/526Vijay Sarathy
No chemical process facility is immune to the risk of overpressure to avoid dictating the necessity for overpressure protection. For every situation that demands safe containment of process gas, it becomes an obligation for engineers to equally provide pressure relieving and flaring provisions wherever necessary. The levels of protection are hierarchical, starting with designing an inherently safe process to avoid overpressure followed by providing alarms for operators to intervene and Emergency Shutdown provisions through ESD and SIL rated instrumentation. Beyond these design and instrument based protection measures, the philosophy of containment and abatement steps such as pressure relieving devices, flares, physical dikes and Emergency Response Services is employed
Excel sheet Download Link: https://www.scribd.com/document/385945712/PSV-Sizing-Tool-API-Based-Calc-Sheets
PSV Sizing for Blocked Liquid Discharge Condition
PSV Sizing for Blocked Gas Discharge Condition
PSV Sizing for Fire Case of Liquid Filled Vessel
PSV Sizing for Control Valve Fail Open Case
Relief Valve Sizing for Thermal Expansion
Restriction Orifice Sizing for Gas Flow
Restriction Orifice Sizing for Liquid Flow
Single Phase Flow Line Sizing Tool
Gas Control Valve Sizing Tool
This document is a piping material specification for a project located in Padur. It includes 3 pages of content listing abbreviations, a table of contents, an index of piping classes and materials, and 4 sheets providing details on pipe sizes, materials, and fitting types for Pipe Class A13A. The document specifies material types, standards, and notes for a 150# carbon steel piping system conveying corrosive hydrocarbons.
The document discusses factors related to casing design, including:
1) The design factor is the minimum acceptable safety factor, which is the ratio of the load applied to the pipe's rating.
2) The axial strength of the pipe is determined by an equation using the pipe's minimum yield strength, outer diameter, and inner diameter.
3) A triaxial stress criterion using three stress components - axial, tangential, and radial - is presented for evaluating combined loading conditions. Loads falling within the resulting design envelope meet the design criteria.
Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies the efficient transport of fluid
Industrial process piping (and accompanying in-line components) can be manufactured from wood, fiberglass, glass, steel, aluminum, plastic, copper, and concrete. The in-line components, known as fittings, valves, and other devices, typically sense and control the pressure, flow rate and temperature of the transmitted fluid, and usually are included in the field of Piping Design (or Piping Engineering). Piping systems are documented in piping and instrumentation diagrams (P&IDs). If necessary, pipes can be cleaned by the tube cleaning process.
"Piping" sometimes refers to Piping Design, the detailed specification of the physical piping layout within a process plant or commercial building. In earlier days, this was sometimes called Drafting, Technical drawing, Engineering Drawing, and Design but is today commonly performed by Designers who have learned to use automated Computer Aided Drawing / Computer Aided Design (CAD) software
John Crane gas seals provide maximum reliability through ensuring a clean and dry seal environment. Key factors include filtering the gas to 1 micron, using coalescing filters to remove liquids, heating the gas above hydrate and liquid formation points, and using an SEPro system to provide heated filtered gas to the seals during shutdown periods. It is also important to properly monitor the outer barrier seal, ensure adequate separation from bearing oil, and have the OEM test the job seal system to validate performance matches duty conditions.
The document is a presentation about industrial compressors used in processing plants. It discusses the main types of compressors, including positive displacement and dynamic compressors. It describes methods of capacity control for different compressor types and flow capacities at varying discharge pressures. Standard speed and flow capacity ranges for compressor drives are also covered. The presentation focuses in detail on centrifugal compressors, explaining their operation and key components like impellers and diffusers. Contact information is provided for questions.
Performance Pulsation Control specializes in the engineering, design, and manufacture of maintenance free and gas charged pulsation control devices for oil and gas, well service and industrial applications. This presentation explains the benefits of discharge dampeners for pulsation control.
Rotating equipment maintenance.
PUMPS
COMPRESSORS
AGITATORS
FANS / BLOWERS
TURBINES
VACUUM PUMPS
VALVES
Type of Seals
Stuffing
SINGLE MECHANICAL SEAL Pusher Type
Bellows Mechanical Seal
Double Mechanical Seal
The document defines mechanical completion and commissioning. Mechanical completion involves checking equipment is installed correctly and ready for commissioning. Commissioning verifies systems function as intended. Key activities for mechanical completion include inspections, testing, and documentation. Commissioning activities include system testing, instrumentation calibration, and verifying equipment and systems meet objectives. The document provides details on planning, executing, and documenting mechanical completion and commissioning.
This document provides guidance on pump maintenance and troubleshooting. It discusses different types of maintenance including fix-on-failure, scheduled, preventive, and predictive maintenance. The document then covers mechanical and hydraulic pump problems, whether internal or external to the pump. Specific issues that could cause problems are identified. The importance of qualitative measurements like sounds and smells is emphasized. Case studies using gauge readings to troubleshoot issues are presented. Maintaining pumps is important to avoid downtime and costs.
This document provides information on gas lift valve mechanics, including the three basic types of gas lift valves, how they operate, and the forces involved in opening and closing them. It discusses unloading valves, orifice valves, and how gas lift valves close in sequence from the bottom of the well upward. Diagrams show the components of different gas lift valve designs and the formulas used to calculate valve opening and closing pressures.
This document provides standards for piping design, layout, and stress analysis. It covers topics such as design and layout considerations including numbering systems, safety, clearance, pipe routing, valves, equipment piping, and stress analysis criteria. The standards are intended to replace individual company specifications and be used in existing and future offshore oil and gas developments. It references other NORSOK and international standards and does not cover all instrument control piping, risers, sanitary piping, or GRP piping.
The document discusses the fundamentals of mechanical seals used in pumps. It describes how mechanical seals work to prevent leaks by creating a close fit between a stationary and rotating seal surface. It covers the basic components of mechanical seals including primary sealing elements, secondary sealing elements, and hardware. It also discusses seal face materials, designs, installation, operation, and ways to control the seal environment through flushing, cooling, and heating.
The document summarizes Shell's experience installing 251 centrifugal pumps for its Scotford Upgrader Expansion 1 project. Key lessons learned are discussed from the design, procurement, construction, and startup phases. During construction, over 1000 deficiencies were found and over 300 non-conformance reports were issued. Strict adherence to standards like API 686 was important for successful leveling, alignment and grouting of pumps. Continuous temperature control and cleaning were also essential for preservation and installation.
Ehsan Nazeer is a design and estimation engineer with over 5 years of experience in HVAC. He has a bachelor's degree in mechanical engineering. His experience includes working as an HVAC engineer for Naser M. Al-Baddah & Partner General Trading & Contracting Co. in Kuwait where he was responsible for HVAC installation, maintenance, and commissioning on various projects. He has also worked as a design and estimation engineer where he performed HVAC design calculations and prepared cost estimates and tender documents.
Ehsan Nazeer is a mechanical engineer with over 5 years of experience in HVAC design, estimation, and project execution. He currently works as an HVAC Engineer for Naser M. Al-Baddah & Partner General Trading & Contracting Co. in Kuwait. Previously, he has worked on projects for KNPC, KOC, US Army Corps of Engineers, Kuwait University, and other clients. He is seeking new opportunities where he can continue learning and helping organizations succeed through his technical skills and experience in HVAC.
John P. Chan has over 20 years of experience as a mechanical project engineer in the petrochemical industry. He has a proven track record of delivering projects on time and within budget using skills in various areas including being hands-on to define project scopes, ensuring buy-in from stakeholders, understanding multi-disciplinary aspects, and maintaining budget and schedule details.
The document discusses Punj Lloyd's execution of the Shah Gas Development Project in Abu Dhabi. Some key points:
- The project involved laying corrosion resistant alloy clad pipelines to transport sour gas, posing technical challenges due to the complex welding requirements.
- Punj Lloyd overcame challenges through meticulous planning, deploying skilled workers, extensive safety practices, and innovative solutions like prefabrication.
- As a result, they achieved project milestones on schedule while maintaining high safety and quality standards, earning recognition and additional profits from the client.
- Key lessons included the importance of planning, skills, safety, logistics, control, cash flow management, technology, and innovative thinking for successful project execution.
Nilo Ramos Taghoy has over 15 years of experience in quality assurance and construction supervision in the Philippines and abroad. He currently works as a Structure Inspector/Supervisor in Qatar. Previous positions include QA/QC Inspector roles in Saudi Arabia, the UAE, and the Philippines supervising projects in oil and gas, infrastructure, and buildings. He has a Bachelor's degree in Civil Engineering from the University of Cebu and is a member of the Philippine Institute of Civil Engineering.
Nilo Ramos Taghoy has over 15 years of experience in quality assurance and construction supervision. He currently works as a Structure Inspector/Supervisor in Qatar. Previous positions include QA/QC Inspector roles in Saudi Arabia, UAE, Philippines, and Qatar. He has experience supervising projects such as highways, bridges, buildings, oil and gas facilities, and railways. Nilo holds a Bachelor's degree in Civil Engineering from the University of Cebu and is a member of the Philippine Institute of Civil Engineering.
Nilo Ramos Taghoy has over 15 years of experience in quality assurance and construction supervision of various infrastructure and industrial projects in the Philippines and Middle East. He is currently a Structure Inspector/Supervisor at WS Atkins & Partners Overseas in Qatar, overseeing quality control on a highway project. Previously he has held QA/QC roles on oil and gas, petrochemical and railway projects in Saudi Arabia, UAE and the Philippines. He has a Bachelor's degree in Civil Engineering from the University of Cebu.
Sunil E.S. has over 18 years of experience as a QA/QC engineer and inspector for various engineering and construction companies in the Middle East. He is seeking a position utilizing his education in mechanical engineering and extensive experience in quality control and inspection. His background includes managing QA/QC teams, developing quality documentation, auditing projects, and inspecting welding, piping installation, and other fabrication work.
This curriculum vitae summarizes Allwyn Leo Stanley's work experience and qualifications. He has over 9 years of overall experience, including 6.1 years of experience in oil and gas projects in Qatar, working on both upstream and downstream facilities. His experience includes project coordination, cost control, subcontractor management, and planning and scheduling projects using Primavera P6. He holds a Diploma in Mechanical Engineering and additional qualifications in areas like project management, CAD, and safety training.
Allwyn Leo Stanley is a mechanical engineer with over 9 years of experience in oil and gas projects in Qatar. He is currently a Project Engineer at Doha Petroleum Construction Company Ltd. (DOPET) where he is responsible for project coordination, cost and budget control, subcontractor management, and ensuring adherence to quality and safety standards on projects. Some of the key projects he has worked on involve shutdown maintenance, EPIC projects, and quality assurance. He is proficient in project planning software like Primavera P6.
This document discusses planning for substation maintenance and reliability. It outlines key steps in the planning process including developing a robust maintenance plan, gathering data from inspections and tests, creating a detailed work scope, coordination between the owner and contractor during the proposal, pre-outage planning and outage stages, and reviewing test results after the outage. The goal is to plan maintenance properly to ensure safety, reliability and regulatory compliance while minimizing downtime.
A post graduate of petroleum Engineer (from PME) with 10 years of experience in project engineering and project management from conception to commissioning of multi-discipline EPC contracts related to chemical, refinery, oil & gas and LNG sectors including Egypt, Qatar, Abu Dhabi and Oman.
Working in Arabian Industries (AI) LLC for nearly 6 years in feasibility, detailed engineering, EPC, EMC and IMC Projects for PDO (Petroleum Development Oman) and ORPIC.
I’m a petroleum Engineer with an Excellent experience In Oil & Gas Projects and industries such as exploration ,drilling ,work over , Oil & Gas well drilling & ALS Production services and Projects in oil & Gas Energy field section ,My experience in the Drilling , Well control & wellhead equipment Inspection ,Refurbishment , Maintenance , Testing , Recertification and Installation As per API(6A , 6D , 16A , 16D, 16C & 7K ) Specification. Oil & Gas artificial lift production technology and solution. Maintenance, Installation and Overhaul of well head and well control tools and equipment; furthermore, many projects for new rigs (on shore) and offshore rig (ST-Bahari1- Jack up), Prove leadership skills involving managing, developing and motivating teams to achieve their objectives. Reliable, trustworthy and meticulous, gained a good understanding of what is required of Oil & Gas engineering.
Having over more than 20 years overall construction experience out of which 17 on QA/QC role, \worked as profession Quality manager on mega projects with various clients Saudi Aramco, Sabic, Marafiq, Modon, on oil, petrochemical, infrastructure, waste water treatment projects.
Vignesh Kumar C has over 7 years of experience as a project coordinator and technical inspector in the oil and gas industry. He currently works for Intertek Global coordinating inspection activities for multiple projects in the UAE and globally. He holds a Bachelor's degree in Electronics and Instrumentation Engineering and has experience managing diverse projects with strict deadlines. Vignesh is proficient in inspection documentation, contract management, and maintaining relationships with project stakeholders.
Hisham Ahmed Kamel Ali is a petroleum engineer with over 10 years of experience in project engineering, project management, and operations & maintenance for oil & gas projects. He is currently a senior engineer at Arabian Industries LLC in Oman, where he manages multi-disciplinary project teams and is responsible for budget monitoring, progress reporting, and ensuring safety and quality standards. He has extensive experience in well control equipment inspection, testing, and maintenance.
Gensol strives to add value from Project Conceptualisation to Commissioning to ensure timely, quality and cost effective completion. From drafting exhaustive EPC contracts to approving engineering drawings and quality control during construction, Gensol's experience of 1500 MW works to ensure Peace of Mind for the Project Developer.
An experienced Engineering Manager with more than 12 years in the Offshore/Onshore renewable Energy, Oil and Gas industry, adhoc vendor inspection, HSE, Pre-shipment Inspection. Also, Abraham has experience as a Third-Party Inspection Subsea Manager, QHSE and QA/QC Inspectors for Onshore & Offshore Projects and has handled, Solar sales Projects, Subsea Inspection Repair Maintenance (IRM) Projects for clients in Norway and abroad. He excels in timely submission of quality reports while ensuring that safety and quality of equipment are in accordance with client’s specifications, using competent hands, up-to-date test equipment, approved test procedures, ensuring correct markings, and that MCCR and MRBs are up to date and correct.
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1. Copyright of Royal Dutch Shell plc CONFIDENTIAL
Installation of API 610 Centrifugal Pumps to
achieve a Flawless Start up for a Large
Project
Presentation by:
Rob Vaughan &
Bill Robertson
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Scotford Upgrader Expansion 1 (SUEX-1)
Shell’s Oil Sands Scotford Upgrader Expansion 1 Project installed
251 API 610 centrifugal pumps. The plant was successfully started
up in the spring of 2011. Shell has developed a worldwide quality
program aimed at delivering a Flawless Start-up. This presentation
focuses on the installation of these API 610 centrifugal pumps.
Topics from each phase of the project will be discussed from initial
design, specification, inspection, installation, preservation, and
commissioning & start-up.
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Scotford Upgrader Expansion 1 (SUEX-1)
Introduction to Project &
Pump Scope
• 21 orders for 251 pumps from 1 vendor
• Ranging from 10-3000KW all API610 design
• 8 manufacturing sites worldwide
• $100M total for purchase order
• 4 Area Works Construction Contractors
• 5 process units for a 100 BBPD Heavy Oil Upgrading Facility
• Engineering and procurement done from 5 locations worldwide with 17 EPC Design
Engineers working on rotating equipment with oversight from 3 Shell rotating equipment
personnel
• Prime construction contractor was a joint Shell and Bechtel owners team.
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Presentation Outline: What Will Be Covered
Rotating Equipment Path to Start-up
Design
1. Review Lessons Learned from previous Shell projects and incorporate into Purchasing
Documentation & Technical Specifications
2. Specification selection leading to clarification rounds with vendors to ensure alignment on
expectations
3. Key Learning’s from Design Phase
Procurement
4. Identify ITP and Quality Surveillance Strategy
- 3rd Party Inspection vs. Client Inspection
5. Key Learning's from Procurement Phase
Construction
6. Rotating Equipment Construction Organization
7. Engineering Receipt Inspection Program & Non Conformance Record Generation
8. API 686 Installation & Shell’s Minimum Requirements for Rotating Equipment
9. Inspection and Test Plan
10. Construction Installation Issues
11. Key Learning’s from Construction Phase
Start-up
12. Mechanical Completion
13. Pre-Start-up Issues
14. Start-up Issues and Outcome
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Design: LL and Specification Selection
Shell’s Quality Program Flawless Project Delivery
•Shell has a formal World Wide Quality Program aimed at delivering a Flawless Start-up
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Design: LL and Specification Selection
Shell’s Quality Program Flawless Project Delivery
•Lessons learned (LL) and Practices Worth Repeating (PWR) were reviewed and carried forward from
previous projects. It is important to capture both positive and negative experiences from a variety of
sources (previous project mgmt, maintenance, operations, industry colleagues, etc)
•Our LL list went through many review cycles producing quality input being placed in the contractual
language of the purchase order. (Sources of contractual language include ITP’s, audit plan, technical
specifications, technical notes, drawings, etc)
•Specification selection leading to clarification rounds with vendor is a process that can not be rushed
and needs to take multiple rounds. All relevant LL and PWR were reviewed with vendor
7. Copyright of Royal Dutch Shell plc CONFIDENTIAL
Design: LL and Specification Selection
Lessons Learned Example:
LCF Charge Pump
— Experienced Erosion issues led to diminished performance and poor life of thrust bearing
— Leaks occurred at the head gasket due to differential expansion in the casing during the
warm up of the pump, especially in the winter time
— This was reviewed with the vendor and led to design a centrifugal, between bearing, 9 stage,
radially split, double casing BB5 pump including a:
— Oversized balance drum with solid tungsten carbide bushing
— Carbon steel barrel with Stainless Steel Overlay
— Addition of 4 temperature indicators, top / bottom, inboard and out board of the casing to help
operator to warm up pump evenly
— External balance line with Ultra sonic flow meters
— Tungsten Carbide direct laser deposit on impellers and sleeves
— String Test of Prototype LCF Charge Pump revealed issues with rotor dynamics with balance
drum and vibration issues with skid and motors
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Design: LL and Specification Selection
Key Learning's from Design Phase
— To do a proper and complete Lessons Learned Review takes a lot of time! {PLAN AHEAD}
— Incorporating these learning's into the contractual language of the Purchasing Documents is
Critical to being able to get what you need.
— Specification clarification / review meetings with vendor can not be rushed and need to be
documented to ensure alignment on expectations.
— Our Project experienced too many late changes to purchasing documents resulting in
escalating costs and projected schedule delays due to confusion of specifications requiring
more clarifications.
— There were too many drawing inconsistencies with fabricated equipment. Issues found after
fabrication had begun, due to coinciding events of concurrent fabrication and engineering.
— Developed an effective process with vendors and EPC to keep track of all new relevant
issues to track them to closures. Rolling Action Item List (RAIL) worked well.
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Procurement
Identify ITP Requirements & Quality Surveillance Strategy
- Having detailed clear Inspection and Test Plans is very important as this provides a leading
indicator of the quality of the equipment you will be receiving
- Debate between 3rd party contract inspectors being used for inspections vs. client personnel
(maintenance, operations, project resources) for inspections
- SUEX-1 used a combination of 3rd Party contract inspectors and dedicated client personnel
inspection. We had dedicated client personnel providing full time inspection at vendor shops
during fabrication of critical equipment orders
- Schedule many multidisciplinary visits to package equipment vendors to ensure that all
disciplines get adequate representation during inspection
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Procurement
Key Learning's from Procurement
- 3rd Party Inspection was an expensive program that produced ultimately poor results with regards
to pre-inspected equipment being sent to site with obvious poor quality.
- Need to have better alignment on expectations and alignment with 3rd party contract inspector to
ensure goals are clear. Remind them they are to report all findings and they work for the Client
not the Fabricator.
- Do not let Procurement / Expediting drive the quality out of vendor shop. If necessary keep
equipment at vendor’s shop as long as possible to provide time to correct known deficiencies.
Transferring scope or known rework to site is not a good idea as it will push out your schedule
and drive up your costs.
- Use more client personnel for critical equipment inspection, { Example BB5 Charge Pumps}
especially for prior to shipment inspection. Best results are to have the receipt inspection done
at the vendor shop prior to shipping of equipment.
- For Packaged Equipment use multi-disciplinary client inspection teams. Our results indicated that
rotating equipment vendors are being asked to package and their competence or experience is
not high within the other disciplines, etc (tubing, piping, heat trace, wiring, CSA, CRN & ABSA
issues…etc)
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Construction
Construction Program Outline
Construction Organization Alignment
Engineering Receiving Inspection Program {Top Findings, upon receipt of
equipment}
Installation Procedures {API 686 Installation & Shell’s Minimum Requirements for
Rotating Equipment Installation}
Field Construction Inspection Test Plans
Construction Issues
—Cleanliness & Preservation {Pre and Post Installation}
—Levelling & Soft Foot
—Grouting
—Field Machining
—Piping Installation
Alignment
Construction Key Learning's
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Construction
Construction Organization
Daily meetings with Operations, Vendor Field Representative, Shell Millwrights & Project
Engineering staff for inspection assignments and overall alignment
Formal weekly meetings with Area Works Construction Contractor. These meetings have Rolling
Action Item Lists and allow the AWC to have clear communication lines to the project for
immediate issue resolution
AWC has direct access and works continually with Shell Inspection on a daily basis
Rotating Equipment Installation Workshops once a month, site meetings to review installation
procedure at various stages of project. Key aspects of upcoming jobs
Benefits of this Construction Organization
Resulted in Success
Clear open lines of communication between field and engineering
across all companies e.g. (Construction Contractor, Projects & Operations)
Timely issue resolution
Management aware of team progress and sometimes included into meetings
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Construction Issues
Engineering Inspection Receipt Program & NCR Generation
- EIR Program consisted of all Equipment to receive inspection upon arrival to site by Shell
Operations and Maintenance Staff.
- For the Rotating Equipment the team consisted of 8 millwrights, 2 contract inspectors, and 3
engineers dedicated to program
- All equipment received inspection according to premade checklists & all deficiencies were
photographed and recoded for NCR records (used API 686 Ch 3 as guide for checklist
development)
- For 251 pumps a total of 1062 ERRORS FOUND CAUSING 313 NCR’S TO BE WRITTEN!
- Typical Deficiencies Discovered during EIR Inspections
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Construction Issues
14
Engineering Receipt Inspection Check lists
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Construction Issues
15
Typical EIR Program Deficiency Findings From Several Shell Projects
Why is an EIR Program Necessary:
To find missed items from factory inspection, it is critical to catch prior to installation
{Last chance to verify, to get it right}
For Documentation Reasons, you need accurate records (photographs of every issue works
best)
Capture the LL for the next project and pass along the findings to improve the quality of the
equipment coming from our future vendors
When to perform an EIR inspection:
ASAP... at PM warehouse
Important to take equipment out of packing and inspect it; then start preservation program.
Do not want the Construction Contractor to have to deal with late known problems that should
have been found at either the pre-shipment inspection or during an EIR.
EIR findings that require action are very expensive and distracting to a construction contractor’s
schedule.
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Construction Issues
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Typical EIR Program Deficiency Findings From Several Shell Projects
Typical issues:
1. Damage due to shipping
2. Verify ship loose items (misplaced, lost in transit, never shipped, etc...)
3. Shims not laser cut and/or are the wrong size
4. Motor does not have 8 jacking bolts
5. Suction/discharge/drain flanges are not covered with a metal closure
6. Water present in the case and drain lines
7. Oil mist lubricated bearings preserved with grease
8. Mounting pads do not meet the level requirements of API 610 and Purchase Order
9. Baseplate lacks levelling screws
10. Motor is bolt bound
17. Copyright of Royal Dutch Shell plc CONFIDENTIAL
Installation Procedures
Installation Procedure {API 686 &
Shell’s Minimum Requirements for
Rotating Equipment Installation}
Need to be reviewed and signed off
by Constructor, and Shell
Important to obtain input from
Operations & Project staff as well as,
for AWC buy in
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Inspection and Test Plan
Important to provide list of key surveillance, review, witness and hold points to
construction contractor for ITP development
Need clear expectations on ITP steps as the ITP is contractual language
For SUEX-1 the Major Hold and Witness Points for the Field Inspection and Test Plan
for Centrifugal Horizontal Pumps were:
Hold:
— Submit Contractor Installation Work Packages (first of every kind)
— Pre-grouting Meeting for alignment of path forward
— Oil System Installation, verification and flushed
— Final Alignment
Witness:
— Pre-installation Baseplate level check
— Pre-installation Preliminary alignment
— Pre-installation soft foot check
— Soft foot check
— Piping equipment / suction system cleanliness
— Pipe stress and flange alignment
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Key Points ITP’s
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Inspection and Test Plan
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Field Inspection and Test Plan of Centrifugal Horizontal Pumps
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Construction Issues
Preservation & Cleanliness
{Pre and Post Installation}
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Construction Issues
Preservation {Pre Installation}
Important to have constant
surveillance as conditions on a
construction site change daily
with work activities, weather,
etc.
Heated indoor storage and
constant auditing are best
preservation program (API 686
Ch 3 par 1.5.1-1.5.19)
Assign ownership of program
early {our experience went
through 2 preventative
maintenance companies during
project}
Define on an equipment tag
basis what equipment needs
what type of PM; have PM
Cards and an overall database;
follow up with regular
inspection.
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Construction Issues
Preservation
{Post Installation}
Issues
Hoarding damaged / removed
exposing equipment to weather
Water in Lube Oil skids
Short / modified dip sticks
Gear boxes with no oil
Uncovered flanges
Tubing and insulation damage
Incomplete PM cards
Key to audit regularly and
express importance to
construction contractor
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Room for levels on pump
pedestal so pump does not have
to be removed to mount level
Ensure motor is not bolt bound;
this is critical for alignment
API 686 tolerance of 0.002” per
foot is a very tight (API 686 Ch 5
3.9.4.4 leveling & Ch 7, paragraph
5.4.4.1 soft foot)
Level can only be achieved after
a constant temperature of the
steel, concrete and air is
normalized {anticipate 24-36 hrs
of constant temperature}
Test & calibrate levels regularly.
Use multiple levels to ensure
accuracy {these things get
dropped, damaged and
uncalibrated very easily}
Enter document title in Footer (Insert > Header & Footer > Apply to All) 23
Leveling & Soft Foot
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Leveling & Soft Foot
Follow Procedure
Test if pump or pedestal is not level
(API 686 Ch 5 Appendix D Figures D1-D10)
Need Pre Grout NCR Agreement Sign off by vendor
“YOU GROUT IT YOU OWN IT”
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Construction Issues
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Desire to achieve Concrete Surface Profile 9
Chipping (not bush hammering) to remove top
laitance layer and expose cracked aggregate
(API 686 Ch 5 par 3.6.2)
Preparation of bottom of base plate (buff/clean)
Ensure area is clean (no oil, water, dust, rags)
Date 07/11/2011 25
Construction Issues Grouting
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New U-Channel Design
Advantages of less grouting
(only of Main I-Beams),
cheaper construction time,
safer design for product
leaks or spills path to main
drain
Requires Rigid Base plates
(offshore base plates
design)
Experienced a design error
as civil wanted the U-
channel to reside in the
grout layer and mechanical
wanted it in the concrete
foundation
Caused some extra time
and drawing revision to
resolve
Enter document title in Footer (Insert > Header & Footer > Apply to All) 26
Construction Issues Grouting
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Construction Issues Grouting
Need continuous
temperature of 25 C,
Hoarding required for
temperature control even in
summer time
Heat is the key to getting
good grout flow
Important that temp of bags,
concrete, foundation & base
plate are all constant at
temperature prior to
starting; may need
circulation fans to keep
temperature; leave on for
24 hrs post grout (API 686 Ch
5 par 3.12.9)
Perform sample test cubes
for quality assurance
Perform a pre and post
level check for verification
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Field Machining
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Construction Issues
Field Machined 30 out of 251 base plates
approximately 12%
Estimated ~ $20,000 per base plate and a
week to ten days schedule delay to resolve
Need to be sure if it is the Pump feet or the
Pedestal that is to be machined
Critical for NCR’s agreement from vendor
prior to grouting
“YOU GROUT IT YOU OWN IT”
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Construction Issues
29
API 686 Piping Alignment Requirements are defined in (API 686 Chapter 6
paragraph 4.6.1-4.6.4)
4.6.1 No Sprung flanges to connect piping (i.e. use of straps, chains, blocking etc.)
Experienced no issues with requirement
4.6.2 Pipe Flange and Pump Flange need to line up within 1/16 inch Experienced no
issues with requirement
4.6.3 Flange Faces shall be parallel to within 0.001 inch per inch of flange outer
diameter Experienced no issues with requirement
4.6.4 Flange face separation shall be within the gasket spacing plus or minus 1/16 inch
Experienced many issues with this requirement
The Issue with 4.6.4:
The piping designer intentionally allowed a vertical load to be applied to the pump
nozzles in the cold condition. (i.e. the piping and pump flanges will be in contact)
The Piping Fitters were unaware of this intentional load and were trying to meet
the dimensions of the isometric drawing and API 686 Ch 6 par 4.6.4
This caused excessive and costly piping alignment / installation time
The resolution was to verify the load on the nozzle in the cold condition as per the
piping design. This entailed providing the pump nozzle loads to the field and
performing verification (i.e. prybar or load weigh scale)
Adjustment of the spring hangers or spring supports as a method of achieving
piping alignment is not acceptable. (API 686 Chapter 6 paragraph 4.7.3). Must be in
the cold locked position Experienced no issues with requirement
Piping Installation
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Construction Issues Piping Installation
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Construction
Alignment
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Very few alignment issues as all parties agreed that
alignment needs to be per API 686
(API 686 CH 7 par 5.4.2.4) All shims shall be full bearing, with
max of 5 shims (API 686 CH 7 par 5.4.2.1)
We experienced good success with alignment. Success
can be attributed to earlier leveling, soft foot checks and
rough alignment chart
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Construction
Key Learning’s from Construction
Job site demands and tasks are ever changing and daily meetings with owner
inspection team is vital
Need a strong relationship between Construction Contractor, Operations and
Project Team to ensure clear communication and for rise and resolution of issues
Our monthly workshops were excellent forums to get alignment and increase trust
in building working relationships
Vendor Representation on site full time to approve NCR’s for immediate
implementation is vital to construction phase success
API 686 tolerance of 0.002” per foot is a tight tolerance to achieve
Ensure all pressure vessels related to rotating equipment (filters, seal pots, etc.)
have proper ABSA registration and Canadian registration numbers
Ensure all tubing related to rotating equipment receives proper documented
pressure testing as per requirements stated in Pressure Equipment Safety
Regulation Section 4 criteria defined in B31.3 (pressure tubing is to be tested as
pressure piping)
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Mechanical Completion
Requires Multidisciplinary Organized Walk downs!
There will be findings
Key learning - budget time to resolve issues &
determine what needs to be resolved before or after
Start-up.
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Pre-Startup Issues & Checklist
Pre-Start-up Issues
Experienced leaks on pump seals due to
poor preservation (residual hydro test
fluid)
Flushing of auxiliary lube oil and barrier
fluid systems took a lot of time.
Cleanliness issues found
Motor Bump testing done to IEEE
Standard for (TEFC) Totally Enclosed Fan
Cooled Squirrel Cage Induction Motors
found high vibration issues, resulting in
additional stiffening support being
required
The need to loop check and fully function
check all instrumentation prior to start up
is critical and takes a great deal of effort
and time
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35. Copyright of Royal Dutch Shell plc CONFIDENTIAL
Start-up
Start-up Issues and Outcome
Issues
Unanticipated high vibration of pumps running off of BEP
Minor cavitation issues
Very few leaks, casing, tubing, instrumentation, etc
Mechanical Seals preservation damage (residual hydro test fluid)
Minor vibration of motor bases
Strainers with a weak delta pressure design
Outcome
Plant was commissioned and Start-up in Spring of 2011
No major incidents, and start-up progression achieved a Flawless Start-up
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