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1、MANUAL INSTALLATIONOF ROTATING EQUIPMENT DEP 31.29.00.10-Gen. July 1996 DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell International Oil Products B.V. and Sh
2、ell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any mean
3、s (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP) and Shell Internation
4、al Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement with the design, construction, operation and maintenance of processing units and faciliti
5、es, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good design and engineering practice applied
6、by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to use
7、rs for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual operating companies to adapt the information se
8、t forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered
9、, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technica
10、l advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be
11、distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other parties who are authorized to use DEPs subject
12、 to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant
13、standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with
14、 the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of DEPs. Without prejudice to any specifi
15、c terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the
16、 user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP may at any time require info
17、rmation satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). DDDs generally intro
18、duce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DE
19、P 31.29.00.10-Gen. July 1996 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.4 1.1SCOPE 4 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS4 1.3DEFINITIONS 4 1.4CROSS-REFERENCES4 2.GENERAL REQUIREMENTS.5 2.1QUALITY PLAN. 5 2.2CONSTRUCTION TOOLS / SPECIAL TOOLS.5 2.3INSTALLATION AND OPERATING MANUA
20、LS5 2.4SPARE PARTS6 3.STORAGE OF EQUIPMENT PRIOR TO INSTALLATION7 4.FOUNDATIONS8 4.1GENERAL 8 4.2FOUNDATION BOLTS8 4.3LEVELLING. 8 4.4GROUTING. 9 5.PIPING ASSOCIATEDWITH ROTATING EQUIPMENT.11 6.SHAFT ALIGNMENT13 6.1GENERAL 13 6.2REQUIREMENTS13 6.3DOWELLING.14 7.COUPLINGS.15 8.CLEANING OF PIPING SYST
21、EMS16 8.1CLEANING OF EQUIPMENT AND RELATED SYSTEMS.16 8.2FLUSHING OF LUBOIL AND SEAL OIL SYSTEMS.16 8.3CHEMICAL CLEANING.16 8.4FILTERS 16 9.FINAL INSPECTION AND CHECKS BEFORE START-UP.18 10.FIRST START, RUN-IN, INITIAL OPERATION19 11.REFERENCES20 APPENDICES APPENDIX 1aSTANDARD FOUNDATION DIMENSIONS
22、FOR THE INSTALLATION OF VERTICAL CLOSE COUPLED PUMPS22 APPENDIX 1bSETTING PLATE FOR VERTICAL CLOSE COUPLED PUMPS, BS 4082 - CODE 20 AND 6023 APPENDIX 1cSETTING PLATE FOR VERTICAL CLOSE COUPLED PUMPS, BS 4082 - CODE 10, 30, 40 AND 5024 APPENDIX 2TYPICAL ARRANGEMENT OF SOLE PLATES, LEVELLING SPINDLES
23、AND SHIMS AS USED FOR RECIPROCATING EQUIPMENT25 APPENDIX 3DIMENSIONS AND TYPICAL ARRANGEMENT OF JACKING BOLTS.26 DEP 31.29.00.10-Gen. July 1996 Page 3 1.INTRODUCTION 1.1SCOPE ThisDEP specifiesrequirementsandgives recommendationsforthemechanical installation of rotating equipment. This DEP shall supp
24、lement and, in those cases where it is more stringent, shall replace the Manufacturers recommendations. This DEP shall be used by the Contractor to prepare checklists to ensure proper installation of rotating equipment. This DEP is a revision of an earlier DEP of the same number dated October 1984.
25、1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIOP and SIEP, the distribution of this DEP is confined to companies forming part of the Royal Dutch/Shell Group or managed by a Group company, and to Contractors nominated by them (i.e. the distribution code
26、is “C“ as defined in DEP 00.00.05.05-Gen.). This DEP is intended for use in oil refineries, chemical plants, gas plants and, where applicable, in exploration and production facilities and supply/marketing installations. If national and/or local regulations exist in which some of the requirements may
27、 be more stringent than in this DEP the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the
28、Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this DEP as closely as possible
29、. 1.3DEFINITIONS The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or some of the duties of the Contractor. TheManufacturer/Supplier/Ven
30、doristhepartywhichmanufacturesorsupplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principa
31、l may also include an agent or consultant authorised to act for and on behalf of the Principal. The word shall indicates a requirement. The word should indicates a recommendation. 1.4CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown i
32、n brackets. Other documents referenced in this DEP are listed in (11). DEP 31.29.00.10-Gen. July 1996 Page 4 2.GENERAL REQUIREMENTS 2.1QUALITY PLAN At an early stage of the project the Contractor shall propose for the approval of the Principal a quality plan covering all aspects of installation, ins
33、pection and pre-commissioning of rotating equipment Each individual item of equipment shall have its own checklist covering all aspects of installation, inspection and pre-commissioning. Such a checklist shall ultimately be signed by the rotating equipment department of the Principal or its represen
34、tative and shall act as a key document in the hand-over procedure. A copy of the completed checklist shall be added to the Equipment Record Card (including installation records, level and alignment data, run-in record, vibration data etc.). Reference is made to DEP 61.10.08.11-Gen. 2.2CONSTRUCTION T
35、OOLS / SPECIAL TOOLS It is the Contractors responsibility to ensure that the correct tools are available and are used for the proper installation of rotating equipment (i.e. stainless steel shims, correct-size spanners and keys, certified slings and chain hoists, torque wrenches, metric alignment di
36、al gauges and calibrated engineering spirit levels, vibration meters, analysers, etc.). Generally, adjustable spanners shall not be used on rotating equipment. Abnormal wear and tear of parts of equipment through the use of improper tools during installation is not acceptable. At hand-over, equipmen
37、t shall be in as-new condition. At an early stage during construction a check should be made on the availability of special tools that shall be supplied by the equipment manufacturer. These special tools shall be used by the Contractor when required, but the Contractor remains responsible for the ca
38、re of these tools and their hand-over to the Principal in an “as-new“ condition. 2.3INSTALLATION AND OPERATING MANUALS The Manufacturers installation and operating manuals shall be available at site at least one month prior to installation of the equipment. The instructions contained therein shall b
39、e followed unless superseded by more stringent requirements in this DEP. Shop test and inspection records and records of all “as built“ clearances shall be collected and made available at site when the installation commences. At the time installation starts, completed Equipment Record Cards of all e
40、quipment supplied shall be available at site. In the Project Specification it shall be specified whether Record Cards are required in electronic form or as hard copies. During installation and commissioning, the Contractor shall add any relevant information to the Equipment Record Cards. The Contrac
41、tor is responsible for ensuring that lubricants comply with the latest Shell grade designation or equivalent, as approved by the Principal. The Contractor should minimise the number of grades by a grade rationalisation exercise in consultation with the Principal and the equipment manufacturer. Howev
42、er, this grade rationalisation shall not violate the individual equipment manufacturers guarantees. The Contractor shall furnish lubricant recommendations for all rotating equipment of the project in the form of a lubrication manual, which shall contain the required grade and quantity of lubricant a
43、s well as the lubrication intervals for each individual rotating equipment item. This information shall be available six months prior to the start-up of the installation. 2.4SPARE PARTS DEP 70.10.90.11-Gen. shall apply. The Contractor shall ensure that initial and insurance DEP 31.29.00.10-Gen. July
44、 1996 Page 5 spare parts are available during the construction and commissioning period. Normal operating spare parts shall be ordered to arrive at site prior to hand-over of the equipment to the Principal. Spare rotors for major rotating equipment are usually furnished with watertight metal transpo
45、rt/storage containers suitable for vertical storage and able to withstand an internal pressure of 0.20 bar (ga). These containers shall be checked on arrival at site for any signs of damage and for absence of moisture and shall be stored according to the Manufacturers instructions. Vertical storage
46、is recommended if allowed by the Manufacturers instructions. Special attention is required to ensure that a proper inert environment is maintained in this container e.g. by nitrogen under a slight overpressure. All sparerotorsshall beproperly supported, preserved in accordancewith DEP 70.10.70.11-Ge
47、n., and supplied with clear instructions for long term storage. The Contractor is responsible for the preparation of separate equipment record cards for major capital spares such as rotors, blade carriers, electric motors, gearboxes, etc. This record card shall correspond to the unique identificatio
48、n number of each item. DEP 31.29.00.10-Gen. July 1996 Page 6 3.STORAGE OF EQUIPMENT PRIOR TO INSTALLATION DEP 70.10.70.11-Gen. shall apply. At an early stage of the project it should be ensured that there will be adequate quantities of rust preventatives at site by the time equipment is received. St
49、ocks of Shell Ensis Fluid G, H, K, Ensis Oil N and Shell Ensis Engine Oil, Ensis Compound CB, VPI-crystals in bags, VSI 8235 additive and sufficient desiccant in bags shall be available. Other equivalent protective fluids may be used if approved by the Principal. If the equipment is received at site and cannnot be installed immediately it shall be stored in a dry location. On receipt the equipment shall be checked against the shipping manifest and inspected for any damage. Shop preservation shall be checked. Where necessary, damage to preservation shall be rectified without delay. Shop
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