Page 555 - Subyek Teknik Mesin - Forsthoffers Best Practice Handbook for Rotating Machinery by William E Forsthoffer

Be st Practice 1 0.1 The Post-Shipment Phase: Installation, Pre-Commissioning, Commissioning and Start-up Best Practices

Best
Best Practice 10.1Practice 10.1
Review and finalize machinery installation details well in effective planning, management and implementation
advance of site construction activities to ensure optimum during the project construction phase.
safety and reliability for the plant life cycle. The following examples show how the reliability of properly speci-
The relevant areas to concentrate on are as follows: fied, designed and tested machinery was challenged by inadequate
Prepare, review and approve all site installation procedures (See construction phase execution:
‘Supporting Material’ below for specific procedures). Preservation procedures not prepared in advance, general in nature
Confirm spare part orders, delivery dates, storage facilities and and not implemented
preservation compounds. Instruction manuals not on site when required and when received,
Review and approve all machinery instruction manuals prior to not complete
shipment, and require manuals be shipped at the same time as the Spare parts not on site when required resulting in start-up delays
machinery. Special tools missing and not available resulting in start-up delays
Review the special tool list during the engineering phase and require
their shipment at the same time as the machinery.
Establish a ‘material receipt’ procedure to confirm that all required Benchmarks
material has been received on or before the promised date. This best practice has been used since the mid-1980s for large pet-
rochemical projects, and requires that all machinery construction de-
Confirm that there is full coordination between the engineering/ tails be addressed during the engineering phase of the project. This
procurement (EP) and construction (C) groups to ensure the above best practice has resulted in smooth, timely start-ups for large ma-
best practice guidelines are executed well before the construction chinery, and critical machinery reliabilities of maximum safety and re-
phase. liability (greater than 99.7%).

Lessons Learned
Critical machinery safety and reliability is not ensured only
by proper specification, design and testing but depends on

B.P. 10.1. Supporting Material Site procedures
The importance of site installation procedures cannot be over-
Regardless of the quality of design and manufacture; regard- emphasized. Figure 10.1.2 shows the most commonly required
less of a successful test and efficient shipment; installation site installation procedures.
will determine the amount of maintenance required and the It must be remembered that the objectives of the construc-
resulting revenue of the process unit. Figure 10.1.1 shows the tion contractor and of the end user are identical in terms of
general site considerations that are required for a successful profit. However, they are dissimilar in the means used to achieve
field installation. Each one of these items will now be these common objectives. The contractor’s objective is to con-
covered. struct a safe and reliable process unit within the budget and on
time. This objective is opposed to the end user’s objective,
which is to operate the process unit for thirty years or more at
maximum profit and thus requires maximum reliability of the
installed equipment. The only leverage that the end user has in
meeting his objectives is to require practical, proven site
installation procedures that will result in the most reliable, safe
and cost effective installation of his equipment. Frequently the
contactor will rely on the equipment vendor to provide most of
the site procedures. It is strongly recommended that the end
user, early in the project, require approved procedures for every
major site installation milestone. These procedures include, but
are not limited to:
- Equipment preservation
- Equipment installation
- Grouting
- Alignment
- Flushing
- Functional checks
- Initial run in of equipment

It must be mentioned that preservation procedures are often
Fig 10.1.1 General site considerations ignored early in a construction project and become written and

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