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SPECIFICATION LEVELING AND INSTALLING OF PACKAGE BASES

Data Control Level

1 Release Stamp

Rev

SPECIFICATION NO. ES 9-414

(Date and PRD No.)

REVISION: C (Letter, Date and CR No.)

A; 09/05/03; CR8405 B; 05/10/05; CR11594

CR

14996 C

ISSUED: 12/16/99; PRD 66541-6

Signature and Title

Date

Prepared by: Benjamin Eyes Staff Design Engineer, OG

10/10/2006

Prepared by: Mark Smolin Program Manager, PG

10/10/2006

Approved By: Frank Peterson Group Manager, Mechanical Analysis, OG

10/10/2006

Approved By: JoJo Malo Manager, Project Support & Commissioning, OG

10/10/2006

Pages Affected

2 thru 27

ATTENTION This copyrighted work and the information herein is proprietary to Caterpillar Inc., Solar Turbines Incorporated, and/or subsidiaries of either. Without express, written proprietor permission, any copying, disclosure, or use except that for which it is loaned, is prohibited.

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CONTENTS Section 1.0 2.0 3.0 4.0 5.0 6.0 7.0

Page 1 1 2 20 20 20 21

Purpose Reference Information Package Elevation and Leveling Package Shimming and Grouting Torquing Foundation Bolts Alignment Check Installation Procedure: Package to Sub-Base

FIGURES Figure 2.1 3.1.1 3.1.2 3.1.3 3.1.4 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.3.1 3.3.2 3.4.1 3.4.2 3.4.3 3.4.4 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10

Page Reference View for Definition of Terms Typical Separate Driver/Driven Package With More Than 4 Mount Points Locations to Measure for Package Level Package Skid Match Marks Recommended Torque Pattern Sequence Typical Separate Driver/Driven Package With 3 or 4 Mount Points Locations to Measure for Package Level Package Skid Match Marks Recommended Torque Pattern Sequence Typical Separate Driver/Driven Package Before Being Placed on Gimbal Mounts Locations to Measure for Package Level Package Skid Match Marks Recommended Torque Pattern Sequence Typical Separate Driver/Driven Package With Gimbal Mounts Typical Single Piece With More Than 4 Mount Points Locations to Measure for Package Level Typical Single Piece With 3 or 4 Mount Points Locations to Measure for Package Level Typical Single Piece Package With Gimbal Mounts Locations to Measure for Package Level Mounting Pads and Jacking Point Locations Mounting System and Jacking Point Locations Verifying Horizontal Planes Support Center of Sub-Base to Prevent Deflection Driver Installation Driver Leveling Driver Installation and Leveling Install Driver/Driven Interface Hardware Install Frame Tie-Down Bolts Remove Center-Support Jacks

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2 4 5 6 6 7 8 8 9 11 11 12 12 13 14 15 16 17 18 19 23 23 24 24 25 25 26 26 27 27

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Specification No. ES 9-414

1.0

Purpose

To describe the procedure to place Solar Turbines packages on their foundation, establish vertical elevation, level package, and prepare for drivetrain alignment.

2.0 Reference Information 2.0a Applicable Documents • • • • •

Project Specific Mechanical Installation Drawing Fastener Installation and Torque Values, ES 9-54 Grout Specification Document (Pending) Hardware/Shim specification (Pending) Anchor Bolt Specification (Pending)

2.0b Definition of Terminology • •

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• • •

•

•

•

Package Skid Interface – The location where the driver and driven skid are bolted together on a package that is constructed with separate skids. Machined pads on both portions of the package skid form the bolted joint. Machined Equipment Mounting Pads – The machined upper pads on the package skid onto which the equipment is mounted. These include pads for the Engine spring mounts and trunnions (depending on package type), Gearbox (if applicable), and the Generator or Compressor. Frame Foundation Pads – The thick steel pads at the lowest part of the package skid that are used to attach the package skid to foundation. These pads have a slot for the tie-down bolt to pass through, and threaded holes for the jacking bolts to pass through. In the case of O&G package skids, these pads are the lowest point on the skid, and their lower surface forms Datum C. In the case of PG package skids, the Frame Foundation Pads are welded to the top of the lower flange of the main package I-beam, and the underside of the I-beam forms Datum C. Solar takes exception to API 5.3.2.9, and does not machine the Frame Foundation Pads. Frame Jacking Pads – Steel pads at the lowest part of the package skid that are used for jacking purposes only. These pads are smaller than the Frame Foundation Pads, and are often located near the package skid interface. Site Watermark – An immovable location at site that should be chosen as the reference point to which all equipment is positioned. Careful use of a consistent Site Watermark will aid in the interfacing of equipment. Datum C – The plane that is formed by the underside of the Frame Foundation Pads. Solar uses this plane as the “benchmark” during the design process to assign the vertical relationship of all component interfaces including ancillary, hydro-mechanical hook-ups, and electrical connections. It is critical that a relation be established between this design datum, and a Site Watermark for the installation and set-up of the package. Site Elevation Point – A reference point that should be chosen at site to use for package elevation purposes. The Site Elevation Point should be positioned higher than the Site Water Mark by a distance equal to the distance between Package Datum C and Datum D. Please refer to the Solar Mechanical Installation Drawing for this relationship. Datum D – The plane that it formed by the machined surfaces located on the tops of the package lifting attachment points. These points are a reference plane that should be used to measure the vertical elevation of the package in relation to the Site Elevation Point. These points are also useful for preliminary package leveling operations, but must not be used for final package leveling. Gimbal Mounts and Anti-Vibration Mounts (AVMs)– Types of package mounts that are designed to lessen the influence of platform/deck deflections on offshore packages. 1

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The mounts will usually attach to the Frame Foundation Pads. These mounts are optional and will not be supplied with every package. Datum E – The plane that is formed by the underside of the Gimbal Mounts or AVMs on a package that is supplied with these mounts. This datum functions the same way as Datum C does on a package without Gimbals or AVMs.

The above listed terms are shown pictorially in Figure 2.1 for clarification.

Figure 2.1: Reference View for Definition of Terms

3.0

Package Elevation and Leveling

The first step for the installation of any package is the verification of the foundation onto which the package will be mounted. It should be verified that there are no high spots in the foundation between the mounting pads or Sole Plates that could possibly contact the underside of the frame. The foundation pads or Sole Plates should be at least level with, if not higher than the rest of the foundation. Each foundation pad or Sole Plate should be installed flat within 0.005”/ft, and coplanar within ±0.120” to the other pads. Before lifting the package into position, confirm that the foundation has been laid out properly, and that all tie-down holes in the foundation also match the Solar Mechanical Installation Drawing. Next, measure the distances between the tie-down foot slots on the package skid and confirm that they match the distances listed on the Solar Mechanical Interface Drawing. This process of checking is to confirm that the tie-down locations in the skid and the foundation will line up once the package is lifted into position. It is preferable to do this as early as possible, so that any foundation misalignments can be rectified before expensive lifting equipment is brought to site. On some of the larger Solar packages, it is very difficult to raise the package upward using the package jacking bolts. As the package is lifted into position, the package jacking bolts should be extended or threaded through the package tie-down foot so that they protrude from the underside of the foundation feet as far as possible. The package jacking bolts can then be backed off more easily to lower the package into the level position. Make sure the area beneath the package jacking bolts has sufficient strength to hold the package. It is imperative that a machinist’s level, or a measuring tool of equivalent resolution (laser beacon or transit) be used to measure the levelness of the skid. Skid level must be measured on the machined equipment mounting pads of the skid, and not the surfaces that make up Datum D. The tops surfaces of the skid I-beam are not Engineering-controlled surfaces, and a package will not be considered level if these surfaces are used to measure the levelness of the package.

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Caution Datum C on the Solar MID drawing refers to the underside of the driver and driven skid foundation feet, and not the top surface of the foundation. In the case of a package that is equipped with AVM or Gimbal mounts, then Datum E is the underside of the AVM or Gimbal. Datum C or Datum E MUST be positioned using a consistent relationship with the same Site Watermark that is used to position all other equipment including ancillary, enclosure, piping, and electrical. Failure to do so could result in equipment misalignments during assembly.

Much of the information in the following instructions is repeated between sections. Please refer only to the section that is dedicated to the type of skid being leveled, and discard the sections that do not apply.

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3.1

Separate Driver/Driven Skid Packages (5 or More Mount Points)

Lift the package into position and lower it onto the foundation pads with the package jacking bolts threaded through the Frame Foundation Pads as far as they will go. Driver and driven package sections that are shipped from the factory bolted together are not considered to be one piece and should have their interface hardware loosened for elevation and leveling operations. Note: Even if it appears that the factory-mated bases have not shifted during transportation, the driver and driven bases should have their interface hardware loosened to achieve proper package elevation and level in preparation for alignment. Once the package interface hardware has been loosened, the elevation of the skids must be set before leveling can begin. A typical multi-point mounted package with a separate driver and driven skid is shown in Figure 3.1.1. The vertical height of the package should be set using the machined surfaces of Datum D, which are shown in Figure 3.1.1. Package jacking bolts have been provided in the package tie down feet and package jacking feet for vertical adjustment. Lower the package using the package jacking bolts, and use a surveyor's transit or equivalent measuring tool to set the elevation of the package leveling datum points to a previously defined Site Elevation Point. The individual Datum D points should be level and coplanar to the Site Elevation Point within 1/16 inch (1.6 mm).

Figure 3.1.1: Typical Separate Driver/Driven Package With More Than 4 Mount Points Once the package is considered to be at the correct elevation by Datum D, the final leveling process can begin. Make sure that the drivetrain equipment hold-down hardware is fully loosened before attempting to level the base. This includes the hardware used to bolt down the engine, gearbox, and the generator or compressor. It is possible to restrain the base in a deflected condition with the drivetrain equipment hardware; the hardware must be loosened to ensure the package skid is leveled properly. Level the driven package first and then the driver package.

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Final leveling must be done using a calibrated machinist’s level, or instrument of equivalent resolution on the machined equipment mounting pads of the package With the skid interface hardware still loose, all machine mounting pads must be leveled to within 0.005”/ft. This includes the engine mount pads, gearbox mount pads (if applicable), and the driven equipment pads. The level criteria of 0.005”/ft is for both the forward to aft as well as side-to-side direction. Measure the pad level next to the tie-down points of each piece of equipment as shown in Figure 3.1.2, and get all pads within the level criteria.

= areas on the machined pads where frame level criteria must be held to 0.005”/ft

Figure 3.1.2: Locations to Measure for Package Level For the rare case of a package with separate driver and driven skids that remain separate, elevate and level the driven base first and then the driver base. Then adjust either base for correct interconnect shaft installation or machinery shaft end distance. Shafts must be pushed against their appropriate active thrust bearings before taking measurements. Once the two sections of the package are considered level, obtain the proper equipment to torque the interface bolts. Use the match marks at the package interface pads (when provided) to ensure the elevation of the bases has been retained in relation to each other. The match marks are shown below in Figure 3.1.3. The elevation between the two sections of the package should have been set very closely during the prior elevation of Datum D, but it needs to be confirmed that correct elevation has not been lost during leveling. If one of the sections of the package is higher than the other, then it must be determined which one should be moved. That package section should be elevated or lowered until the match marks are aligned. This must be done evenly and carefully to retain the level of the package. If the factory match marks are not provided, then the interface boltholes must be used as the guide to elevating the skids.

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Interface Match Marks

Figure 3.1.3: Package Skid Match Marks Ensure that both sections of the package are still within the level criteria, and then torque the interface bolts to their full torque spec. The interface bolts should be re-tightened in the pattern shown below:

Figure 3.1.4: Recommended Torque Pattern Sequence Monitor the level of each package section during the torque sequence, and make sure the package sections are not moving in relation to one another. Make sure all machined pads have remained level after the interface bolts have been torqued. If the combined package is not level, use the package jacking bolts in the Frame Foundation Pads to get the package back within the level spec. If level cannot be achieved simultaneously on all pads, then the two sections of the package were shifted during the interface bolt torque-up, and the joint must be loosened again, and the process must be repeated. The Package tie-down feet are now ready to be shimmed, and have the tie-down bolts torqued. Please refer to Section 4 for instructions on grouting or shimming the package.

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3.2 Separate Driver/Driven Skid Packages 3.2a Packages Mounted on 3 or 4 points (Not using Gimbal Mounts or AVMs) Lift package into position and lower it onto the foundation pads with the package jacking bolts threaded through the Frame Foundation Pads as far as they will go. Driver and driven package sections that are shipped from the factory bolted together are not considered to be one piece and should have their interface joint loosened for elevation and leveling operations. Note: Even if it appears that the factory-mated bases have not shifted during transportation, the driver and driven bases should have their interface joint loosened to achieve proper package elevation and level in preparation for alignment. Once the package interface hardware has been loosened, the elevation of the skids must be set before leveling can begin. A typical 3-point mounted package with separate driver and driven skids is shown in Figure 3.2.1. The vertical height of the package should be set using machined surfaces of Datum D, which are shown in Figure 3.2.1. Package jacking bolts have been provided at the package foundation feet and package jacking feet for vertical adjustment. Lower the package using the package jacking bolts, and use a surveyor's transit or equivalent measuring tool to set the elevation of the package leveling Datum D points to a previously selected Site Elevation Point. The individual datum points should be level and coplanar to the Site Leveling Point within 1/16 inch (1.6 mm).

Figure 3.2.1: Typical Separate Driver/Driven Package with 3 or 4 Mount Points Once the package is considered to be at the correct elevation by the Datum D points, the final leveling process can begin. Make sure that the drivetrain equipment hardware is fully loosened before attempting to level the base. It is possible to restrain the base in a deflected condition with the drivetrain equipment hardware; the hardware must be loosened to ensure the package skid is leveled properly. Level the driven package first and the driver package second.

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Final leveling must be done using a calibrated machinist’s level, or instrument of equivalent resolution on the machined equipment mounting pads of the package With the skid interface hardware still loosened, all machine mounting pads must be leveled to within 0.005”/ft. This includes the engine mount pads, gearbox mount pads (if applicable), and the driven equipment pads. The level criteria of 0.005”/ft is for both forward to aft as well as side-to-side level. Measure the pad level next to the tie-down points of each piece of equipment as shown in Figure 3.2.2, and get all pads within the level criteria.

= areas on the machined pads where frame level criteria must be held to 0.005”/ft

Figure 3.2.2: Locations to Measure for Package Level Once the two sections of the package are considered level, obtain the proper equipment to torque the interface bolts. Use the match marks at the package interface pads (when provided) to ensure the elevation of the bases has been retained in relation to each other. The elevation between the two sections of the package should have been set very closely during the prior elevation of Datum D, but it needs to be confirmed that correct elevation has not been lost during leveling. If one of the sections of the package is higher than the other, then it must be determined which one should be moved, and that package half should be elevated or lowered carefully to retain level, until the match marks are aligned. If the factory match marks are not provided, then the interface boltholes must be used as the guide to elevating the skids.

Interface Match Marks

Figure 3.2.3: Package Skid Match Marks Ensure that both sections of the skid are still within the level criteria, and then torque the interface bolts to their full torque spec. The interface bolts should be re-tightened in the pattern shown below:

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Figure 3.2.4: Recommended Torque Pattern Sequence Monitor the level of each package section during the torque sequence, and make sure the package sections are not moving in relation to one another. Make sure all machined pads have remained level after the interface bolts have been torqued. If the combined package is not level, use the package jacking bolts to get the package back within the level spec. If level cannot be achieved simultaneously on all pads, then the two sections of the package were shifted during the interface bolt torque-up, and the joint must be loosened again, and the process must be repeated. Once the entire, combined package is considered level, release the package jacking bolts that are threaded through the Frame Jacking Pads and allow the frame to be supported by the 3 or 4 package jacking bolts that are threaded through the Frame Foundation Pads. It is not always possible to have the forward to aft level within tolerance on all of the machined pads on a package that is mounted on 3 or 4 points. The package will sag under its own weight, and the machined pads at the forward and aft end of the package will end up being sloped downward toward the center of the package. Depending on the package size and weight, the forward to aft slope may be outside of the 0.005”/ft tolerance. In this case, the gearbox mount pad becomes the critical point of measurement and this pad must be leveled within 0.005”/ft in both the forward to aft, and side to side directions. All machined pads still must be leveled within 0.005”/ft from side to side. Use only the package jacking bolts that are located in the 3 or 4 final skid foundation feet to adjust the level of the machine pads. Do not use the package jacking bolts that are in the Frame Jacking Pads. The Package tie-down feet are now ready to be shimmed, and have the tie-down bolts torqued. Please refer to section 4 for instructions on grouting or shimming the package.

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3.2b Separate Driver/Driven Skid Packages (Mounted on AVM’s or Gimbals) The method for leveling a package mounted on Anti-Vibration Mounts (AVMs) or Gimbal Mounts has some significant differences from the procedure used for packages without these mount. The AVMs/Gimbals (referred to as “mounts” from here on) should be placed correctly on the foundation pad, and in the correct orientation according to the MID. With the mounts in their correct positions, carefully measure the distances between them to confirm that they match the MID before lifting the package into position. This measuring step is to help ensure that the boltholes in the mounts will line up with the boltholes in the package skid. The mounts are shimmed for vertical adjustment between the foundation and the mount, not between the mount and the package skid. For this reason, the top surface of the mount can be treated as if it were Datum C. Use a transit or equivalent measuring tool to compare the vertical height of the foundation pads that the AVM or Gimbal mounts will bolt down to. It is much easier to adjust the shim under the mounts before the package is resting on them, so every effort should be made to get the mounts level to each other before the package is set on the mounts. By accurately measuring the relative heights of the foundation pads and compensating with shims, the top surfaces of the AVMs or Gimbals can and should be made coplanar within 0.060” before the package is set on the mounts. The mounts are now ready to receive the package. Once the package is placed on the mounts, the driver and driven skids cannot be unbolted from each other. Because of this, the driver and driven skid must be elevated and leveled in relation to each other on a separate, flat surface. Lift the package onto a flat, level surface with the package jacking bolts threaded through the Frame Foundation Pads as far as they will go. Driver and driven package sections that are shipped from the factory bolted together are not considered to be one piece and should have their interface joint loosened for elevation and leveling operations. Note: Even if it appears that the factory-mated bases have not shifted during transportation, the driver and driven bases should have their interface joint loosened to achieve proper package elevation and level in preparation for alignment. Once the package driver to driven hardware has been loosened, the elevation of the skids must be set equal to each other before leveling can begin. The vertical height of the package should be set using the machined surfaces of Datum D, which are shown in Figure 3.2.5. Package jacking bolts have been provided in the package tie down feet and package jacking feet for vertical adjustment. Lower the package using the package jacking bolts, and use a surveyor's transit or equivalent measuring tool to set the elevation of the package leveling datum points relative to each other. A view of a typical package with separate driver/driven skids is shown in Figure 3.2.5 before it is placed on the AVM or Gimbal mounts. The individual datum points on the package skid should be level and coplanar to each other within 1/16 inch (1.6 mm).

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Figure 3.2.5: Typical Separate Driver/Driven Package Before Being Placed on Gimbal Mounts Once the package is considered to be at the correct elevation by the Datum D points, the final leveling process can begin. Make sure that the drivetrain equipment hardware is fully loosened before attempting to level the base. It is possible to restrain the base in a deflected condition with the drivetrain equipment hardware; the hardware must be loosened to ensure the package skid is leveled properly. Level the driven package first and the driver package second. Final leveling must be done using a calibrated machinist’s level, or instrument of equivalent resolution on the machined equipment mounting pads of the package With the skid interface hardware still loosened, all machine mounting pads must be leveled to within 0.005”/ft. This includes the engine mount pads, gearbox mount pads (if applicable), and the driven equipment pads. The level criteria of 0.005”/ft is in both the forward to aft as well as side-to-side level direction. Measure the pad level next to the tie-down points of each piece of equipment as shown in Figure 3.2.6, and get all pads within the level criteria.

= areas on the machined pads where frame level criteria must be held to 0.005”/ft

Figure 3.2.6: Locations to Measure for Package Level

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Once the two sections of the package are considered level, obtain the proper equipment to torque the interface bolts. Use the match marks at the package interface pads (when provided) to ensure the elevation of the bases has been retained in relation to each other. The elevation between the two sections of the package should have been set very closely during the prior elevation of Datum D, but it needs to be confirmed that correct elevation has not been lost during leveling. If one of the sections of the package is higher than the other, then it must be determined which one should be moved, and that package half should be elevated or lowered until the match marks are aligned. This must be done carefully and evenly to retain the level of the skid. If the factory match marks are not provided, then the interface boltholes must be used as the guide to elevating the skids.

Interface Match Marks

Figure 3.2.7: Package Skid Match Marks Ensure that both sections of the skid are still within the level criteria, and then torque the interface bolts to their full torque spec. The interface bolts should be re-tightened in the pattern shown below:

Figure 3.2.8: Recommended Torque Pattern Sequence Monitor the level of each package section during the torque sequence, and make sure the package sections are not moving in relation to one another. Make sure all machined pads have remained level after the interface bolts have been torqued. If the combined package is not level, use the package jacking bolts in the Frame Foundation Pads and the Frame Jacking Pads to get the package back within the level spec. If level cannot be achieved simultaneously on all pads, then the two sections of the package were shifted during the interface bolt torque-up, and the joint must be loosened again, and the process must be repeated. Once the entire, combined package is considered level, the package is ready to be lifted onto its mounts. Lift package onto the AVMs or Gimbals, and bolt the package to the mounts. Release the lifting cables, and allow the frame to sag under its own weight Once the package is laid onto the 12

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mounts, the vertical elevation of the package must be checked in relation to a Site Elevation Point using the machined surfaces of Datum D. A typical AVM/Gimbal mounted package with separate driver and driven skids is shown in Figure 3.2.9. Jack up the package using hydraulic jacks, and shim under the mounts to adjust the vertical height of the package. Use a surveyor's transit or equivalent tool to measure the elevation of the Datum D surfaces, and elevate the individual datum points to be level and coplanar to a Site Elevation Point within 1/16 inch (1.6 mm).

Figure 3.2.9: Typical Separate Driver/Driven Package with Gimbal Mounts Once the skid is considered to be at the correct elevation by the Datum D points, the final leveling process can begin. Final leveling must be done using a calibrated machinist’s level, or instrument of equivalent resolution on the machined equipment mounting pads of the package. It is not always possible to have the forward to aft level within tolerance on all of the machined pads on a package that is mounted on 3 points. The package will sag under its own weight, and the machined pads at the forward and aft end of the package will end up being sloped downward toward the center of the package. Depending on the package size and weight, the forward to aft slope may be outside of the 0.005”/ft tolerance. In this case, the gearbox mount pad becomes the critical point of measurement and this pad must be leveled within 0.005”/ft in both the forward to aft, and side to side directions. All machined pads still must be leveled within 0.005”/ft from side to side. Jack up the package and adjust the shim under the package mounts to adjust the level of the package until the gearbox pad is level within 0.005”/ft in both horizontal planes, and the rest of the pads are level within 0.005”/ft from side to side. Once the package has been shimmed correctly with the provided shims, the tie-down bolts must be torqued to the spec given on the Solar MID. Package leveling is now complete, go onto Section 6 for Final Package Alignment.

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3.3 Single Piece Skid (5 or More Mount Points) Lift package into position and lower it onto the foundation pads with the package jacking bolts threaded through the Frame Foundation Pads as far as they will go. When the package has been laid on the foundation, the elevation of the skids must be set before leveling can begin. A typical multi-point mounted, single piece package is shown in Figure 3.3.1. The vertical height of the package should be set using the machined surfaces of Datum D, which are shown in Figure 3.3.1. Package jacking bolts have been provided in the package tie down feet and package jacking feet for vertical adjustment. Lower the package using the package jacking bolts, and use a surveyor's transit or equivalent measuring tool to set the elevation of the Datum D points to a previously selected Site Elevation Point. The individual Datum D points should be level and coplanar to the Site Elevation Point within 1/16 inch (1.6 mm).

Figure 3.3.1: Typical Single Piece Package With More Than 4 Mount Points Once the package is considered to be at the correct elevation by the Datum D points, the final leveling process can begin. Make sure that the drivetrain equipment hardware is fully loosened before attempting to level the base. It is possible to restrain the base in a deflected condition with the drivetrain equipment hardware; the hardware must be loosened to ensure the package skid is leveled properly. Final leveling must be done using a calibrated machinist’s level, or instrument of equivalent resolution on the machined equipment mounting pads of the package All machine mounting pads must be leveled to within 0.005”/ft in both the forward to aft, and side to side directions. This includes the engine mount pads, gearbox mount pads (if applicable), and the driven equipment pads. Measure the pad level next to the tie-down points of each piece of equipment as shown in Figure 3.3.2, and get all pads within the level criteria.

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= areas on the machined pads where frame level criteria must be held to 0.005”/ft

Figure 3.3.2: Locations to Measure for Package Level The Package tie-down feet are now ready to be shimmed, and have the tie-down bolts torqued. Please refer to section 4 for instructions on grouting or shimming the package.

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3.4

Single Piece Skids (3 or 4 point mounted)

3.4a Skid Mounted on 3 or 4 Points (Not Using Gimbals or AVMs) Lift package into position and lower it onto the foundation pads with the package jacking bolts threaded through the Frame Foundation Pads as far as they will go. Once the package has been laid on the foundation, the elevation of the skid must be set before leveling can begin. A typical 3-point mounted package with a single piece skid is shown in Figure 3.4.1. The vertical height of the package should be set using machined surfaces of Datum D, which are shown in Figure 3.4.1. Package jacking bolts have been provided in the package tie down feet and package jacking feet (if applicable) for vertical adjustment. Lower the package using the package jacking bolts, and use a surveyor's transit or equivalent measuring tool to set the elevation of the package leveling datum points to a previously selected Site Elevation Point. The individual Datum D points should be level and coplanar to the Site Elevation Point within 1/16 inch (1.6 mm).

Figure 3.4.1: Typical Single Piece Package with 3 or 4 Mount Points Once the package is considered to be at the correct elevation by the Datum D points, the final leveling process can begin. Make sure that the drivetrain equipment hardware is fully loosened before attempting to level the base. It is possible to restrain the base in a deflected condition with the drivetrain equipment hardware; the hardware must be loosened to ensure the package skid is leveled properly. Level the driven package first and the driver package second. . Final leveling must be done using a calibrated machinist’s level, or instrument of equivalent resolution on the machined equipment mounting pads of the package Since most packages of this type only have package jacking bolts in the 3 or 4 Frame Foundation Pads, and no additional Frame Jacking Pads, it is not always possible to achieve forward to aft level on all machine pads. The package will sag under its own weight, and the machined pads at the forward and aft end of the package may end up being sloped downward toward the center of the package. Depending on the package size and weight, the forward to aft slope may be outside of the 0.005”/ft tolerance. For this type of package, the critical machined surface to measure is the gearbox pad. The level criteria for the gearbox pad is 0.005”/ft for both forward to aft as well as side-to-side level. All other machined pads including the driven equipment pads, and engine mount pads must be level within 16

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0.005”/ft from side to side. Measure the pad level next to the tie-down points of each piece of equipment as shown in Figure 3.4.2, and get all pads within the appropriate level criteria using only the package jacking bolts in the Frame Foundation Pads. If the package does have Frame Jacking Pads near the center of the package, do not use these for final package leveling.

= areas on the machined pads where frame level criteria must be held to 0.005”/ft

Figure 3.4.2: Locations to Measure for Package Level The Package tie-down feet are now ready to be shimmed, and have the tie-down bolts torqued. Please refer to section 4 for instructions on grouting or shimming the package.

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3.4b Single piece skids (Mounted on AVM’s or Gimbals) The method for leveling a package mounted on Anti-Vibration Mounts (AVMs) or Gimbal Mounts has some significant differences from the procedure used for packages without these mount. The AVMs/Gimbals (referred to as “mounts” from here on) should be placed correctly on the foundation pad, and in the correct orientation according to the MID. With the mounts in their correct positions, carefully measure the distances between the mounts and confirm that they match the MID before lifting the package into position. This measuring step is to help ensure that the mounts are spaced correctly, and that they will line up with the boltholes in the package skid. The mounts are shimmed for vertical adjustment between the foundation and the mount, not between the mount and the package skid. For this reason, the top surface of the mount can be treated as if it were Datum C. Use a transit or equivalent measuring tool to compare the vertical height of the foundation pads that the AVM or Gimbal mounts will bolt down to. It is much easier to adjust the shim under the mounts before the package is resting on them, so every effort should be made to get the mounts level to each other before the package is set on the mounts. By accurately measuring the relative heights of the foundation pads and compensating with shims, the top surfaces of the AVMs or Gimbals can and should be made coplanar within 0.060” before the package is set on the mounts. The mounts are now ready to receive the package. Lift package onto the mounts, and bolt the package to the mounts. Release the lifting cables, and allow the frame to sag under its own weight Once the package is laid onto the mounts, the vertical elevation of the package must be checked in relation to a Site Elevation Point using machined Datum D surfaces. Jack up the package using hydraulic jacks, and shim under the mounts to adjust the vertical height of the package. Use a surveyor's transit to measure the elevation of Datum D, and elevate the individual Datum D points to be level and coplanar to the Site Elevation Point within 1/16 inch (1.6 mm). A view of a typical single-piece package skid mounted on Gimbals is shown in Figure 3.4.3.

Figure 3.4.3: Typical Single-Piece Package with Gimbal Mounts Once the skid is considered to be at the correct elevation by the Datum D points, the final leveling process can begin. . Final leveling must be done using a calibrated machinist’s level, or instrument of equivalent resolution on the machined equipment mounting pads of the package 18

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Specification No. ES 9-414

It is not always possible to have the forward to aft level within tolerance on all of the machined pads on a package that is mounted on 3 points. The package will sag under its own weight, and the machined pads at the forward and aft end of the package will end up being sloped downward toward the center of the package. Depending on the package size and weight, the forward to aft slope may be outside of the 0.005”/ft tolerance. In this case, the gearbox mount pad becomes the critical point of measurement and this pad must be leveled within 0.005”/ft in both the forward to aft, and side to side directions. All machined pads must still be leveled within 0.005”/ft from side to side. Jack up the package and adjust the shim under the package mounts to adjust the level of the package until the gearbox pad is level within 0.005”/ft in both horizontal planes, and the rest of the pads are level within 0.005”/ft from side to side. The locations where the pad level should be measured is shown on a typical package below in Figure 3.4.4.

= areas on the machined pads where frame level criteria must be held to 0.005”/ft

Figure 3.4.4: Locations to Measure for Package Level Once the package has been shimmed correctly with the provided shims, the tie-down bolts must be torqued to the spec given on the Solar MID. Package leveling is now complete, go onto Section 6: Final Package Alignment.

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4.0

Package Shimming and Grouting

Once the skid is in the level position it must be shimmed or grouted properly to minimize any possible movement as the tie-down bolts are torqued. Customer experience has shown the use of Non-Shrinking Epoxy Grout to be the most successful method for mounting Solar packages. If grout is chosen to be used, then a grout contractor should be consulted. In order to shim the skid most effectively, and minimize the risk of losing the level of the skid, it is recommended to shim and torque one foot at a time while the others remain elevated on their package jacking bolts. The shims must contact the skid with at least 50 in2 of contact area. The shim should encompass the tie-down bolt as well as possible, and be shaped so that it passes under the nearest structural member such as the vertical web of the I-beam. The shim does not need to cover the entire frame foundation foot. It is ideal shim the skid tie-down feet as completely as possible without moving the skid. Once the package is fully shimmed and torqued down, skid level should be checked again. Slight adjustments may have to be made to the shim packs to get the skid back within the level criteria if the shim packs were crushed down as the tie-down bolt was torqued. If the shim packs crush down enough to move the skid out of level, then not enough shim was used to fill the gap.

Not having enough shim under a foundation pad can lead to the very undesirable condition known as “soft foot”. If the package came out of the level spec as the tie-down bolts were torqued, then the shim packs should be adjusted slightly to bring it back within the level spec. It is advisable to perform a “spring back” check on each frame foundation foot to ensure that there is no occurrence of “soft foot”. The spring back check should be performed by zeroing a dial indicator on the surface of the frame mount pad, and un-doing the tie down bolts one at a time. If the frame tie-down foot moves more than 0.010”, then the package shimming needs to be reworked to eliminate the “soft foot”.

5.0 Torquing Foundation Bolts When the base leveling is completed, and the package is shimmed or grouted to the foundation, the foundation bolts must be torqued to the specified values. The jackscrews, used for vertical adjustment, must be backed off prior to torqueing the package to the foundation.

6.0 Alignment Check The package is now ready for a preliminary alignment check. Use the shims provided in the loose ship kit and adjust rotating equipment as necessary. The package oil tank should be filled to the level recommended on the MID drawing before beginning the final alignment procedure.

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Some O&G CS/MD packages are provided with sub-bases due to customer needs, if your package does not have a sub-base, please disregard Section 7. 7.0 Installation Procedure: Package to Sub-Base A sub-base is installed under the driver and driven frames to create a single rigid package assembly that provides three point marine mounting capabilities to reduces stress and deflection. •

Identify or establish the three mounting pads and the two center-support jacking locations on the underside of the sub-base see Figure 7.1.

•

Ensure the ground or deck can support the combined weight of the driver, driven, and sub-base. Place the sub-base on the three vertical point mounting pads. When AntiVibration Mounts (AVM) are required the sub-base must be temporarily assembled on three solid mounts suitable to carry the total package weight. Add a 1 inch (25.4mm) minimum steel plate between the sub-base mount pads and the temporary support pads to ensure a flat surface for the placement of the leveling shims. When gimbals are used the sub-base can be supported directly on the gimbals see Figure 7.2. When possible it is desirable to assemble all packages at a temporary assembly location prior to final installation as shown in Figure 7.3.

•

Using a transit, laser sight, or machinist levels, ensure the sub-base is leveled as shown in Figure 7.3. If sub-base needs leveling, use a hydraulic jack to raise sub-base and add needed shims as shown in Figure 7.4. Note: The sub-base should be within a tolerance of 0.030 inch (0.76mm) from a theoretical horizontal flat plane.

•

Place additional hydraulic support jacks under the sub-base, located at the pads closest to the driver/driven interface pads (datum A), see Figure 7.4. Ensure that the structure supporting the center support can bear the specified center support pad loads. Place a rigid support (8 to 10 inch schedule 80 minimum pipe or suitable I-beam) next to the jack. Add a 1-inch (25.4mm) minimum steel plate and shim as necessary to fill gap and fully support the sub-base. Slowly release the jack until the sub-base rests on the center support. Note: This step establishes and maintains all pads in a horizontal plane for the driver and driven frame installation. This center support is required to prevent deflection and assure proper load distribution of package during assembly. Additional supports can be added along the sub-base side beams to ensure a rigid base.

•

Before installing either the driver or driven measure the height from the top beam flange to the bottom of the tie-down pad as shown in Figure 7.5. Install the taller frame on the sub-base first. Center the first frame’s tie-down slots over the hold- down holes in the sub-base. Note: Height measurements for driver and driven frames may differ due to different manufacturing tolerances or different equipment manufacturers. In most cases, the driver frame will be the taller.

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•

Place a machinist level on the rear machined engine-mount pad, see Figure 7.6, located at the exhaust end of the turbine. Install the hold-down bolts, but do not tighten them at this time. Use the package vertical jacking bolts to level the taller frame. Place shims under the package tiedown pads, as required to fill gaps and release the vertical jacking bolts. Tighten package holddown hardware in sequence to specified sequence and torque value per ES9-54. Note: The package is considered level when machined equipment mounting pads are level within 0.005 inch (0.13mm).

•

Install the second frame on the sub-base. Center the tie-down slots over the hold- down holes in the sub-base pads. Position the frame such that the driver and driven interface pads just come into contact. Place a machinist level on the driven equipment machined mounting pad and use package vertical jacking bolts to align the match marks and level the package, see Figure 7.7. If there are no match marks, align the driven to the driver interface boltholes. Place shims under the package tie-down pads as required to fill gaps and achieve package level, then release vertical jacking bolts. Ensure the interface pads are parallel.

Note: The package is considered level when machined equipment mounting pads are level within 0.005 inch (0.13mm). •

Install driver/driven interface hardware, and torque to the specified sequence and torque value per ES 9-54, see Figure 7.8.

•

Install the driven frame tie-down hardware and torque to the specified sequence and torque value per ES 9-54, see Figure 7.9.

•

Remove the rigid supports under the sub-base and slowly release the two center-support jacks so the entire bolted assembly is supported by the designed three-point mount system, see Figure 7.10.

•

Package is now ready for final installation on the deck or module. See Mechanical Interface Drawing for recommended shims and hardware to attach the AVM’s/Gimbals to the final supporting structure.

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Figure 7.1: Mounting Pads and Jacking Point Locations

Figure 7.2: Mounting System and Jacking Point Locations

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Figure 7.3: Verifying Horizontal Planes

Figure 7.4: Support Center of Sub-Base to Prevent Deflection

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Figure 7.5: Driver Installation

Figure 7.6: Driver Leveling

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Figure 7.7: Driver Installation and Leveling

Figure 7.8: Install Driver/Driven Interface Hardware

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Figure 7.9: Install Frame Tie-Down Bolts

Figure 7.10: Remove Center-Support Jacks

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