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GEBERAL SPECIFICATION FOR ASSEMBLY OF MECHANICAL EQUIPMENT

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GENERAL SPECIFICATION FOR ASSEMBLY OF MECHANICAL EQUIPMENT

INDEX

1. OBJECT .................................................................................... 2 2. SCOPE OF THE SERVICES .................................................... 3 3. ASSEMBLY OF STATIC EQUIPMENT................................. 5 4. ASSEMBLY OF DYNAMIC EQUIPMENT ........................... 7 5. ASSEMBLY OF SPECIAL EQUIPMENT ............................ 10 6. CHECKING AND TESTING ................................................. 11 7. QUALITY ASSURANCE....................................................... 14 8. WELDING .............................................................................. 15 9. DOCUMENTATION .............................................................. 16 10. RIGGING PLAN ..................................................................... 17

SGG APPRD CHKD

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Nov 10 DATE

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GENERAL SPECIFICATION FOR ASSEMBLY OF MECHANICAL EQUIPMENT

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1.
1.1

OBJECT
This Specification contains the general conditions required for the erection, assembly, inspection and testing of the mechanical equipment, which should be fulfilled during the execution of the field construction works. When this general Specification is accompanied by a Particular Specification which enlarges, modifies or complements it, the latter shall have priority. The prescriptions contained in this Specification shall not release the Subcontractor from the liabilities arising from the performance of the works. Following, the definitions to be employed through this Specification: - Contractor: buyer of Subcontract and Services - Subcontractor:

1.2 1.3 1.4

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2.
2.1

SCOPE OF THE SERVICES


The Scope of services includes the works listed for each type of equipment and, in any case: 2.1.1 Receiving, unloading and storage of all the equipment and materials to be assembled at their arrival to site and their transfer to the warehouse or the place designated by the Subcontractor. Inspect the receipt material, communicating any discrepancy. Any loss or damage in materials occurred till the reception of plant by the client, shall be communicated through the specific QA/QC forms. 2.1.2 Un-packing, checking of Packing List, classification, cleaning, preassembly protection and installation of all the auxiliary and/or secondary elements and piping which form part of the set of equipment and which are necessary for its correct functioning. The Contractor must be informed of any no conformity detected before proceeding to the erection of any equipment. 2.1.3 Maintenance of received materials and equipments, checking and recording periodically the inspections points according to the Maintenance Manuals, such us: turning of shafts, connection of space heaters for motors, grease the designated parts or devices, preservation... 2.1.4 Loading and transfer of the equipment and materials from the warehouse to the assembly point. The withdrawal of materials and equipment from the warehouse will be fractioned as required. The warehouse manager must be presented a material issue voucher authorized by the Contractor for the withdrawal of any equipment item or material. 2.1.5 Checking the equipment, foundation or support structure and anchor bolts for accordance with their positions established in the drawings before proceeding to the assembly. 2.1.6 Chipping of the concrete surface for each foundation up to maximum 50mm. 2.1.7 Placing noticeable signs forbidding welding over sensitive parts or equipments. 2.1.8 To provide and use wood blocks to avoid contact between equipment and ground during handling, storage or erection. Also adequate protection should be provided to protect the equipment form dust, rain, hot, sun, cold, etc 2.1.9 To provide suitable temporary protections for dynamic equipment during storage or erection 2.1.10 To provide, place and verify the necessary materials and plates for levelling of the equipment. 2.1.11 To Clean and prepare both surfaces equipment and foundation for grouting. Grout work will be performed by others. 2.1.12 Provision of the necessary elements and execution of the necessary welding, annealing, x-rays and total or partial hardness tests for the finalisation on site of the equipment delivered in more than one part.

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2.1.13 Supply of the necessary scaffolding, hoisting equipment and auxiliary structures for the assembly operations. 2.1.14 Supply of the necessary materials for hydraulic testing, such as water handling, blind flanges, temporary piping, screws, temporary joints, pumps, calibrated pressure gauges, thermometers and test water pipe diagrams. 2.1.15 Supply of the solvents, rust-proofing oils and other products or materials necessary for cleaning and protection of the equipment and materials. 2.1.16 Attachment name plate to the equipment. 2.1.17 Application of rust removers on the studs and screws, and subsequent grease protection. 2.1.18 Provision of the necessary resources to fulfil the requirements of maintenance and cleaning according to supplier conservation manual and specifications. 2.1.19 Provision of the necessary resources to fulfil the requirements of HSE plan and Local, State and Governmental Regulations. 2.1.20 Provision the necessary number of copies of the reports, certificates, schedules and other documents specified. 2.1.21 Provide the necessary and calibrated tools for the equipment erection, which includes as minimum: o o o o o o o o 2.2 2.3 Precision dial gauges. Magnetic bases for dial gauges. Gauges Precision gauges Micrometers Precision levels rulers (2m and 4m length) Optic level equipment for levelling. Telescopic gauges (in mm and inch).

The scope includes first load with oils and greases in the equipment. The necessary fluids will be supplied by the Contractor. The installation of equipment shall include the assembly of all the elements which form the set, such as structures, platforms, grating, couplings, rails, belts, rollers, elevators, switch etcaccording to the corresponding specification, drawings, manuals, procedures and vendor instructions, and always under the instruction of the Contractor.

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3.
3.1

ASSEMBLY OF STATIC EQUIPMENT


This Specification considers static the equipment substantially fabricated from steel plate, included, but not limited: - Vessels, Tanks and Silos - Towers and Columns - Stacks and Chimneys - Heat Exchangers and Air Coolers - Furnaces and Boilers forge parts, etc. - Bins, hoppers, ducts, etc The Subcontractor shall provide the necessary qualified personnel and specific means for the necessary assembly operations, in particular:

3.2

The Subcontractor will submit the erection plan for every equipment for the approval of the Contractor with the necessary anticipation, checking at such time the foundation and equipment dimensional discrepancies (if any). The Subcontractor, with previous authorization of the Contractor, shall disassemble and re-assemble the elements that could interfere with the operations. Place the equipments on their foundations or support structures in the position defined in the drawings. Adapt the equipment's base to the anchor bolts, levelling and fastening the equipment to its foundation or base plate, completing the relevant reports according to the QA/QC Plan requirements. Check verticality with the plumb and with tachymeter. The maximum permissible tolerance shall be h/1000. It is defined as h the distance between two measurements points. The maximum deviation allowed shall be 25mm. The Subcontractor will minimize the possible deviation due to a potential manufacturing error. Assembly and weld the necessary support brackets for platforms and pipes, strips for grounding, insulation support clips, etc., according to drawings and welding procedures approved for construction. Install platforms, stairs and ladders, included grating floor. Install the service devices for the equipment, fastening them suitably in order to prevent interference with other assembly works. The operations described in 3.4, 3.5 and 3.6 may be performed at ground level with the previous authorization from the Contractor.

3.3

3.4

3.5

3.6 3.7

3.8 3.9 3.10 3.11

Drill draining holes in the skids of the equipment, when necessary. Apply a coat of molybdenum bisulphide on all the sliding bases, before setting over the equipment Assembly the corresponding process and control valves in all the manifolds of the equipment. Verify the expansion joints before the assembly for blocking and with the previous authorization from the Contractor, remove the blocking bolts after assembly.

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3.12 3.13

Carry out all the checks and tests described in chapter 6 of this Specification. In the towers, columns or other equipment delivered to the site in two or more sections, the Subcontractor shall: 3.13.1 Install the reinforcing rings, platform clips, pipes, saddles, manifolds, grounding connection plates and any other accessory part, either internal or external, which were necessary in order to complete the equipment on each of the sections, including platforms, stairs, ladders and grating. 3.13.2 Align, assemble and weld or bolt the different parts of the equipment together. These operations shall be carried out both in the horizontal and vertical position and in accordance with the instructions from the Contractor. 3.13.3 Perform the annealing of the welding, radiographic inspection and total or partial hardness tests in accordance with the equipment specifications, QA/QC Plan and the instructions from the Contractor.

3.14

For the assembly of the internal components of the equipment, the Subcontractor shall carry out the following operations: 3.14.1 Open the ports of the equipment. 3.14.2 Provide, erect and withdraw the necessary scaffolding and temporary platforms, lighting and ventilation, checking the air concentration according to HSE Plan. 3.14.3 Dismantle any element, such as plates, saddles, clips, which may come mounted or fastened to the equipment. 3.14.4 Verify and adjust the supports welded to the equipment within a tolerance of h/1000. 3.14.5 Perform the seal-pan test and on the opening and closing of the manholes. 3.14.6 Mount plates, support grids, coils, seal pans, diffusers, clips for internal lining and exterior insulation and any other accessory indicated in the drawings, including those dismantled previously. Bench assembly of each model of internal will be required before proceeding to the field assembly. 3.14.7 Carry out the hydraulic test in accordance with chapter 6 of this Specification and in the equipment documentation. 3.14.8 Introduce and place, after hydraulic test, the catalyst charges, "raschig rings, demisters, or other filling or similar materials in accordance with the drawings, equipment specifications and instructions from the Contractor.

3.15

Once the internal parts have been assembled and after the approval and authorization from the Contractor, close the manholes and eliminate all the blind disks leaving the equipment ready for piping connection.

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4.
4.1

ASSEMBLY OF DYNAMIC EQUIPMENT


This Specification considers as dynamic the equipment whose main characteristic is the internal movement, either rotary or alternating, such as: - Turbines and Generators - Pumps - Compressors, Ventilators and Blowers - Rotary Filters - Agitators, etc. The Subcontractor shall provide the necessary qualified personnel and specific tools for the necessary assembly operations, included, but not limited:

4.2

The Subcontractor will submit the erection plan of every equipment to the approval of the Contractor with the necessary anticipation, checking at such time the foundation and equipment dimensional discrepancies (if any). The Subcontractor, with previous authorization of the Contractor, shall disassemble and re-assemble the elements that could interfere with the operations. Place the equipments on their foundations or support structures in the position defined in the drawings. Adapt the equipment's base to the anchor bolts, levelling and fastening the equipment to its foundation or base plate, including preparation for grouting. Couple, by aligning and levelling, the different elements which compose the equipment, in strict agreement with the tolerances and instructions of the vendor and this Specification. Machining and adjust the couplings to their axes. Drill and thread as many holes as necessary for fastening the equipment in its base plate. Place stay bolts for aligning the motor/equipment set in the motor part of the units driven by electric engines, in accordance with the Contractor. Disassemble, revise, clean and assemble the cooling and sealing lines and associated equipments. Some equipment requires oil/water flushing for cleaning. Connect the exhaust and discharge lines to the equipment, taking the following precautions to avoid harmful stresses. - Before proceeding to the connection of the aforementioned lines, check the correct alignment of the different components of the equipment and the parallelism and alignment between the equipment's flanges and those corresponding to the pipes to be connected, proceeding to correct the deviations detected. - Once the connection has been made, check the alignment of the equipment in order to verify that no deviation has occurred. If any deviation were detected in this verification, proceed to dismantle the pipes and to carry out the operations described in the preceding paragraph again.

4.3

4.4

4.5 4.6 4.7 4.8

4.9

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- Carry out a third check and correction of defects, if these are detected, after the equipment's operation test. 4.10 4.11 4.12 When the equipment supplier does not indicate coupling tolerances, the permitted maximum in both axial and radial alignment shall be 0.03 mm. In the case of agitators, vertical pumps, in line pumps, etc, the lack of verticality of the unit shall not exceed 1/1000. When, due to the characteristics of the equipment (large compressors, turbines, pumps and/or special equipment), the Vendor were responsible for the Supervision of the assembly, the works shall be carried out under the direction and supervision of his delegates. Uncouple motors for free running (polarity test). Provide and install the necessary parts and devices to carry out the test. Restore the equipment to be ready for operation. The equipment shall be properly signalled to prevent accidents during the period of test according to the HSE Plan. For the protection and maintenance of these sets of equipment during the assembly period and until their final delivery, the Subcontractor shall carry out the following operations: - Replace, when required by the Contractor, the mechanical seals by soft, nongraphited gaskets, delivering them immediately to the store correctly labelled with the identification of the pump to which they belong. - Substitute the gaskets mounted by the manufacturer on the equipment, by other soft and non-graphited packing, delivering the originals to the store correctly labelled with the identification of the item that they belong. - When the Contractor authorizes, collect, clean and install seals and gaskets in their original place. - Dismantle, identify and deliver to the store any accessory which has developed a fault during the assembly, duly justifying the causes of the fault to the Contractor, and mount it once repaired or replaced to the satisfaction of the Contractor. - Clean all the surfaces of the equipment's flanges with solvent and proceed to cover it immediately with rust-proofing protective oil previously approved by the Contractor. Place immediately thin plate blind flanges with asbestos joints, to prevent the entrance of foreign matters. - Clean the bearings, gear boxes, parts of axles and machined surfaces exposed to the elements with solvents. Protect immediately rust-proofing oil which provided by the Contractor or Subcontractor and approved by the Contractor. - Fill the bearing housings with rust-proofing oil up to the axle level, making the movable parts turn round several times, so as to form a protective layer on them. Repeat this operation twice a week. - In the event where any element cannot be dismantled, it shall be filled or sprayed with rust-proofing oil. - Drain the water which may be accumulated in the bearing boxes and equipment and gearing down devices' housing, and make the axles turn by hand, in order to maintain the film of rust-proof oil, twice a week.

4.13.

4.14

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- Remove all the oil from the bearing boxes and equipment and gear boxes every two months, cleaning them with solvent and filling again with rustproofing oil. - If the equipment has a pump or any other centralized lubrication system, run this twice a week, making it rotate by hand and simultaneously turning the main shaft by hand. - Remove all rust-proofing oil after the running test of the engines. Proceed to first load with oils and greases supplied by the Contractor. Proceed to apply grease on all bearings. 4.15 If the Manufacturer has placed any drying agent within the equipment, such us silica-gel bags, Subcontractor shall carefully inspect the sealed openings and inform subsequently the Contractor when finding any of them deteriorated. Proceed to repair and change the drying agent. When necessary the same precautions shall be maintained until the final delivery of the equipment.

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5.
5.1

ASSEMBLY OF SPECIAL EQUIPMENT


In addition to which may be applicable in what is described in chapters 3 and 4, the following additional prescriptions for certain types of special equipment shall be applied. Air-coolers Their assembly includes the assembly and levelling of the corresponding structures, hoist, tube banks, platforms, chimneys, fans, power transmissions, and the execution of both interior and exterior and input and output connections, all in strict compliance with the manufacturer's instructions and drawings.

5.2

5.3

Ejectors and Injectors and Vacuum units These items of equipment and their corresponding auxiliary condensers shall be very carefully overhauled and cleaned, especially their nozzles, and installed in accordance to the corresponding drawings and technical documentation.

5.4

Driers, Filters and Dampers These items of equipment shall be supplied to the Subcontractor fully assembled for installation and anchor to their corresponding foundation. The Subcontractor, previously, shall perform the operations described in the equipment specifications and/or in the Vendors instructions.

5.5

Handling Equipment The installation of these sets of equipment shall include the assembly of all the elements which form the set, such as structures, conveyor belts, rollers, elevators, hoppers, switch, vibration feeders, scales, etc.. Moreover, it will include the alignment and levelling of the motors and reducers. Also includes the erection of crane rails for travelling cranes and hoists.

5.6

Miscellaneous equipment Any other set of equipment, included in the order but not described in this Specification shall be assembled by the Subcontractor according to the corresponding Specification, drawings and Vendors instructions, and always under the instructions of the Contractor.

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6.
6.1

CHECKING AND TESTING


The Subcontractor shall carry out the following checks during the development and completion of the works: - Verticality of the equipment - Levelling and location of the equipment - Levelling and location of its internal parts - Alignment of components and coupling (before and after piping connection to nozzles). - Piping parallelism to nozzles (min. 0,1 mm parallelism tolerance between different measures with gauges and free of stress). - Internal cleanliness - Drying All the checks shall may inspected by the Contractor. Final check reports must be recorded by the Subcontractor and approved by the Contractor.

6.2

The Subcontractor shall carry out the following operations: - Clean of the interior of the equipment in order to eliminate any foreign matter. - Internal scraping of the equipment when required and according to the instructions of the Contractor. - Provision, installation and connection of calibrated instrument such us pressure gauges, thermometers, pressure pumps and any other element or equipment necessary the test. - Tight sealing of all the equipment's connections. - Opening of vents and complete filling of the equipment with water. The quality of the water, especially when testing vessels made of special steel, shall be approved by the Contractor. - After authorization of Contractor, perform the test according to the equipment Specification and the applicable Regulations, Orders and prescriptions. The Subcontractor shall use at least two pressure gauges calibrated and approved by the Contractor at each point of measure. The gauges shall be placed at the lower and highest points of the equipment tested. - The test pressure shall be maintained during the time period prescribed by the Contractor and not less than 60 minutes. Neither leaks nor deformations shall be allowed during the test. - If the equipment must remain filled with water after the test, all pressure shall be relieved and preventive provisions against the effect of sudden changes on the ambiance temperature should be taken. - Once the test has been completed, the equipment shall be drained though its own drains and lower points, checking beforehand that venting and higher points have been opened. The Subcontractor shall never perform this operation without the prior written authorization from Contractor.

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- After draining the water of the equipment, the Subcontractor shall flush the circuits with fresh water and carry out another internal cleaning in order to eliminate sludge or any other foreign residue - The Subcontractor will proceed to a careful internal inspection to detect any damage originated by the test and to amend the faults. When reparations were made, the Contractor will decide if a new hydraulic test is necessary. When the equipment was ready, the Contractor will authorize the Subcontractor to assembly the internal and sensitive parts and dry of the equipment. - After completion and approval of the previous operation the Subcontractor shall be given written authorization for the final closing of the manholes, elimination of blind disks and joints. - When necessary and in particular for inspection from the officials of the Administration, the hydraulic test will be repeated even when the result of the first test is satisfactory. 6.3. Dynamic equipment: The following tests shall be made: - Situation of the different sections - Levelling - Verticality - Alignment of axes - Load test Contractor shall carry out all the checks and tests with the Contractor as a witness. Final checks must be approved by the Contractor. 6.4. The situation of the different sections must agree with the equipment documentation Levelling of bases and equipment shall be made with a precision level Verticality of axis of agitators, vertical pumps etc., shall be verified with level or plumb. . Alignment of axes shall be verified using axial and radial dial gauges Load test over handling equipment to be made according to Vendor specifications and under the instructions from the Contractor

Internals: The following tests and verifications shall be made: Levelling of horizontal supports of the internals with bubble level. Verticality of supports of vertical internals with level and plumb. (Tolerance 1/1000.) Installation, centring, fixing, level and verticality after assembly of the internal.

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Tightness test over the pertinent elements. Leak test of valve plates, accumulators, etc., controlling time of emptying.

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7.
7.1

QUALITY ASSURANCE
Contractor shall submit, as a minimum, the following documents to the Contractor and in accordance to the Site QA/QC Site Plan. Any work is authorized to start without the approval of the documentation from the Contractor. - Organization and functions of the people in charge of QA/QC. - Equipment and premises to be used in this activity. - Models and formats of the planned documentation and its distribution. - Qualification and homologation of welders in accordance with the project requirements. - Welding procedure (and its homologation), applicable heat treatments, and X-raying procedures and other control systems applicable. - Internal inspection procedure of the materials to be supplied by the Subcontractor or workshops sub-contracted by him. - Procedure for hydraulic testing, pipe cleaning, etc. Once works are finished, Subcontractor shall submit a final QA/QC Report, that shall include all the documentation referring to testing and trials carried out during the performance of the work. The documentation shall be grouped by specialities, and which were approved by the Work Supervision in a proper time. The number of copies of this documentation shall be the established for each Work.

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8.
8.1 8.2

WELDING
In addition to the provisions of chapter 7, the following prescriptions shall be observed in respect to welding: Before beginning any welding job, the Subcontractor should submit to the approval from the Contractor the welding procedure to be applied, duly homologated, and homologation certificates of the welders, as well as of the makeup materials and welding equipment that intends to use. A record of the results of the quality assurance on the welding for each procedure will be kept, in which the incidents which occurred during its application will be noted. This record will always be at Contractor's disposal. Welding over any pressure equipment will not be done without express written authorization from the Contractor; this welding shall be carried out by the authorized qualified welders, and in strict compliance with the equipment specifications and drawings.

8.2

8.3

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9.
9.1.

DOCUMENTATION
QA/QC documentation. The Subcontractor shall submit to the Contractor all documentation related to: - Homologation tests of welding procedures and welders (WPS/PQR) - Welding tests (NDT and hardness tests, if any) - PWHT - Pressure tests - Leakage tests of internals of equipment - Levelling Record - Alignment Record: coupling and flanged connections Contractor shall submit to the Contractor the relevant certificates from an independent, officially authorized, organization (Third Party) of all homologations, pressure tests and NDTs.

9.2.

Oficial certificates. The Subcontractor shall obtain and submit to the Contractor any necessary official certificates to legalize the equipments under his responsibility, (equipment delivered to the site in two or more sections and finalised on the site and package units assembled field assembled ), as required.

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10.

RIGGING PLAN
Within two months after the signing of the Contract or the reception of the Order, the Subcontractor shall submit to the Contractor for their approval a general study of all the lifting of equipment (more than 10 ton or big size, unless HSE Plan requested another rate). That study must include their proposal for lifting, internal transportation, cranes plan, and interference solving, hoisting equipment data included relevant certificates- and calculations for power required and stability. No equipment lifting shall be authorized without the aforementioned approval. Lifting study for certain equipment requiring early assembly may be requested on a shorter delay.

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