Pipe Strain

Pipe strain is the root cause of multitudes of pump and bearing problems on
new and existing systems. Pipe strain can show itself as rubbing contact inside the pump in extreme conditions, but more commonly, there are no obvious physical signs. Bearing failure and vibration are some common signs of piping strain. The following discusses how piping should line up with the pump and how to check for pipe strain.

All piping must be supported independently of, and line up naturally with the
pump flanges. Before connection of piping to the pump flanges, attach indicators to the equipment shafts as illustrated, zero indicators, and connect suction piping and observe indicators. If more than .002" movement is indicated, adjust piping and or piping supports to eliminate pipe strain. Follow the same procedure for the pump discharge.

Baseplates
The pump baseplate is the structure on which the pump, motor, and if needed, the gear reducer are mounted. The baseplate is the structural member that is intended to rigidly support and maintain the shaft alignment between the mounted equipment. The design of the baseplate can significantly influence the MEAN TIME BETWEEN PLANNED MAINTENANCE and unplanned maintenance. The baseplate design can also influence the cost of installation, alignment, and overall life cycle cost. Baseplate designs range from open ended formed plate to fabricated structural monoliths with machined mounting surfaces. When correctly installed, the most economical baseplate may provide satisfactory service. But, for superior life cycle performance, a rigid, fabricated and machined base plate 5 is required. THE DECISION TO CHOOSE ONE BASEPLATE DESIGN OVER ANOTHER SHOULD BE EVALUATED BASED ON PERFORMANCE AND LIFE CYCLE COST. The following items should be considered when evaluating a baseplate design:

Torsional stiffness. Ease of shaft alignment. Provisions for grouting. Ability to support the mounted equipment.

The following items should be considered in specifying the baseplate:

The minimum material thickness at the point of attachment for threaded fasteners will be one times the diameter of the fastener.

The motor mounting surface is to provide for a minimum of 1/8" of shim under the motor for alignment. The baseplate should include grout holes of sufficient size for proper grouting and located at a maximum of 30" spacing. The baseplate should also have vent holes (one half inch) provided at the end of all grout runs. The baseplate should include provisions for lifting the base assembly with pump and driver. The baseplate should include a means of moving the driver and other movable components (gear reducer) for the purpose of shaft alignment. The baseplate should include machined mounting surfaces for pump, driver and if included, reducer.

Foundations
Designed and installed foundations can add years to the life of rotating equipment. The pump and foundation should be located near the supply of liquid and have adequate space for operation, maintenance, and inspection. Normally rotating pumps such as centrifugal, rotary gear, lobe, and progressive cavity pumps are supplied complete with some type of structural base as describe earlier. The following are some criteria to be used in designing or specifying the foundation.

Design the foundation so that its natural frequency does not match the running frequency of the mounted equipment or adjacent equipment. Provide a means of "tuning" the structure after installation in case the calculated natural frequency does not match the actual installed natural frequency. Size the foundation to minimize vibration from the mounted equipment. It is generally recommended that the mass of the foundation should be three times the mass of the mounted equipment (pump, base, driver) for rotary pumps and five time the mass for reciprocating pumps. The foundation should be designed to eliminate or minimize shaft misalignment due to equipment or externally induced forces. The stiffness of a foundation varies with the cube of its thickness. Installation of the anchor bolts should allow for thermal growth and stretch. This can be accomplished by use of a sleeve as shown in the following illustration. The proper use of anchor bolt sleeves will allow sufficient unrestrained bolt length to "stretch" without fatigue. This will also permit minor adjustment in location to align with mounting holes in the baseplate if needed. Select a contractor that has extensive experience in installing rotating equipment and foundations.

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Setting the Baseplate and Pump Unit

After the foundation has been installed and allowed to cure, the baseplate should be set. The following are some general steps involved in setting the baseplate / pump unit.

ALWAYS FOLLOW THE MANUFACTURER'S RECOMMENDATIONS FOR THE

INSTALLATION OF ITS EQUIPMENT.

Prepare the foundation for setting the pump baseplate and pump unit. It may be necessary to chip the top 1/2" to 1" from the surface of the foundation to remove the cement-rich surface called laitance. The laitance is a weak surface created when concrete is cast and would not provide for proper adhesion or support for the grout that will be installed under the baseplate. Setting the baseplate: Lower pump unit onto foundation. On the foundation pad, elevate the baseplate with shims, wedges or jacking bolts (3/4" to 1-1/2") to allow for adequate grout. Leveling baseplate: Level the baseplate over its length and width by adjusting leveling shims, wedges or jacking bolts. Before tightening anchor bolts, align unit. Align the pump and drive equipment following the pump manufacturer's recommendations. Dial indicators or laser alignment. After the unit has been brought into the pump manufacturer's recommended alignment, and the alignment devices are still attached to the equipment shafts, hand tighten the anchor bolts while observing the indicators. If a shaft movement or more that .002" is indicated, the baseplate has a "soft" anchor bolt/shim. This condition must be corrected before proceeding. As part of the foundation after the baseplate has been properly set, the baseplate should be grouted. The use of an epoxy grout should be considered. Epoxy grout can provide a rigid vibration and chemical resistant mounting for the baseplate. Follow the grout manufacturer's recommendations for preparation of the foundation and grout. After the grout has been allowed to cure, check alignment to insure that it has not changed. If the alignment has changed, realign unit. All piping must be supported independently of, and line up naturally with the pump flanges. Before connection of piping to the pump flanges, attach indicators to the equipment shafts as previously illustrated, zero indicators, and connect suction piping and observe indicators. If more than .002 movement is indicated, adjust piping and or piping supports to eliminate pipe strain. Follow the same procedure for the pump discharge. After attachment of the piping, re-check alignment and adjust if necessary. Prior to starting the unit, review the manufacturer's installation, operation and maintenance manual for proper start-up procedures. Follow manufacturer's instructions for proper startup of unit. Run the unit under actual operating conditions for a sufficient length of time to bring the pump and driver to operating temperature. Check alignment while unit is still hot per the manufacturer's recommendations.

At installation of the foundation and pump pump unit, prepare a check list of steps to be taken during the installation. Check lists are helpful, handy reminders that make the job go more smoothly. A check list can also be used to assist in verifying that the installer has taken all the necessary steps. This can be done by requesting the installer to notify you at each step in the installation, allowing you to inspect the work's progress, and signing off that the proper

work has been completed. An example of an installation check list follows in the sample documents. Back to Top

Pump Handbook

Horizontal End Suction ANSI Pumps

A - Foundation and Baseplate

Foundation mass for centrifugal pumps should be three times the mass of the driver and baseplate. The foundation should be designed to avoid resonant vibration conditions originating from normal excitation forces at operating speed or multiples of the rotating speed. Specify a baseplate that has machined mounting surfaces. This will cost a little more, but the additional cost will probably be saved at the shaft alignment. Before setting the pump baseplate, chip the surface of the concrete pad to remove the cement rich surface concrete, called laitance. This will provide a stronger bond between the grout and concrete foundation. The anchor bolts should be properly sized for the equipment being installed. Provide sufficient free length in the anchor bolt to allow for

thermal expansion of the baseplate.

The Baseplate: All machined mounting surfaces should be coplanar to within 0.002". All baseplate welds should be continuous and free of cracks. All cross bracing under the baseplate should have cutouts to allow for grouting. Vent holes (0.5" D) should be provided at each cross brace and corner. The baseplate should be designed with a minimum of 1.0" radius corners to prevent cracking of the grout. The mounting pads under the driver should provide for a minimum of 1/8" shims under the motor. Jacking screws should be provided to assist in shaft alignment of driver to pump. Machined mounting pads should extend 1.0" beyond pump and driver mounting feet on all sides. Setting the baseplate: The underside of the baseplate should be cleaned and sandblasted, providing a surface that insures a good bond between the baseplate and grout. Set and level the baseplate, using wedges or jacking screws to achieve level. Whichever method is used, remember to remove the leveling device after the grout has set. This is especially important when using wedges. The wedges generally have sharp edges which can cause stress concentration points that can eventually result in cracking of the grout. Check the pump suction and discharge connections for proper location and elevation. Remember, "Bring the piping to the pump, not the pump to the piping."

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