Installation, Operation and Maintenance · PDF file3.2 Application ... Appendix I. Corrosion Guide Appendix II. Insert Installation Guide ... Appendix IV Alignment

Installation, Operation and Maintenance Instructions

ChemBasePlus™ 02/15/02— 1/2002 Page 1 of 16

TABLE OF CONTENTS

1.0 Introduction …………………………………………………………………… 2

2.0 Safety Considerations….…………………………………………………… 2

3.0 General Overview……………………………………………………………. 23.1 Warranty Statement……………….………………………………… 23.2 Application……………………….…………………………………… 23.3 Storage / Handling……………….………………………………….. 3

4.0 Installation…………………………………………………………………………………..… 44.1 General Description………………………………………………………………… 44.2 Motor Mounting System……………………………………………………………. 54.3 Foundation Mounted Baseplates …………………………………………..……. 54.4 Stilt Mounted Baseplates …………………………………………………………. 7

Appendix I. Corrosion Guide

Appendix II. Insert Installation Guide

Appendix III Recommended Fastener Torques

Appendix IV Alignment

Questions?

Please contact your local Goulds Pumps representative.

ChemBasePlus™ — 1/2002 Page 2 of 16

SECTION 1. 0 INTRODUCTION

This Installation, Operation, and MaintenanceInstructions manual contains instructions andguidelines for the installation of the GouldsPumps ChemBasePlus™ baseplate.

It is extremely important that this entireguideline be reviewed prior to installationand handling of the baseplate. This isimportant for both safety and reliabilitypurposes.

SECTION 2.0 – SAFETY CONSIDERATIONS

The Goulds ChemBasePlus™ baseplate hasbeen designed and packaged for safe handlingand installation. It is very important to reviewthe contents of this manual before removingthe baseplate from its shipping skid. Gouldsshall not be liable for physical injury, damagecaused by failure to observe the instructionsfor installation and handling in this manual.

Please make special note of the followinggeneral precautions as listed below:

1. Do not remove the ChemBasePlus™from its shipping skid until you areready to lift it onto its foundation.

2. Do not subject the ChemBasePlus™to rough handling or unnecessaryhammer shock.

3. Do not attempt to lift theChemBasePlus™ by any means otherthan that which is described in thismanual.

4. Do not hammer shock or use otherimpact loading techniques to adjustthe positioning of theChemBasePlus™. Do not pry againstthe motor mounting blocks whenmoving the motor during shaftalignment.

5. Do not tighten the anchor bolt nutsuntil you have verified that theChemBasePlus™ is properlysupported.

6. Do not attempt to transport, handle orinstall a ChemBasePlus™ whenambient temperature is below -45° F.

7. Do not operate a pump installed on aChemBasePlus™ at process fluidtemperatures in excess of 290° F.

SECTION 3.0 - GENERAL OVERVIEW

3.1 WARRANTY STATEMENTAll due care is taken in producing the Gouldsline of baseplates and complimentaryaccessory items. Goulds warrants to provideequipment that meet Goulds’ standards andspecifications, but not to be suitable for anyparticular application. No warranty is made inregard to the use of the materials or finishedgoods, in the Purchaser’s application. Alldesign considerations and acceptance of theGoulds products for use in the Purchaser’sapplications are the Purchaser’s soleresponsibility. In no case will Goulds beresponsible for more than supplyingreplacement products.

3.2 APPLICATIONThe polymer composite material used in themanufacture of the Goulds ChemBasePlus™has been formulated for application in a broadrange of corrosive fluid handling services. Thismaterial does not, however, offer universalcorrosion resistance. Goulds highlyrecommends that the Corrosion Guide inAppendix I be reviewed prior to specifying orinstalling a ChemBasePlus™ baseplate.The ChemBasePlus™ is also suitable forapplication in a wide range of fluid processtemperatures, specifically, -45° F to 290° F.For temperature boundaries exceeding theserecommended limitations, please contactGoulds for assistance in determiningacceptability of a specific application.


3.3 STORAGE / HANDLINGGoulds’ normal packaging is designed toprotect the ChemBasePlus™ during shipment.

! CAUTION !It is extremely important to observe properhandling procedures during transport andinstallation of the ChemBasePlus™. While thepolymer composite material is constructed ofinherently high strength materials, subjecting itto impact or bending loads through roughhandling or improper lifting or mounting mayresult in irreparable damage to the baseplateas well as potential damage to the mountedequipment or put personnel at risk of injury

Leave the ChemBasePlus™ strapped to itswooden shipping pallet until installation isready to occur. If the ChemBasePlus™ isintended for indoor installation and comes withcarbon steel inserts, but is to be stored in anoutdoor location, cover the base completelywith some weather resistant material so as toprevent rusting of the insert material.

! WARNING !Do not stand the ChemBasePlus™ on end tomake more efficient use of storage space.Severe personal injury or death as well aspossible permanent damage to theChemBasePlus™ may result should it tip over.

LIFTING

Lifting should be performed by trainedpersonnel only. Pumps and motors typicallyhave integral lifting eye bolts. These areintended for use of the individual units only.Do not use these features to lift aChemBasePlus™/ Pump and Motor Assembly.

ChemBasePlus™Baseplates With No Mounted Equipment

! WARNING !Do not install eye bolts in theChemBasePlus™ threaded inserts for thepurpose of lifting the baseplate. This practicemay induce excessive loading on the inserts,which they were not designed to withstand.

Remove the straps that secure theChemBasePlus™ to the wooden pallet. Sliptwo slings underneath the baseplate betweenthe pallet cross members as shown inFigure 1. Slings should be positioned to allow

for safe, even lifting. Raise theChemBasePlus™ slightly off the pallet andverify that it suspends reasonably level andthat the slings are not subject to slipping out ofposition.

! WARNING !Be sure to keep hands and feet out from underthe baseplate during these steps to preventinjury.

FIGURE 1ChemBasePLUS™ with no mounted equipment

Should the slinging appear unstable, set thebaseplate back down on the pallet andreposition the slings for more stable condition.After satisfactory slinging has been achieved,the baseplate may be hoisted onto itsfoundation. Slowly lower the baseplate overthe foundation using care to engage theanchor bolts in the holes provided. Placeshims or wedges under the baseplate at aminimum of four locations to allow for removalof the slings.

ChemBasePlus™Baseplates With Installed Equipment:

Pump only installed:Remove the straps that hold theChemBasePlus™ to the wooden pallet. Installa sling around the pump suction nozzle using achoker hitch pulled firmly tight. Install anadditional sling around the motor end of theChemBasePlus™ using a basket hitch asshown in Figure 2.


FIGURE 2 - Pump only Installed

Pump and motor installed:Remove the straps that hold theChemBasePlus™ to the wooden pallet. Installa sling around the pump suction nozzle andaround the outboard end of the motor frameusing choker hitches pulled firmly

tight as shown in Figure 3. The motor slingshould be positioned so the weight is notcarried through the motor fan housing.

FIGURE 3 - Pump and motor installed

SECTION 4.0 – INSTALLATION

4.1 GENERAL DESCRIPTION OF THEChemBasePlus™

The Goulds ChemBasePlus™ is a solidpolymer composite baseplate that ismanufactured to conform to ASME/ANSIB73.1M-1991 and custom versions. TheGoulds ChemBasePlus™ has been designedto provide a solid and rigid foundation underthe pump and its respective motor, whereby,serving the purpose of maintaining soundalignment between them.The ChemBasePlus™ has been madeavailable in two basic types:

• Foundation mounted (grouted indesign – Figure 4)

FIGURE 4 – Foundation Mounted


• Stilt Mounted (free standing –Figure 5)

FIGURE 5 – Stilt Mounted

The foundation -mounted style utilizes grout toadd rigidity to the structure. Because theChemBasePlus™ by nature offers excellentrigidity, the Stilt-mounted style can beemployed without sacrificing on reliabilitywhatsoever. The Stilt-mounted base offers afree-standing rigid foundation void of anyadditional grouting needs.

The ChemBasePlus™ performs the properfunction of a reliable baseplate foundation for apump and motor. Those basic functions are asfollows:

1) To provide adequate rigidity to assurethe pump/motor assembly can beshipped and installed without damageand to withstand the operating loads ofthe given assembly. The solidstructure of the ChemBasePlus™offers superior dampening to vibrationassociated with the rotatingpump/motor assembly.

2) To provide a flat mounting surface forthe pump and motor assembly. TheChemBasePlus™ product is designedto hold under a .005 inch flatnessspecification (end-to-end). Theaforementioned flatness specificationsare measured across the diagonalcorners of the baseplate top surface.These excellent flatness specificationsare achieved by the superior Epoxy

Resin Aggregate Material utilized inthe construction of these baseplates.

3) To allow the end user to perform finalfield alignment to their respectivetolerance standards.

4.2 MOTOR MOUNTING SYSTEM

The Goulds ChemBasePlus™ utilizes asstandard the polymer block mounting system.This system is comprised of corrosion resistantpolymer composite mounting blocks whichhave surface flatness to .005”. Motor mountingblocks incorporate a counterbore / jam nutfeature for secure attachment to theChemBasePlus™

FIGURE 6

Optional Bi-Directional motor adjusters provideboth axial and transverse motor adjustment.The top mounted adjusters assist with preciseshaft alignment when critical tolerances aretrying to be achieved as they do not disturbindicator equipment.

4.3 FOUNDATON MOUNTED BASEPLATES

1) The baseplate should be positioned asclose to the liquid supply source aspossible. There should be anadequate amount of space forpersonnel to install, operate andmaintain the pump/motor assembly.As mentioned above, the end result ofthe grouted in baseplate should offerexcellent rigidity and dampen anyvibration associated with the operatingpump/motor assembly.


2) Using the recommended slingingprocedures shown in Figures 2 and 3,hoist the ChemBasePlus™ unit off itsshipping pallet.

3) Lower the ChemBasePlus™ intoposition over the foundation. Proceedto engage the anchor bolts in the fourholes provided. As seen in Figure 7,protective sleeves should be placedover the anchor bolts to prevent groutadhesion to the bolts.

FIGURE 7

4) The baseplate assembly should beproperly leveled. It is suggested toutilize the pump suction and dischargeflanges as reference points for levelingpurposes. If the ChemBasePlus™ isequipped with the recommendedoptional leveling screw inserts, installthe leveling screws and thread themfar enough to provide the desiredgrouting clearance underneath. Applywax to screws to allow for theireventual removal.

5) If the ChemBasePlus™ is notequipped with leveling screws, shimunder the baseplate to bring thedischarge flange into proper level.Never stress the baseplate under anycondition to bring the assembly intothe desired level. Hold off bolting thepump’s flanges until the baseplate iscompletely installed. A properpractice is to shim under all baseplateanchor bolt locations. Apply wax toshims to allow for their eventualremoval.

6) Install the flat washers and nuts to theanchor bolts and snug them down butdo not torque them at this point.

7) Alignment should now be done inaccordance with procedures identifiedin Appendix IV.

8) The baseplate should now be properlygrouted. Grout the baseplate inaccordance with the groutmanufacturer’s recommendedprocedures. Mask off areas notintended to be grouted. Goodprocedure is to utilize a non-shrinkinggrout material. Pour or trowel thegrout into the desired area until theproper level is reached. Immediatelywipe away any spills as this must bedone before the grout sets. Allow atleast two days for the grout to fullycure.

9) Check for voids after the grout hasproperly cured. Remove the formsand withdraw the leveling screws orshims used for leveling. Remove themasking from all surfaces.

10) Fill the leveling screw holes (ifprovided) with a flexible sealer.

11) Lubricate the anchor bolt threads andtighten the nuts to the following torquevalues: ½” bolt – 22 lb/ft or ¾” – 65lb/ft.

12) Connect piping to the flanges of thepump. Assure that no adverse pipingloads are transmitted to the pumpflanges. Perform a final alignmentcheck for verification that there are nosignificant piping loads.

13) Final alignment of the pump/motorassembly should now be brought intothe tolerances as specified inAppendix IV.

14) It is possible that a realignment maybe deemed necessary should thetemperature of the process conditionscause suspect thermal expansion ofthe piping.

ChemBasePlus™ 02/15/02— 1/2002 Page 7 of 16

4.4 STILT MOUNTED BASEPLATES

As mentioned previously, theChemBasePlus™ is inherently rigid due to itsthickness of construction. The end result is abaseplate that can be stilt mounted while notsacrificing on reliability. The pump/motoralignment techniques for Goulds’ Stilt Mountedbaseplates follow the same methodology of thegrouted in baseplates. The key differencerevolves around the way the baseplate isleveled.

1) The stilt mounted baseplate is set on aflat surface with no anchor boltsneeded.

2) The baseplate is leveled by using thenut stilt adjuster kit. Refer toFigures 8 and 9 for suggestedassembly instructions.

FIGURE 8

FIGURE 9

a) Elevate the baseplate assemblyabove the floor to allow stiltassembly.

b) Measure the approximate desiredheight of the baseplate assemblyabove the foundation.

c) Locate the bottom nuts above thestilt threaded bolts to desiredheight.

d) Insert the lock washer over the stiltbolt.

e) Move the threaded stilt bolt upthrough the holes in the bottom ofthe baseplate and secure in place.

f) Attach the remaining lock washerand nuts on to the threaded stiltbolt. Fasten the nut on to the lockwasher.

g) Secure all four threaded stilts.Now locate the baseplateassembly over the flexible levelingfeet and tighten the feet to thethreaded stilts. Now lower theentire assembly to the foundation.

h) Make final level and heightadjustments by simply looseningthe top nuts and turning the bottomnuts to raise or lower thebaseplate assembly.

i) Finally, first tighten the top andbottom nuts located on therespective lock washers and thentighten the other nuts to insure thebaseplate is properly locked inplace.

At this point, follow the steps as listed above(Steps 12, 13, and 14) for grouted baseplates.


APPENDIX ICorrosion Guide


Corrosion Guide, con’t.


Corrosion Guide, con’t.


APPENDIX IIInsert Guide

The following guide is to assist with the fieldinstallation of inserts if there is a need toreplace a damaged thread or to install a newinsert into a custom location. In order toachieve a successful installation the followingprocedures are recommended:

! WARNING !Field installation should only be performed byqualified personnel using suitable drillingequipment. Personnel should be sure to use aface mask to prevent inhalation of silica dustas the ChemBasePlus™ casting is penetratedduring drilling operations. If MSDSspecifications are required, contact your localGoulds representative. Also, be sure to utilizeprotective eyewear while performing anydrilling operation.

1. It is recommended to utilize a carbide tipdrill bit to perform drilling procedure.Please refer to Table 1 for drill bit sizerecommendation. We suggest providinga hole diameter that will allow amplespace to install the insert yet still maintaina snug fit as to not need too much fillerepoxy resin.

Table 1Hole Drill Size Recommendation

Insert Size Drill Size*1 / 4 – 20 0.625 in.

5 / 16 – 18 0.625 in.3 / 8 – 16 0.875 in.1 / 2 – 13 1.000 in.5 / 8 - 11 1.375 in.

*NOTE: Drill size listed above is minimum —increasing the hole diameter by an extra 0.125inches may assist in allowing for any holelocation variances established by installer.

2. Drill approximately 1/8” (.125) lower thenthe given length of the provided insert.

3. Drill the new hole (Figure 1) or drill outthe damaged insert taking care not toenlarge or elongate the hole into whichthe new insert will be installed. Removeall dust and metal particles from thedrilled hole using compressed air.

FIGURE 1

4. It is critical that perpendicularity in relationto the surface of the ChemBasePlus™ ismaintained. Goulds prescribes two basicmethods of insuring that the insert willachieve proper perpendicularity and are asfollows:

a) Fabricate a template (i.e. constructed ofplywood or metal) based off the numberof inserts. The template should bedesigned to locate the holes off areference point located on the respectivedrawing of the given baseplate (pleasecontact your Goulds Pumpsrepresentative if you are in need of aparticular drawing or consult factory).Fasten the insert to a stud with a nut onthe top side of the template


(Figure 2). Prior to placing the template /insert assembly down on the baseplate asseen in Figure 2, proceed to step 5 forfilling the hole with the proper amount ofepoxy resin.

FIGURE 2

b). With the pump assembly elevated abovethe baseplate, fasten the insert to thebottom of the motor hex bolt that isintended to mount the pump/motorassembly down to the baseplate. Do notfully tighten the bolt at this time as someslip is desired so as to insure that theinsert drops slightly below the surface ofthe baseplate. Proceed to step 6.

5. Dispense epoxy resin material into thedrilled hole (Figure 3) following theinstructions provided – the two-part epoxycan be mixed together to activate in thehole. Make certain not to overfill the holeas excess material may spill over on to thetop surface of the insert and down into thethreads. Goulds prescribes that you fill thehole about half-way when utilizing atemplate device. Now locate the templatearrangement down over the epoxy filledholes and allow epoxy to harden. Top offthe hole accordingly after the template hasbeen removed and wipe away any excessmaterial so as to keep the top surfaceclean.

FIGURE 3

6. Dispense the epoxy resin material into thedrilled hole as seen in Figure 3. Fill thehole only a third of the way. Lower thepump/motor assembly (if C-Flange motoris being used) or motor down into theepoxy filled holes (Figure 4). Check thatall inserts are centered accordingly andallow the epoxy to harden. After the epoxyresin has hardened, remove the motorassembly and top off the holes accordinglyand wipe away any excess material so asto keep the top surface clean.

FIGURE 4

The baseplate in now ready to be installedor shipped, respectively. Do not exceedthe recommended fastener torques asshown in Appendix III.


APPENDIX IIIRecommended Fastener Torques

FASTENERSTANDARD

FASTENERNOMINAL

SIZE

RECOMMENDEDTORQUE

LB/FT¼” 4

5/16” 8S A E 3/8” 13

½” 345/8” 66¾” 118


APPENDIX IVAlignment

SET UP1. Mount two dial indicators on one of the

coupling halves (X) so they contact theother coupling half (Y) (Fig. IV-1).

2. Check setting of indicators by rotatingcoupling half X to ensure indicators stay incontact with coupling half Y but do notbottom out. Adjust indicators accordingly.

MEASUREMENT1. To ensure accuracy of indicator readings,

always rotate both coupling halvestogether so indicators contact the samepoint on coupling half Y. This will eliminateany measurement problems due to runouton coupling half Y.

2. Take indicator measurements with driverfeet hold-down bolts tightened. Loosenhold down bolts prior to making alignmentcorrections.

3. Take care not to damage indicators whenmoving driver during alignment corrections.

ANGULAR ALIGNMENTA unit is in angular alignment when indicator A(Angular indicator) does not vary by more that.002 in. (.05 mm) as measured at four points90° apart.

Vertical Correction (Top-to-Bottom)

1. Zero indicator A at top dead center (12o’clock) of coupling half Y.

2. Rotate indicators to bottom dead center (6o’clock). Observe needle and recordreading.

3. Negative Reading - The coupling halvesare further apart at the bottom than at thetop. Correct by either raising the driver feetat the shaft end (add shims) or loweringthe driver feet at the other end (removeshims), (Fig. IV-2).

Positive Reading - The coupling halvesare closer at the bottom than at the top.Correct by either lowering the driver feet atthe shaft end (remove shims) or raising thedriver feet at the other end (add shims).

4. Repeat steps 1-3 until indicator A reads.002 in (.05 mm) or less.

Horizontal Correction (Side-to-Side)1. Zero indicator A on left side of coupling

half Y, 90° from top dead center(9 o’clock).

2. Rotate indicators through top dead centerto the right side, 180° from the start(3 o’clock). Observe needle and recordreading.

Fig. IV-2

Fig. IV-1


3) Negative Reading - The coupling halvesare further apart on the right side than theleft. Correct by either sliding the shaft endof the driver to the left or the other end tothe right.

Positive Reading - The coupling halvesare closer together on the right side thanthe left. Correct by either sliding the shaftend of the driver to the right or the otherend to the left (Fig. IV-3).

4) Repeat steps 1 through 3 until indicator Areads .002 in. (.05 mm) or less.

5) Re-check both horizontal and verticalreadings to ensure adjustment of one didnot disturb the other. Correct asnecessary.

PARALLEL ALIGNMENTA unit is in parallel alignment when indicator P(parallel indicator) does not vary by more than.002 in. (.05 mm) as measured at four points90° apart at operating temperature. Note thepreliminary vertical cold setting criteria, Table1.

Vertical Correction (Top-to-Bottom)1. Zero indicator P at top dead center of

coupling (12 o’clock) half Y (Fig. III-1).

2. Rotate indicator to bottom dead center (6o’clock). Observe needle and recordreading.

3. Negative Reading - Coupling half X islower than coupling half Y. Correct byremoving shims of thickness equal to halfof the indicator reading under each driverfoot.

Positive Reading - Coupling half X ishigher than coupling half Y. Correct byadding shims of thickness equal to half of

the indicator reading from each driver foot(Fig. IV-4).

NOTE: Equal amounts of shims must beadded to or removed from each driver foot.Otherwise the vertical angular alignment will beaffected.

4. Repeat steps 1 through 3 until indicator Preads within .002 in. (.05 mm) or less whenhot, or per Table 1 when cold.

Horizontal Correction (Side-to-Side)1. Zero indicator P on the left side of coupling

half Y, 90° from top dead center(9 o’clock).

2. Rotate indicators through top dead centerto the right side, 180° from the start(3 o’clock). Observe needle and recordreading.

3. Negative Reading - Coupling half Y is tothe left of coupling half X. Correct bysliding driver evenly in the appropriatedirection (Fig. IV-5).

Positive Reading - Coupling half Y is tothe right of coupling half X. Correct bysliding driver evenly in the appropriatedirection.

NOTE: Failure to slide motor evenly will affecthorizontal angular correction.

4. Repeat steps 1 through 3 until indicator Preads .002 in. (.05 mm) or less.

5. Re-check both horizontal and verticalreadings to ensure adjustment of one didnot disturb the other. Correct asnecessary.

Fig. IV-4

Fig. IV-3

Fig. IV-5


COMPLETE ALIGNMENTA unit is in complete alignment when bothindicators A (angular) and P (parallel) do notvary by more than .002 in. (.05 mm) asmeasured at four points 90° apart.Vertical Correction (Top-to-Bottom)

1. Zero indicators A and P at top dead center(12 o’clock) of coupling half Y.

2. Rotate indicator to bottom dead center(6 o’clock). Observe the needles andrecord the readings.

3. Make corrections as outlined previously.

Horizontal Correction (Side-to-Side)1. Zero indicators A and P on the left side of

coupling half Y, 90° from top dead center(9 o’clock).

2. Rotate indicators through top dead centerto the right side, 180° from the start(3 o’clock). Observe the needle, measureand record the reading.

3. Make corrections as outlined previously.4. Recheck both vertical and horizontal

readings to ensure adjustment of one didnot disturb the other. Correct asnecessary.

NOTE: With experience, the installer willunderstand the interaction between angularand parallel and will make correctionsappropriately.

ge 14 of 15Form No. I-Chembase — 1/2002© copyright 2002 Goulds Pumps, Inc.

a subsidiary of IT Industries, Inc.

Documents

Installation, Operation and Maintenance · PDF file3.2 Application ... Appendix I. Corrosion Guide Appendix II. Insert Installation Guide ... Appendix IV Alignment