CAUTION: Based upon the publication date, this document may not contain the latest guidance. The user is strongly advised to contact the Technology Manual Sponsor to 1000 Pump Installation

Abstract This section contains general guidelines and checklists for installation of new pumps and reinstallation of existing ones.

Contents Page

1010 Introduction 1000-2

1020 Installation Checklist 1000-2

Revision History 1000-7

determine the appropriate subject matter expert for consultation on applicability to the users specific case.

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1000 Pump Installation Pump Manual1010 Introduction Although these guidelines focus on new installations, many aspects also apply to existing installations where equipment has been repaired, rerated, retro-fitted, etc.

Proper pump installation helps ensure trouble-free startup and long term reliability. If installed improperly, even the best pump can be a source of costly maintenance. For example, a pump running perfectly in a well-designed installation may experi-ence many problems if moved to a poorly designed installation. The opposite is also true. Additionally, an unreliable pump installation can affect plant availability, even if fully spared. Two fully spared but poor installations never equal a single, reliable installation.

This section discusses general items that should be considered to ensure reliable pump installations.

Although the items on the checklist in Section 1020 are simple, it is surprising how often they are not checked or not properly followed. Typical examples include:

Baseplates improperly grouted. This leads to excessive deflection and vibration, shortening pump and driver life.

Pump and driver shafts improperly aligned. This shortens bearing, seal, and coupling life.

Excessive pipe cold-springing. This distorts the pump case and baseplate, short-ening bearing, seal, and coupling life.

These problems can be expensive. For example, the cost of three or four seal fail-ures may equal the original pump purchase price. There is a significant economic incentive to achieve good, reliable pump installations from the start.

1020 Installation Checklist The attached checklist covers most common onshore and offshore pump installa-tions. Where appropriate, installation items specific to certain types of pumps are listed separately. This checklist does not include specific acceptance criteria (align-ment tolerance, pipe forces, etc.). These criteria should be developed for the specific application according to the manufacturer's service manual, applicable industry standards, and local practices.

The following checklist assumes that there are no problems inherent in the equip-ment. This means that the pump design matches the intended service, materials are correct, and the pump has been properly manufactured. It also assumes that the associated process and auxiliary piping system, foundations, and baseplate are prop-erly designed and built.

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Pump Manual 1000 Pump InstallationPump Installation ChecklistInitial Date

General - All Pump Types1. Data Sheets (Pump & Driver)

Drawings:

Properly Completed Data Sheets ________ ________Pump Cross Section/Performance Curves ________ ________Shaft Seals/Packing ________ ________Coupling ________ ________Auxiliary Systems (lubrication, sealing, cooling) ________ ________Shop Performance/Mechanical Test Results ________ ________Service Manual (covering all major pump train components) ________ ________Safety Instruction Sheets ________ ________Maintenance History (existing pumps) ________ ________Performance/Vibration History (existing pumps) ________ ________Spare Parts List ________ ________

2. Foundations and Grouting

Concrete Foundations:

Concrete properly cured before grouting ________ ________Concrete surface properly roughened and cleaned ________ ________Mounting plate metal surface clean/properly painted ________ ________Mounting plate corners properly rounded ________ ________Proper grout material/thickness ________ ________Coupling disconnected before levelling ________ ________Mounting plate levelled ________ ________Pump mounting pads horizontal and at same elevation ________ ________Grout properly cured ________ ________No hollow areas in grouting ________ ________Anchor bolts properly tightened ________ ________

Other Foundations:

Mounting plates located at load bearing support beams ________ ________Shims of non-corrosive material ________ ________Baseplate/skid properly levelled ________ ________Bolting properly tightened ________ ________

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1000 Pump Installation Pump ManualPump Installation Checklist (continued)Initial Date

3. Equipment Condition (Before Installation)

Storage protection requirements met ________ ________Internal/external cleanliness checked ________ ________Rust preventative/lubricant compatibility acceptable ________ ________Baseplate/skid straight and flat ________ ________Pump feet free of burrs ________ ________Pump and driver not bolt-bound ________ ________Nozzle gasket surface finish acceptable ________ ________Pump and driver rotates freely by hand (no excessive radial or lateral play) ________ ________Alignment shims (number, material, condition) acceptable ________ ________Coupling condition acceptable ________ ________Seal leak free (static or running test) ________ ________Rotation arrow permanently marked, checked ________ ________Oil level marked, checked ________ ________Alignment jack screws ________ ________

4. Process Piping Systems

P&ID Check ________ ________Proper blinding & tagging suction/discharge lines ________ ________Suction screen location and orientation correct ________ ________Check/block/bypass valves location and orientation correct per P&ID ________ ________Correct gasket design/material installed ________ ________Relief valves properly set ________ ________Piping/pump flanges parallel ________ ________Check for cold spring with indicators ________ ________Correct piping supports (hot and cold) installed ________ ________Expansion joints properly adjusted ________ ________Piping strain acceptable (hot service check) ________ ________Check ANSI Class on flanges for correct rating ________ ________Eccentric reducers - flat side up, angled side down ________ ________Suction piping sloped to prevent vapor traps ________ ________Piping clean as dictated by installation ________ ________

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Pump Manual 1000 Pump InstallationPump Installation Checklist (continued)Initial Date

5. Auxiliary Piping Systems

General:

Piping properly braced ________ ________Piping cleaned ________ ________Piping proper size and material ________ ________Piping properly sealed/socket welded ________ ________Piping properly traced and insulated ________ ________Proper thread lubricant used ________ ________Check instrumentation per any available drawing ________ ________

Seals:

Flush properly connected ________ ________Flush system orifice/strainer/cyclone separator correctly located ________ ________Quench properly connected/plugged ________ ________Vent properly connected/plugged ________ ________Drain properly connected/plugged ________ ________

Packing:

Lantern ring location/flush connection correct ________ ________Cooling:

Stuffing box properly connected ________ ________Lube oil cooler connected ________ ________Pump pedestals connected (hot services) ________ ________

Lubrication:

Piping properly cleaned/water-free ________ ________Proper orifices installed (pressure systems) and tagged ________ ________Housings flushed with correct oil ________ ________Screwed piping properly assembled (without tape) ________ ________Oil levels correct ________ ________No bends/kinks between housing & oiler (purge mist) ________ ________Oilers properly vented (at bearing cap) ________ ________Oil sump bottle non-vented (purge mist) ________ ________Oil sump bottle vented (pure mist) ________ ________Oil mist fittings - proper sizes ________ ________Oil mist - check flow ________ ________

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1000 Pump Installation Pump ManualPump Installation Checklist (continued)Initial Date

Case Vents/Drains:

Vent properly piped ________ ________Drain properly piped/plugged ________ ________Warm-up connection properly piped for hot pumps ________ ________Ports properly connected for Sundyne pumps ________ ________

6. Couplings and Alignments

Alignment shims entirely under each pump foot ________ ________Soft foot checked ________ ________Avoid spring effect due to an excessive number of shims ________ ________Correct axial spacing between pump & driver shafts (hot and cold) ________ ________Axial float of motor driver checked ________ ________Motor driver properly positioned (limited end float coupling) ________ ________Proper coupling interference fit ________ ________Coupling lube holes properly positioned ________ ________Gear coupling properly greased and gaskets installed ________ ________Flexible coupling shim packs properly installed ________ ________Pump/driver cold aligned & bolting properly tightened ________ ________Coupling hub runout checked ________ ________Cold alignment to manufacturer's recommended tolerances ________ ________Hot alignment checked ________ ________Pump/driver properly dowelled ________ ________Coupling guard installed ________ ________

7. Miscellaneous

Proper packing installed, gland not cocked ________ ________Special tools available ________ ________Driver rotation checked (prior to coupling) ________ ________Instrumentation, alarms, and shutdown in proper condition ________ ________Pump/driver properly protected during idle period ________ ________

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Pump Manual 1000 Pump InstallationRevision History

Pump Installation Checklist (continued)Initial Date

Other Specific Pump Types1. Vertical Centrifugal

Curb ring properly leveled and grouted ________ ________Pump assembly within acceptable vertical deviation (proper lift with axial setting)

________ ________

2. Rotary Pumps

Internal cleanliness checked ________ ________Belts and sheaves properly aligned ________ ________Matched belt sets used ________ ________Belts properly tensioned ________ ________Suction strainer cleanliness checked ________ ________Pressure gage installed before/after strainer ________ ________Jacket piping properly connected ________ ________Belt guards installed ________ ________

3. Reciprocating Pumps

Baseplate/foundation bolts retightened ________ ________Belt and sheaves properly aligned ________ ________Matched belt sets used ________ ________Belts properly tensioned ________ ________Belt guards installed ________ ________Plunger/piston/packing correct size ________ ________Rod straightness/runout/surface condition acceptable ________ ________Packing properly installed and lubricated ________ ________Packing gland properly adjusted (initial) ________ ________Correct bladder pressure/fluid level in pulsation dampers ________ ________Lubricators operating correctly ________ ________

Date Description Author Technology LeadJanuary 1991 Initial release

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1000 Contents1010 Introduction1020 Installation ChecklistRevision History