PUMP INSTALLATION. Tim Sullivan, P.E. 12/1/2017 PUMP INSTALLATION PRESENTATION 1
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1 PUMP INSTALLATION Tim Sullivan, P.E. 12/1/2017 PUMP INSTALLATION PRESENTATION 1
2 PRESENTATION AGENDA Prior to installation Pipe, Fittings, and Valves Nozzle Strain, Couplings and Offsets Seals, Packing and Gauges Pump Pedestal, Anchors and Grout 12/1/2017 PUMP INSTALLATION PRESENTATION 2
3 Questions? Fire Away Pump Orientation 12/1/2017 PUMP INSTALLATION PRESENTATION 3
4 PRIOR TO INSTALLATION: Get customized (annotated) O&M manuals Off loading Maintenance (storage and prior to installation Installation Maintain (rotate shaft) while in storage 12/1/2017 PUMP INSTALLATION PRESENTATION 4
5 Suction Pipe Important hydraulically (for centrifugal pumps) Straight runs 4-6 diameters Example: 6 pipe 2 ft. to 3 ft. straight run min. Reducer Eccentric Connect to the pump 12/1/2017 PUMP INSTALLATION PRESENTATION 5
6 Discharge Pipe Not as important hydraulically (Get it out of the way) Vertical use Base elbows (watch out for check valves) Horizontal go back to suction header Reducer Conncet to pump Concentric reducer Provide air vents stop cocks Consider 45 Degree Fittings, Wyes and Laterals 12/1/2017 PUMP INSTALLATION PRESENTATION 6
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10 Couplings Use to help disassemble pipe pump Install btw isolation valve and pump Dresser, Victaulic (grooved) Disassembly style coupling Thrust restrained on discharge (always, sometimes on suction Generally best to use on suction side Not suitable for offsets Use mitered fitting 12/1/2017 PUMP INSTALLATION PRESENTATION 10
11 Couplings 12/1/2017 PUMP INSTALLATION PRESENTATION 11
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14 Nozzle Strain, Pipe Alignment, Couplings and Offsets Nozzle strain Couplings (Dresser style) Excellent to align in X axis Only 4 degrees in off-set direction Mechanical vs flanged fittings Rotate Flex Connectors Bevel and filler flanges Fabricated off-set pipe (best for significant off-sets) 12/1/2017 PUMP INSTALLATION PRESENTATION 14
15 Isolation Valves Generally both suction and discharge sides of pumps Suction: Install upstream of straight diameters Discharge: Install downstream of check valve Type very dependent on the service 12/1/2017 PUMP INSTALLATION PRESENTATION 15
16 Check Valves Always on the pump discharge Install check valve after reducer Be careful of check valves in the vertical Foot Valves generally not a good idea 12/1/2017 PUMP INSTALLATION PRESENTATION 16
17 Reducers Connect at the Pump 12/1/2017 PUMP INSTALLATION PRESENTATION 17
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19 Energy Considerations Laterals, Wyes, 45 s and Long Radius 90 s Watch out for checks valves WIDE variety of Headloss 12/1/2017 PUMP INSTALLATION PRESENTATION 19
20 Laterals and 45 s vs 90 Watch checks valves 12/1/2017 PUMP INSTALLATION PRESENTATION 20
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23 Eccentric on Suction Side 12/1/2017 PUMP INSTALLATION PRESENTATION 23
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27 Mag meters 3 to1 straight pipe diameters, suction to discharge minimum Ideal 10 to 3 pipe diameters Example 6 pipe: 3 x 6 = 18 straight pipe suction (min.) 1 x 6 = 6 strainght discharge pipe (min.) 60 and 18 ideal 12/1/2017 PUMP INSTALLATION PRESENTATION 27
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32 SEALS AND PACKING Mechanical seals MANY styles and materials, consult mfr. Generally silicone-carbide seals work for WW applications, carbonceramic for W applications Single seal fine with flush-water, double if not available Consider split seals for large diameter shafts Seal water pressure greater than stuffing box pressure Packing rings make sure gland is centered at flushing port Adjust periodically, but don t overtighten 12/1/2017 PUMP INSTALLATION PRESENTATION 32
33 GAUGES AND INSTRUMENTS Gauges Required start-up, and to assess pump performance / trouble shoot Gauge not necessarily required, just fittings Compound gauges required on suction lift pumps Consider vibration monitoring, amp draw, temperature monitors, preferable on critical assets and larger ($$$) pumps Get baseline data and compare over time 12/1/2017 PUMP INSTALLATION PRESENTATION 33
34 Seal Water System
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36 Pipe Installation Directions To the pump from both sides not good To the pump, then away from the pump - best 12/1/2017 PUMP INSTALLATION PRESENTATION 36
37 Nozzle Strain, Pipe Alignment, Couplings and Offsets Nozzle strain Couplings (Dresser style) Excellent to align in X axis Only 4 degrees in off-set direction Mechanical vs flanged fittings Rotate Flex Connectors Bevel and filler flanges Fabricated off-set pipe (best for significant off-sets) 12/1/2017 PUMP INSTALLATION PRESENTATION 37
38 PUMP BASEPLATE, PEDESTAL, ANCHORS, AND GROUT System, act in unison Pedestal: anchors pump mass to structural base slab Gap required to adjust and align pump baseplate Grout: fill void between pump baseplate and pedestal Baseplate designed to HI Standard Anchors tie the baseplate, grout and pedestal together in unison 12/1/2017 PUMP INSTALLATION PRESENTATION 38
39 Concrete Pedestal Size 3 5 times pump motor mass Set 6 + away from pump baseplate edge (all sides) Bush hammer floor slab Install Reinforcing steel into floor slab Apply bonding agent Pump anchors system: Locate with template Secured in pedestal or embedded into floor slab 12/1/2017 PUMP INSTALLATION PRESENTATION 39
40 Anchor System Sized by Mfr. (or Engineer) but Owner/Contractor can purchase J-bolt (new) epoxy anchors (existing) Anchor, nut, plate, and sleeve Protect sleeve void (foam insulation) and threads (grease, putty, tape, etc.) 12/1/2017 PUMP INSTALLATION PRESENTATION 40
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42 Pump Base Alignment Wedges / Shims vs jacking screws DON T use double nuts Front to back first (X), then side to side (Y) Always remove shims 12/1/2017 PUMP INSTALLATION PRESENTATION 42
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46 Grout Course Use non-shrink grout or flowable epoxy under baseplate 1 to 2 thick Some baseplates are fabricated and entire void needs to be filled (i.e. chopper pump) Require air vent Consult with manufacturer. Grout must harden (~25+ hours) prior to torqueing Remove shims / wedges prior to torqueing Grout must cure (72+ hours) prior to testing 12/1/2017 PUMP INSTALLATION PRESENTATION 46
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53 Mechanical Displacement - dial indicators Check pump/motor alignment (angular alignment) Eyesight straight edge & feeler gauges
54 Laser Optic Systems Check pump/motor alignment (parallel alignment) Eyesight straight edge & feeler gauges
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60 Away from Electrical Panel Electrical Rubber SS
61 Any Questions? (I may have an answer) Thank you! Tim Sullivan, P.E /1/2017 PUMP INSTALLATION PRESENTATION 61
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