PUMP BASEPLATE INSTALLATION AND GROUTING by Monroe, Jr. Senior Staff Engineer-Machinery Perry Exton Chemical Company Baytown, Texas Mechanical seals get the “bad rap" for pump failures, because Perry C. Monroe, Je is present «they usually ae the fist indication ofa problem, A mechanical Senior. Staff Engincer in the Polymers sealfailure isnot the real problem, but the resultofa pump prob- Technology Division of Exxon Chemeat lem. With this in mind, plans were pat into action to start atthe Company, located in Baytown, Teras. In root of the problem and improve the pump baseplate installa- this position, he provides technical sup- _tou-The plan included the observation of present installation port'to Maintenance and Process, and practices, improvements tothe installation methods, execution Conducts training on turbomachinery re- of the new installation methods, and evaluation of the results. lated subjects, Prior to joining Eton, ‘The improved methods of bseplate installation described here- Mr. Monroe spent 18 months in East snsielded reduction of pump vibration fom 0,3 oO. inch per Kalimantan, Indonesia (Borneo) with second (ips) to below 0.15ips. Observations of pumps which had Pay A. Hujfington, Incorporated, at the been installed with the new methods indicated much longer RT. Badak LNG Plant, asthe Assistant Maintenance Manager “meantime between failure” (MTBF) over existing pamps. The and Logistics Manager. His duties eluded the startup superet- tet program started in mid 1952 with the use ofepony grout. AS ston of six 42000 hy steam turbine dricen compressor trains. As result ofthe test program, epoxy grout is being used almost Logistics Manager, he was responsible forthe actions of 78 peo- exclusively for pump baseplate grouting. ple to furnish plantwide seretees forall foreign and domestic The “one time” cost to install epoxy grout was paid for by the purchasing air and sea custom cledrances, air and sea transpor- reduction ofthe number of repeated pump failures which aver tation, and warehouse fttes. These sercicey were for both aged $5,000 to $10,000 per repair. Cost of epoxy grout ran ap plant and community needs proximately 875 to 880 per eubie foot as compared to $30 per ‘Mr. Monroe graduated from Auburn Unicersity in 965, .cith cubic Toot fer cementitious grout, But remember, this wasa"one B.S.M.E. degree, and has worked forthe past 22 vears in tur~ time” cost compared to a repeated failure cost had epoxy grout omachinery repair techniques, optical and mechanical align- ot been used. ‘nent, eibration anclysis ond field balancing, nondestructice Epoxy grout bonds toa properly prepared baseplate, with a testing, mechanical seals, and corrosion. Prior %0 graduation, 2,000 psi tensile strength ond which tansforms the baseplate Ie worked asa designer of rocket engine components for NASA into monolith with the conerete foundation. This formation of| at Redstone Arsenalin Huntsile, Alabama, andasadraftsman _asingle block reduces the natural frequenes ofthe pump base- For TCI (USS) Steet Works in Birmingham, Alabama. plate, reducing pump shaft vibrations, and prevents moistete or ‘Mr. Monroe is a member of the International Pump Sym- _ oilfrom damaging the conerete under the baseplate. There is no postum Adcisory Committee, bond when cementitious grout is used and there is « possibilty of moister oril geting between the underside ofthe baseplate nd foundation Pump baseplate installations are ike marriage vows, “until ABSTRACT death do ux part." Once a baseplate has been grovted, saint hance personnel have t ive with until the unt is torn davin In most cases this would befor twenty or more Years, a0 be hooves us to install the baseplate level and with mounting sur faces coplanar ‘Allthe time and eflor spent specifying the right pump, mate- rials, mechanical seals, and baseplate can he ruined by poor in Eallation practices. Generally the leat tried person, in terms of pumps, has free reign on how baseplates are set, leveled and routed it becomes an even bigger problem when epoxy grout Fused, because instalation techniques ae diferent from the ‘more eammonly known cementitious grout. Over the past three ‘ears four hou traning cass on epot grouting has been con- dicted forall personnel invalved sth peimp instalation. This ‘nchided both company and contact personnel fom the labor Methods used by the author to Jevel and epoxy grout pump baseplates. The methods used are not the only way pumps can be installed, but followed, will ensure a 100 percent vod free rout job. Execution of the leveling and grouting uses known techniques, but with a new twist, and are designed to shorten the pump installation and alignment time by application of “one pout” grout procedure. The reasons for the use of epoxy grout in place of cheaper cementitious grout willbe covered along with special baseplate preparations. Pump baseplete installation and grouting tech- hiques covered are applicable to any terbomachinery baseplate, bbed ail, oF skid installation , ersto the engineers. The results have justified the expense and INTRODUCTION effort of training, because in al cases, inexperienced grouting “Why ll the fass over how a pump baseplate is installed and personnel have correctly installed and grouted pump baseplates routed?” The answer is to reduce maintenance costs. Experi- void fiee, Wis now the practice for machinists or millwrights to tence has proven that pumps with poorly installed baseplates place the grout and have complete responsiblity for pump in- have more vibration and alignment problems which cause more __stallations,aliguments, ad commissionings. This practice has frequent beating, mechanical seal, and coupling failures. fostered ownership and pride ina job well dane. uyns PROCEEDINGS OF THE FIFTH INTERNATIONAL PUMP USERS SYMPOSIUM BASEPLATE LEVELING PROCEDURE Tt is necessary to discuss the baseplate leveling procedure frst, in order to fully understand certain baseplate and found tion preparations. These preparations mst be performed before the placement of the baseplate on the foundation The following assumptions are made coneeming the pump foundation: + The foundation has been adequately designed to support the pump. Foundation mass for centrifugal pumps should e at least three times the mass of the pump, driver and baseplate Reciprocating pump foundation mass should be at least five times the pump system mass. + The foundation should rest on solid or stabilized earth com- pletely independent of other foundations, pads, walls, or operat ‘ng plafortns, A minitnum of3,000 ps steel relaforeed concrete should be used. + The foundation has been designed to avoid resonant vibra tion conditions originating from normal excitation forces at operating speed or multiples ofthe operating speed. + The pump, gearbox (ifused), and driver rest on @ common foundation, + The foundation is designed for uniform temperatures tore duce distortion and misalignment. Do not take these assumptions for granted. Check the found tion at the design stage, not after it has heen poured. There are some good computer programs available for fotindation designs ‘The preferred method of leveling a pump baseplate is lus trated in Figute 1. Jack screws located on both sides of each a chor bolt are ased to elevate the baseplate tothe level position ‘while the anchor bot lightly holds the baseplate firm. It may not be necessary to use both jack serews if the baseplate is lat, but both are required iPtrying to bend the baseplate machined sur faces fat. Notice that circular plates ent from 2.0 in to 2.5 in diameter steel bar stock, approximately 0.5 in thick, are used to prevent the points ofthe jack screws from digging into the con- ‘rete and altering the level. Use just enough tightening force on the jack serewsand anchor bolts to hold the baseplate in position until the grout has been poured and cured. A ca Po es i cs | Vy I Bee ema Figure 1, Jack Screws Located on Both Sides of Each Anchor Bolt Are Used to Level ond Support the Baseplate Until the Grout Is Poured rior tothe baseplate placement onthe foundation, the con cxete must be chipped to remove the cement rich concrete (called laitance) and expose the aggregate. This provides a stronger conerete/epoxy grout bond, because the strength ofthe concrete depends on the aggregate. The chipped surface must be blown clean with oil free air and kept dev. Moisture and oil are the big enemies of good epoxy grouconerete bonding, el race has indicated that 2.0 in to 3.0 in of epoxy grout are required under the pump baseplate fanges to reach the desired compressive strength. Thinner pours do not gener ate enough exothermie reaction heat to fully cure the epoxy. Be fore leveling, the baseplate should be high enough for the 2.0 into 3.0 in grout thickness, The use of jack serews for leveling is much faster than the ‘more common method of using square steel plates and shins. Jack serews also eliminate the problem of removing the leveling shims alter grout placement. The baseplate should be tot supported by the epoay’ grout and not point supported at the leveling shims. Sharp cornered shims should not be left in epoxy trout, beeause they form stress concentrations and cause crack- fing. Onee the epoxy grout has cured, the jack screws are re moved and the holes are filled with epoxy or sealant. The jack serews are greased prior to installation to allow for their removal Baseplate leveling begins with the pump and driver removed, alter checking the pump suction and discharge anges for proper location and elevation, Piping should not be attached to the pump until the baseplate has been leveled, grouted and the Griver/pomp aligned. The use of a Starrett 95 Machinist’ Level Figure 2. A Starrett 98 Machinist Level Placed on the Driver Mounting Surface Was Used to Level in the Axial Direction, ACY B Figure 3. After Leveling Axially, Rotate the Machinist Level 90 Degrees and Adjust the Level.PUMP BASE] Figure 4. The Pump Mounting Surfaces are Leveled Using the Saine Procedure as the Driver Mounting Surfaces mounted on the machined surfaces for the driver i illustrated in Figures and. The jack screws and anchor bolts are adjusted until a level of 0.0005 int is obtained im twa divections 90 de- srees apart. The machined surfaces for the pump receive the Same treatment (Figure 4) with & maximum elevation variation across the length of the baseplate of0,010in. A precision straight ‘edge should be used across the mounting surfaces to check for Figure 5, A KE Model 71-3015 Optical Level Being Set Up ond Adjusted Prior to Leveling a Baseplate Figure 6. In Hot Weather, Shade the Baseplate for 24 Hours be fore and 48 Hours after Pouring the Grout ATE INSTALLATION AND GROUTING 19 coplannarity, The mounting suelices should be coplannae within (0.008 in the baseplate is long (over 15 ft), an optical level similar to the K&E Model 71-3015 might be used to speed up the leveling operation (Figure 5}. ‘Once the baseplate i leveled, grouting operations ean begin, If grouting is to be done during hot weather (above 90°F), it should be started early in the moming while the baseplate is level. Check level afer the baseplate temperature has stabilized ‘overnight, ad shield the baseplate from direct sunlight (Figure 6). BASEPLATE PREPARATION Now that the baseplate leveling procedure has been dis cussed, listed below are some baseplate requirements that should be included in the pump specfications/purehase order + Aiiwelding.on the baseplate shall be completed and stress relieved prior to machining pump av driver mounting sur faces + All machined mounting surfaces shall be coplannarto 0.002 {n. All baseplate welds shall be continuous (no skip welding) and free of racks. * Underside of baseplate shall be sandblasted to white metal and coated with 0.003 in wet thickness of epory coating. as Specified by purchaser + Alleross bracing on underside of baseplate shall have 2.048, X 6.0 in minimum opening to allow for grout fl + Drill 0.5 in diameter vent holes on 24.0 in centers around periphery of baseplate at the highest point + Radiusall sharp corners of baseplate flanges. Minimum 1.0 in radius + Provide 1/8 in minimum shim adjustment under driver feet for alignment + Provide eight alignment positioning serews for driver. + Machined mounting susfices shall extend 0.1 in bevond pump aad driver feet om all sides. + Drilland lap two holes on the baseplate Manges, one on each side of the anchor bolt holes, for one-half inch diameter jack/ leveling serews, he imosating suafaces ane machined to 0,002 in coplannar afer the welding has been completed, the same tolerance ean be repeated in the field. This helps to eliminate "soft feet” and to speed up alignment, The common practice of machining steel plate mounting surfaces avd welding them to the baseplate ‘eases skewed surfaces that cannot be leveled in the Reld, ‘Avoid free grout jolvis ensured by providing vent holes at the baseplate periphery and in each compartment, Some pump pit chasets never look under the baseplate to see how cross bracing makes a good grout job impossible. On oceasions, the author has torched upenings through braces, to provide a path for saout, The request fora 1,0 in wider mounting surface on each side ofthe equipment feet ean be a life saver, i baseplate leveling is required with pump and driver mounted. The additional cost of ‘afew more inches of steel plate is peanuts, compared tothe flex: ibility of baseplate leveling with mounted equipment in ‘energeney conditions. A machinis’s level ean be placed on the additional margin arousd the pump and driver, allowing the baseplate to beleveled. Thiss not the preferredmethad oflevel- sng, but it will work, NEW CONCRETE PREPARATION Freshly poured concrete must he allowed to eure before epoxy grout is applied. As mentioned earlier, moisture will rin the epoxy grouveonrete bond, even the siall amount of mois: