Method Statement Form - Fire Pump

Title : Page 1 of 74
Document No. : Effective Date : Revision :
Revision History
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Category Contents Page

1 GENERAL
2 STORAGE AND PROTECTION
3 SAFETY AND HEALTH PRECAUTIONS
4 FIELD INSTALLATION
5 VENDORS INSTALLATION GUIDELINE
Appendix 1
Appendix 2
1. GENERAL
This procedure covers the installation and operation of Pump horizontal split case
pumps. The pump is a centrifugal, single stage, double suction type. When properly installed
and when given reasonable care, centrifugal pumps should operate satisfactorily for a long
period of time. Centrifugal pumps use the centrifugal force principal of accelerating the liquid
within a rotating impeller, and then collecting it and converting it to pressure head in a
stationary volute.
The pump consists of two assemblies:
1.1. Casing assembly or stationary part

1.2. Rotating element or moving part
This casing is split along the horizontal centerline of the pump shaft, suction and discharge
Nozzles both being located in the lower half. With this arrangement, it is not necessary to
disconnect suction or discharge piping to make repairs to, or replace the rotating element.
Upper and lower half casings are bolted together and doweled to maintain a smooth volute
contour inside the pump.
2. STORAGE AND PROTECTION
All pumps are shop serviced and ready for operation when delivered, but there is occasions
when considerable time elapses between the delivery date and the time the pump is put into
operation. Equipment, which is not in service, should be kept in a clean, dry area. If
equipment is to be stored for long periods of time (six months or more), the following
precautions should be taken to ensure that the equipment remains in good condition.
2.1. Be sure that the bearings are fully lubricated.
2.2. Unpainted-machined surfaces, which are subject to corrosion, should be protected
by some corrosive resistant coating.
2.3. The shaft should be rotated 10 to 15 revolutions by hand periodically in order to
spread the lubricant over all the bearing surfaces. Suitable intervals are from one
to three months, depending on atmospheric conditions, etc. In order to ensure that
the pump shaft does not begin to sag, do not leave the shaft in the same position
each time.
2.4. Space heaters on motors and controllers should be connected and fully
operable if atmospheric conditions approach those experienced in operation.
Consult instruction manuals for other precautions concerning storage of individual
components of pumping unit.

2.5. Fresh lubricant must be applied to bearings upon removal of equipment form
storage.
3. SAFETY AND HEALTH PRECAUTIONS
All activities of Fire water pump installation work shall be followed the job safety analysis
(JSA). Prior to erection work, below are the following assessments/checks to be made:
3.1 Equipment to be used for lifting and hoisting are properly inspected and obtain
safety clearance.
3.2 Inspect all tools, which are used in the job site.
3.3 The scaffolding to be used shall be erected by experienced scaffolder and tagged
"Safe to Use" by Safety Officer and make sure that scaffold is made of sound
material and free from any defect.
3.4 New workforce must undergo safety induction before working to ensure that they
are aware of all the rules and regulations at the job site.
3.5 Tool box meeting shall be conducted every morning before starting the work and all
the activities on that day will be explained to all including safety work.
3.6 All personnel involved with the works shall use proper Personal Protective
Equipment.
3.7 Suitable fire extinguishers and fire blankets must be available at the working area.
3.8 Precautionary warning sign boards shall be displayed and working area to be
barricaded most specially during lifting works.
3.9 Only one competent signalman will be used during lifting work. Communication
between Crane operators – Signalman – Riggers shall have clearly understanding
with each other
3.10 Suitable PPE must be used inside the confined space
4 FIELD INSTALLATION
4.1 Codes and Standards

Fire Pumps field installation shall be performed in accordance with the
requirements of client’s specification and the following standard
(1) NFPA 20 Standard for the Installation of Stationary Pumps for Fire Protection.
4.2 Location
Several factors should be considered when selecting a location for the pumping
unit (pump, base, drive, and coupling). The unit should be accessible for both
inspection and maintenance. Headroom should be provided for the use of crane,
hoist or other necessary lifting devices. The pump should be located as close as
possible to the liquid supply so that the suction line is short and direct. Location
should require a minimum of elbows and fittings in the discharge line to minimize
friction losses. The unit should be protected against flooding.
4.3 Foundation
The foundation should be sufficiently substantial to absorb vibration and to form a
permanent rigid support for the base plate. Concrete is most widely used for
foundation. Before pouring the foundation, locate anchor bolts per outline drawing.
Allow for 3/4 inch to 1 1/2 inch of grout between foundation and base plate. The top
surface of the foundation should be roughened to provide a good bond for the
grout.
4.4 Mounting
Coupling halves should be disconnected when mounting the pumping unit on the
foundation. Wedges should be used to support the unit at the time of grouting
Wedges should be located adjacent to anchor bolts (one on each side of bolt) and
midway between bolts. Adjust the wedges to raise or lower the unit as required to
align suction and discharge flanges to piping and to level the base plate. Leveling
bolts made of cap screws and nuts are useful when leveling large base plate, but
should not replace shims or blocks for supporting the load.
4.5 Alignment
Two types of misalignments may exist: parallel misalignment and angular
misalignment. Limits of misalignments are stated in the coupling manufacturer's
instructions, but should be kept to a minimum for maximum life of equipment
components.
To check coupling alignment, the following procedure should be followed
- Set the coupling gap to the dimension shown on the outline drawing.
- Check for parallel misalignment by placing a straight edge across both coupling
halves at four points 90 apart. Correct alignment occurs when the straight edge is
level across the coupling halves at all points.
- Check angular misalignment with a feeler gauge at four points 90 apart Correct
alignment occurs when the same gauge just enters between the halves at all four
points.
Angular and parallel misalignment are corrected by shifting the motor and adding or
removing shims from under the motor feet. After each change, it is necessary to
recheck the alignment of the coupling halves.
Adjustment in one direction may disturb adjustment already made in another direction.
An alternative method for checking coupling alignment is by use of a dial gauge or
Laser alignment device. Proceed as follows:
Use of a dial gauge

- Scribe index lines on coupling halves or mark where the indicator point rests.
- Set indicator dial gauge to zero.
- Slowly turn both coupling halves so that the index lines match, or the indicator
point is always on the mark.
- Observe dial reading to determine whether adjustments are needed. --
Acceptable alignment occurs when total indicator reading does not exceed 0.05
mm. for both parallel and angular alignment.
Use of the laser alignment device

- Installation bracket set, Laser and Receiver set on shaft of driver and driven
Machine.
- Set and added dimension machine to computer with measure tape.
- Turn shaft for measurement mis-alignment value.
- Show the alignment value and show data for correction mis-alignment value.
Coupling
Alignment
Data for
correction
- Correction the mis-alignment in vertical direction with shim / and in horizontal

direction with adjusting bolts.
- Tighten all bolts of motor and measurement alignment value again.
The smile alignment should be show

when the alignment value was within
the tolerance alignment only
- Sample for alignment result and certificated


4.6 Alignment Criteria

The suggested alignment tolerances shown at right are general Values based upon
experience and should not be exceeded. They are to be used only if exiting in-house
standards or the manufacturer of the machine or coupling prescribes no other values.
To use the table, consider all values listed to be the maximum allowable deviation from the
alignment target, be it zero or some desired value to compensate for thermal growth, in
most cases, a quick glance at the table will tell whether coupling misalignment is allowable
or not.
As an example, a machine running at 1500 rpm has coupling offsets of -0.04 mm. vertically
and +0.02 mm. horizontally: both these values fall within the “excellent “limit of 0.06 mm.
An angularity is usually measured in terms of gap width at edge of the coupling. For a given
amount of angularity, the target the diameter, the wider the gap at the coupling edge, so the
table lists values for coupling diameters of 100 mm. You may compare results diameter into
entered then multiply the value from the table by the appropriate factor.
For example, a machine running at 1500 rpm has coupling of diameter75 mm. At this
diameter, the maximum allowable gap would be
(0.07 mm.) X 75/100 = 0.0525 mm. (Or 5/100)
For spacer shaft, the table gives the maximum allowable offset for each 100 mm. or inch of
spacer shaft length. To take an example, a machine running at 6000 rpm with a 300 mm.
Spacer shaft installed would allow a maximum offset of (0.03 mm.) x 300/100 = 0.09 mm.
(Or 9/100 mm.) At either coupling at the ends of the spacer shaft.
‘Acceptable ‘limits are calculated from sliding velocity of lubricated steel on steel, using a
conservative value of 12 mm/sec. (0.5 in/s) for allowable sliding velocity. These values also
coincide with those derived from elastomer shear rate, so they also apply to short couplings
with flexible elements. The ‘excellent ‘values draw on vibration observations made upon a
wide variety of industrial machines to determine the critical misalignment for vibration;
however, compliance with these tolerance values does not guarantee vibration-free
operation of a particular machine.
Since rigid (flanged) couplings have no tolerance for misalignment, they should be aligned
as accurately as possible.
SUGGESTED SHAFT ALIGNMENT TOLERANCES

The importance of correct alignment cannot be overemphasized. Alignment should

be checked and corrected as required after:
1. Mounting
2. Grouting has hardened
3. Foundation bolts are tightened
4. Piping is connected
5. Pump, driver, or base plate is moved for any reason.
The importance of correct alignment cannot be overemphasized. The following

procedure should be used for initial installation.
1. Place complete pump assembly on anchor bolts allowing room under the base
plate for leveling wedges or shims. Make sure the base plate is level by using
the leveling wedges adjacent to the foundation bolts and midway between the
bolts.
2. Put nuts on the anchor bolts and tighten evenly, but not too tight.
3. At this point check alignment of the coupling. This should not be more than that
recommended by the coupling manufacturer.
4. If misalignment is evident, determine which direction the coupling needs to be
moved.
5. Loosen all nuts and add the shims underneath the base plate at the opposite
corners. Use the anchor bolts to flex the base plate to bring the coupling into
alignment.
6. After the alignment has been made with all anchor bolt nuts tight, the grouting
can take place.
7. After grouting is completed, final alignment should be checked to be sure it is
within
allowable tolerances. Use of shims under the driver can be used to obtain final
alignment.
Alignment should be checked and corrected as required after:
- Mounting
- Foundation bolts are tightened
- Grouting has hardened
- Piping is connected
- Pump, driver, or base plate is moved for any reason
4.7 GROUTING
Grout compensates for unevenness in the foundation and distributes the weight of
the unit uniformly on the foundation. It also prevents lateral shifting of the base plate
and reduces vibration. Use a non- shrinking grout. Foundation bolts should be
tightened evenly, but not too firmly. Grout the unit as follows:
1. Build a strong form around the base plate to contain the grout.
2. Soak the foundation top thoroughly, and then remove surface water.
3. Pour grout. Tamp liberally while pouring in order to fill all cavities and prevent air pockets.
The space between the foundation and base plate should be completely filled with grout.
In order to prevent the base plate from shifting, fill under the base plate at least four
inches in from all four edges. Wedges may be left in place.
4. After the grout has hardened (usually about 48 hours), thoroughly tighten foundation
bolts and check alignment.
4.8 PIPING
Connect pipelines after the grout has thoroughly hardened. The suction and
discharge piping should be installed with the shortest and most direct runs. Elbows
should preferably be of the long radius type. Pipes must line up naturally. The piping
must never be pulled into position by the flange bolts. Such action may draw the pump
out of alignment. Pipes should be support independently of the pump so as not to put
any strain on the pump casing. Suction piping, if not properly installed, is a potential
source of faulty operation. Suction lines should be free of air leaks, and arranged so
there are no loops or high spots in which air can be trapped. Generally, the suction line
is larger than the pump suction nozzle, and eccentric reducers should be used.
Eccentric reducers are not necessary for bottom suction pumps. If the liquid supply is
located below the pump centerline, the reducer should be installed with the straight
side up.
Discharge piping should be installed with check valve and gate valve, with the
check valve being between the pump and the gate valve. The check valve prevents
reverse flow and protects the pump from excessive backpressure. The gate valve is
used to isolate the pump for maintenance, priming and starting. If a diffuser is used, it
should be placed between the pump and check valve.
4.9 Installation Equipment list
BOP Equipment
1. Fire water pump - Electric
2. Fire water pump - Diesel
3. Fire water pump – Jockey
Piping Equipment
1. Valve Support
2. Pipe Support
3. Automatic Air Release Valve
4. Main Relief Valve
5. Check valve
Electrical Equipment
1. Control Panel
4.10 INSTALLATION RECORD SHEET
- Location & Elevation Record Sheet


- Grouting Inspection Record Sheet

- Coupling Alignment Inspection Record Sheet

5. VENDORS INSTALLATION GUIDELINE






















































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Title : Page 1 of 74

Document No. : Effective Date : Revision :

Category Contents Page

Document No. : Effective Date : Revision :

1.1. Casing assembly or stationary part

2. STORAGE AND PROTECTION

Document No. : Effective Date : Revision :

components of pumping unit.

3. SAFETY AND HEALTH PRECAUTIONS

4.1 Codes and Standards

Document No. : Effective Date : Revision :

Document No. : Effective Date : Revision :

Use of a dial gauge

Use of the laser alignment device

Document No. : Effective Date : Revision :

- Set and added dimension machine to computer with measure tape.

- Turn shaft for measurement mis-alignment value.

Document No. : Effective Date : Revision :

- Correction the mis-alignment in vertical direction with shim / and in horizontal

- Tighten all bolts of motor and measurement alignment value again.

The smile alignment should be show

Document No. : Effective Date : Revision :

- Sample for alignment result and certificated

Document No. : Effective Date : Revision :

Document No. : Effective Date : Revision :

4.6 Alignment Criteria

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SUGGESTED SHAFT ALIGNMENT TOLERANCES

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The importance of correct alignment cannot be overemphasized. Alignment should

The importance of correct alignment cannot be overemphasized. The following

Alignment should be checked and corrected as required after:

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4.9 Installation Equipment list

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4.10 INSTALLATION RECORD SHEET

- Location & Elevation Record Sheet

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- Grouting Inspection Record Sheet

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- Coupling Alignment Inspection Record Sheet

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5. VENDORS INSTALLATION GUIDELINE

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