Chapter 4

Pump Installation
 Pump Installation
PROPER INSTALLATION OF A PIECE OF
ROTATING EQUIPMENT ADDS AS MUCH TO
THE LIFE OF THE EQUIPMENT AS PROPER
SELECTION.
Installation involves several aspects,
including;
piping configuration, NPSHa, pipe strain,
base plates, foundations, and alignment.
 PIPING CONFIGURATION
When designing the piping system for pumps, some
basic rules of thumb can be used to help extend the
life of the equipment. These basic rules evolve
around a couple of concepts:

• The pump does not create pressure. It overcomes

resistance.
• Resistance is caused by the resistance to flow of a
liquid in a piping system and existing pressures and
elevations in the system.
• The pump is a device that adds energy to the
medium being pumped.
• Flow is created by a difference in pressure.
 PIPING CONFIGURATION
• A pump creates a low pressure at its inlet to
allow liquid in the suction piping to flow into
the pump.
• The suction piping is necessary to provide a
means of getting the liquid to be pumped
from its source to the pump inlet or suction
nozzle of the pump.
 Suction Piping
Suction piping should be one or more pipe
sizes larger than the pump inlet
connection.

A pump with a pulsing flow may require

suction piping sized for three or more
times the average flow rate because of
acceleration and velocity characteristics.
 Suction Piping
• Keeps the suction piping as short as possible?
• Keeps the suction piping as straight as
possible?
• Keep a minimum of 5 to 10 pipe diameters of
straight run in the piping prior to the pump inlet.
• Avoid high points in the suction piping. Go
around objects instead of over them.
• Where possible, allow the piping to slope
upwards toward the pump suction to reduce air
pockets.
• Reducers used in the suction piping should be
eccentric with the flat side of the top.
 Suction Piping
• Strainers should be used to prevent foreign
objects from entering the pump. The strainer
should be sized based on minimum pressure
drop and not on line size.
• Valves in the suction line should be sized for
minimum pressure drop, and never used as
throttling valves.
• Always provide a gauge connection between
the suction valve and the pump connection.
The gauge connection should be located as
near to the pump suction connection as
possible.
 Suction Piping
• Insure that the suction piping connection to the
source reservoir is sufficiently submerged or
baffled to prevent vortices or drawing in air.
• Calculate the losses in the suction line to insure
you have sufficient NPSH available.
• Support the piping independently of the pump.
(A pump is a very expensive pipe support.)
• Use expansion loops or flexible connectors in
systems where thermal expansion of the piping
will occur.
 Discharge Piping
• The size and configuration of discharge
piping is primarily an economic issue.
• Keep in mind that the material and
installation cost of the piping system is a
one-time cost.
• Reducing the size of the discharge piping
to save cost at installation may increase
initial equipment cost by requiring a larger
or more expensive pump and monitor.
 Discharge Piping
there are some conditions that can cause
problems and should be considered in the
design of the discharge piping system:
• Avoid large air traps. This problem occurs
when the piping system is routed over large
objects, such as building, and then back
down.
• Avoid "dead heading" the pump. It will cause
increased radial loading of the impeller,
which can affect the life of the pump
bearings and mechanical seals/packing.
 NPSHa (Net Positive Suction
Head available )
NPSHa = Ps (+/-) H - F – V

Where:
Ps = The pressure on the surface of the liquid.
H = The distance from the pump centerline to the
surface of the liquid.
F = Total of the friction losses in the suction system.
V = Vapor pressure of the liquid at maximum
operating temperature.
 In troubleshooting the system, two questions are
:needed
Is this a new system?
Is this a system that has been around for a while,
and the problem with cavitations has just
started?
With a new system:
• Rework the NPSH calculation to verify that there
were no errors.
• Verify that the installation is as specified and
matches the data use for calculating the NPSH.
• Verify that the process conditions are as
specified.
 In troubleshooting the system, two questions are
:needed
If the above are OK,
then a new system can be looked at in the
same as an existing one.

The first thing to consider is, has anything

changed? If not, break the simplified
NPSH equation into parts and look at the
components of the equation with respect
to the system.
The place to start troubleshooting a cavitations
:problem is with a simplified equation for NPSHa
Pressure on the surface of the )Ps(
liquid
• If the liquid is in a closed tank, are the
vents properly installed and operating?
• If the supply vessel has an inert gas
blanket, is it working correctly?
• Can it keep up with the volume being
removed by the pump?
• Does it have a supply of inert gas?
 :Height of the liquid )H(

• Is the liquid at its normal level?

• If the tank level is controlled automatically,
are the controls working properly and
maintaining a sufficient level of liquid?
:Friction losses in the system )F(
• Are all valves from the liquid source to the pump
suction connection fully open?
• Is the suction strainer clean?
• If a startup strainer is use, is it clean?
• If the liquid must be heated to lower the viscosity, is
it at the proper temperature?
• If the line is heat traced and insulated, is the
insulation intact and the tracing working properly?
• If the liquid is prone to building up inside the piping,
has the piping been checked?
• Has the flow rate increased?
:Vapor pressure of the liquid )V(

• Has the liquid changed, or is a different

product being used?
• Is the liquid at is normal temperature?
• If heat tracing or cooling jackets are
being used, are they working properly?
 Pipe Strain
Pipe strain is the root cause of multitudes of
pump and bearing problems on new and
existing systems.
Bearing failure and vibration are some
common signs of piping strain.

The following discusses how piping should

line up with the pump and how to check for
pipe strain.
 Pipe Strain
All piping must be supported independently of,
and line up naturally with the pump flanges.

Before connection of piping to the pump

flanges, attach indicators to the equipment
shafts, zero indicators, and connect suction
piping and observe indicators.

If more than .002" movement is indicated,

adjust piping and or piping supports to
eliminate pipe strain.
 BASE PLATES
• The pump base plate is the structure on which
the pump, motor, and if needed, the gear
reducer are mounted.
• The base plate is the structural member that is
intended to rigidly support and maintain the shaft
alignment between the mounted equipment.
• The design of the base plate can significantly
influence the mean time between planned
maintenance and unplanned maintenance.
• The base plate design can also influence the
cost of installation, alignment, and overall life
cycle cost.
 BASE PLATES
The following items should be considered
when evaluating a base plate design:

• Tensional stiffness.
• Ease of shaft alignment.
• Provisions for grouting.
• Ability to support the mounted equipment.
 FOUNDATIONS
Designed and installed foundations can add
years to the life of rotating equipment.

The pump and foundation should be located

near the supply of liquid and have
adequate space for operation,
maintenance, and inspection.
 The following are some criteria to be used in
.designing or specifying the foundation

• Design the foundation so that its natural

frequency does not match the running
frequency of the mounted equipment or
adjacent equipment.
• Provide a means of "tuning" the structure
after installation in case the calculated
natural frequency does not match the
actual installed natural frequency.
 The following are some criteria to be used in
.designing or specifying the foundation
• Size the foundation to minimize vibration from
the mounted equipment. It is generally
recommended that the mass of the foundation
should be three times the mass of the mounted
equipment (pump, base, and driver) for rotary
pumps and five time the mass for reciprocating
pumps.
• The foundation should be designed to eliminate
or minimize shaft misalignment due to
equipment or externally induced forces. The
stiffness of a foundation varies with the cube of
its thickness.
 The following are some criteria to be used in
.designing or specifying the foundation
• Installation of the anchor bolts should allow for
thermal growth and stretch. This can be
accomplished by use of a sleeve. The proper
use of anchor bolt sleeves will allow sufficient
unrestrained bolt length to "stretch" without
fatigue. This will also permit minor adjustment in
location to align with mounting holes in the base
plate if needed.
• Select a contractor that has extensive
experience in installing rotating equipment and
foundations.
 SETTING THE BASE PLATE
AND PUMP UNIT
• Prepare the foundation for setting the pump base
plate and pump unit.
• Setting the base plate.
• Leveling base plate.
• Align the pump and drive equipment following the
pump manufacturer's recommendations.
• As part of the foundation after the base plate has
been properly set, the base plate should be grouted.
• After the grout has been allowed to cure, check
alignment to insure that it has not changed. If the
alignment has changed, realign unit.
 SETTING THE BASE PLATE
AND PUMP UNIT
• All piping must be supported independently of,
and line up naturally with the pump flanges
• After attachment of the piping, re-check
alignment and adjust if necessary.
• Prior to starting the unit, review the
manufacturer's installation, operation and
maintenance manual for proper start-up
procedures.
• Follow manufacturer's instructions for proper
startup of unit.