PUMP BASEPLATE INSTALLATION AND GROUTING by Perry C. Monroe, Jr. Senior Staff Engineer-Machinery Exxon Chemical C pany Baytown, Texas Perry C. Monroe, Jr, is presently a Senior Staff Engineer in the Polymers Technology Dieision of Exxon Chemical Company, located in Baytown, Texas, In this position, he procides technical sup- port to Maintenance and Process, and conducts training on turbomachinery re- lated. subjects. Prior to joining Exxon, Mr. Monroe spent 18 months in East Kalimantan, Indonesia (Borneo) ith Roy M. Huffington. Incorporated, at the PT. Badak LNG Plant, asthe Assistant Maintenance Manager ‘nd Logistics Manager. His duties included the startup superci- ‘in of sit 42000 hp steams turbine dricen compressor trains, Ax Logistics Manager, he was responsible for the actions of 78 peo- ple to furnish plantwide sereices for all foreign and domestic purchasing air and sea custom clearances, air and sea transpor- tation, and warchouse facilities. These sercices were for both plant and community needs, ‘Mee Monroe graduated from Auburn University in 1966, ith 4 BS.MLE. degree, and has worked for the past 2 years in ture Domachinery repair techniques, optical and mechanical align- ‘ment, cibration analysis and field balancing, non-destructice testing, mechanical seals, and corrosion. Prior to graduation, Ihe worked as a designer of racket engine components for NASA at Redstone Arsenal in Hantscille, Alabama, and.as-a draftsman ‘for TCI (USS) Stee! Works in Birmingham, Alabama, Mr. Monroe ts a member of the International Pun Sym posium Adcisory Committee. ABSTRACT Methods sed by the author to level and eposy’ grout pump baseplates, The methods used are not the only way paimps ean be installed, but iffollowed, will ensure a 100 percent void 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 a ‘one pout” grout procedure ‘The reasons for the use of eposy’ grout in place of cheaper ‘cementitions grout wil he covered along with special baseplate preparations. Pump baseplate installation and geouting tech hiques covered are applicable to any turbomachinery baseplate, bed ai, or skid installation INTRODUCTION “Why all the fuss over how a pimp baseplate is installed and routed?” The answer is to reduce maintenance costs. Experi tence has proven that pumps with poorly installed baseplates hhave more vibration and alignment problems which cause more frequent bearing, mechanical seal, and coupling failures ro Mechanical seals get the “bad rap" for pump failures, because they usually ate the rst indication of problem. A mechanical seal failure isnot the real problem, but the resultof «pump prob Tem. With this in mind, plans were put into action to start a the root of the problem and improve the pamp baseplate installa- tion-The pln inchided the observation of present instal practices, improvements to the installation methods, execution, of the new installation methods, and evaluation of the results. The improved methods of haseplate installation described here in yielded a reduction of pump vibration from 0.3 to0.4 inch per second (ips to helow 0.15 ips, Observations of pumps which had alled with the new methods indicated much longer nean time between failure” (MTBF) over existing, pumps. The test program started in mid 1982 with the use of epory gro, As a rsult of the test program, epoxy gout is being used almost cexdusively for pump baseplate grouting “The “one time” cost to install epoxy grout was paid for by the recuction of the sumer of repeated pump fulures which aver- axed $5,000 to $10,000 per repair. Cost of epoxy grout ran ap preaimately 875 to $80 per cubic fot as eompared to $30 per ‘eubicfoot lorcementtious grout. But remember, thiswasa”one time” cost compared toa repeated failure cost had epoxy krout not been used, pony xront bonds toa properly prepared baseplate, with a (OO psi tensile strength bond which transforms the baseplate >a monolith with the conerete foundation. This formation of asngle block reduces the natural frequency of the pump base pte, reducing pump shalt sibations, and prevents moisture or bilfrom dams bond when cementitions grout is used and there is of moisture or ol geting between the underside ofthe baseplate and foundation Pump baseplate installations are like marrkuge vows, “until death do us part.” Once a haseplate has been grouted, mainte hance personnel have to live with i until the unit is torn down. In most caves this would be for twenty or more years, so ithe hooves us to install the baseplate level and with mounting sur= faces coplannar Allthe time and effort spent specifying the right pump, mate- vials, mechanical seals, and baseplate can be ruined by poor n= stalltion practices. Generals, the least trained person, in terms, ‘of pumps, as free reign on how basephates are set, leveled and sited. ithecomes an even bigger problem when epoxy grout, ts ased, because installation techniques are different from the :mcre commonly known cementitious grout. Over the past three years a four hous training class on epoxy grouting has been con- ‘usted forall personnel iavolved with pump installations. This, included both company anxl contract personnel from the labor ersto the engineers, The results have justified the expense and, effort of taining, because in all eases, inexperienced grouting, personnel have correctly installed and grouted pump baseplates, voll free. It is now the practice for machinists or millwrights to place the grout and have complete responsiblity for pump in- Salltions, alignments, and commissionings, This practice has fostered ownership and pride in a job well done.us PROCEEDINGS OF THE FIFTH INTERNATIONAL PUM BASEPLATE LEVELING PROCEDURE tis necessary to discuss the baseplate leveling pricedure first in order to fully understand certain baseplate and founda- tion preparations, These preparations must he performed before the placement ofthe baseplate on the foundation “The following assumptions are made conceming the pump foundation: * The foundation has been adequately designed to support the pump. Foundation mass for centrifugal pumps should be at Teast 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 sold or stabilized eaeth com pletely independent of other foundations, pads, walls, or operat Ing platforms, A minimum of 3,000 psi steel reinforced co should be used. * The foundation has been designed to avoid resonant vibra nating from normal excitation forces at ultiples ofthe operating speed tion conditions o ‘operating speed or * The pump, gearbox (fused), and driver rest on a common foundation, * The foundation is designed for uniform t duce distortion and misalignment Do not take these assumptions for granted. Check the founda tion atthe design stage, not alter it has heen poured. There are some good computer programsavailabe fr fotmdation desis. “The preferred method of leveling a pump baseplate i lls trated in Figure 1. Jack serews located on both sides of each chor bolt are used to elevate the baseplate while the anchor bolt lightly holds the be necessary to use both jack serews if peratures tore ‘baseplate is at, but both are required if trying to bend the baseplate machined sur- faces lat. Notice that circular plates cut from 2.0 in to 2.5 in diameter steel bar stock, approximately 0.5 thick, are used to prevent the points of the jack serews from digging into the eo ‘rete and altering the level. Use just enough tightening foree on the jack serews and anchor bolts tohold the baseplate in position until the grout has heen poured and cued en Co St vf Bee mae Figure 1. Jack Screws Located on Both Sides of Each Anchor Bolt Are Used to Level and Support the Baseplate Until the Grout Is Poured. Prior to the baseplate placement on the foundation, the con- cexete must he chipped to remove the cement rich concrete (called laitance) and expose the aggrexate. This provides a USERS SYMPOSIUM stronger concrete/epony grout bond, because the strength of the concrete depends on the aggregate. The chipped surlace must be blown clean with ol free air and kept dry. Moisture and oll are the big enemies of good epoxy groutieonerete bonding Field experience has indicated that 2.0 in to 3.0 in of epoxy rout are required under the pump baseplate flanges to reach the desired compressive strength. Thinner pours do not gener ate enough exothermic reaction heat to fll cute the epory. Be= fore leveling, the baseplate should be high enough for the 2.0, into 3.0 in grout thickness. “The use of jack screws for leveling is much faster than the ‘more common method of using squate steel plates and shims. Jack serews also eliminate the problem of removing the leveling shims after grout placement. The baseplate should be totally Supported by the epoxy grout and not point supported at the leveling shims. Sharp comered shims should not be left in epoxy rout, because they form stress concentrations and cause erack- ing, Once the epoxy grout has cured, the jack screws are re= Toles are filled with epoxy or sealant. The jack sased prior to installation to allow for their removal Baseplate leveling begins with the pump and driver removed ater checking the pump suction and discharge Manges for proper location and élevation, Piping should not be attached to the pump until the baseplate has been leveled, erouted and the driver/pump aligned. The use ofa Starrett 95 Machinists Level > aS r zs ce Figure 2. A Starrett 98 Machinist Lecel Placed on the Driver Mounting Surface Was Used to Level inthe Axial Direction = Figure 3. After Leceling Axially, Rotate the Machinist Level 90 Dearees and Adjust the LevelPUMP BASEPLATE INSTALLATION AND GROUTING 9 Figure 4. The Pump Mounting Surfaces are Leceled Using the Same Procedure as the Driver Mounting Surfaces mounted on the machined surfaces forthe driver is illustrated in Figures 2 and 3.The jack serews and anchor boltsare adjusted until a level of 0,0005 inv is obtained in 0 directions 90 de sees apart. The machined surfaces for the pump receive the Same treatment (Figure 4) with a maximum elevation variation across the length of the baseplate of 0,010. A precision straight edge should be used across the mounting surfaces to check for Figure 5. -E Model 71-3015 Optical Level Being Set Up and Adjusted Prior to Leveling a Baseplate Figure 6. In Hot Weather, Shacle the Baseplate for 24 Hours be- {fore and 45 Hours after Pouring the Grout coplannarity. The mounting surfaces should be coplannar within 0.003 in, F the baseplate is long (over 15 8), an optical level similar to the K&CE Model 71-3015 might be used to speed up the leveling ‘operation (Figure 5). ‘Dace the baseplate is leveled, grouting operations ean begin If zrouting is to be done during hot weather (above 90°F), it should be started early in the morning while the baseplate is Tevel. Check level after the baseplate temperature has stabilized ‘overnight, and shield the baseplate from direct sunlight (Figure 6). BASEPLATE PREPARATION Now that the baseplate leveling procedure has been dis- cessed, listed below are some baseplate requirements that should be included in the pump specifications/purchase order » ll welding on the baseplate shall he completed and stress relieved prior to machining pamp and driver mounting sur- fies + Allmachined! mounting surfaces shall be coplanar to 0.002 in, Allbaseplate welds shall be continuous (no skip welding) and fice of eracks + Underside of baseplate shall be sandblasted to white metal ul evated with 0.003 in wet thickness of eposy coating as specified by purchaser + Allcross bracing on underside of baseplate shall have 2.0 in 6.0 in minimum opening to allow for grout Mow + Drill 0.3 in diameter vent holes on 24.0 in centers around periphery of baseplate at the highest point + Radius all sharp comers of baseplate flanges, Minimum 1.0 inradivs + Provide Lin mininn for alignment + Provide eight alignment positioning serews for driver + Machined mounting surfaces shall extend 0.1 in beyond pump and driver feet om all sides + Drilland lap two holes on the baseplate flanges, one on each side of the anchor bolt holes, for one-half inch diameter jack/ leveling serews. Ifthe mounting surfices are machined to 0,002 in coplannae afer the welding has heen completed, the same tolerance ean be repeated in the field. This helps to eliminate “soft feet” and tospeed up alignment, The common practice of machining steel phite mounting surfaces and welding them to the baseplate femses skewed surfices that eannot be leveled in the Feld A void free grout jl is ensured by providing vent holes at the beseplate periphery and in each compartment, Some pump pu chasers never look under the basepkite to see how eross brac Intkes a good grout job impossible, On oceasions, the author has torched openings through braces, to provide a path for grout “The request fora 1.0 in wider mounting surface on each side ofthe equipment feet ean be a life saver, if baseplate leveling is required with pump and driver mounted. The additional cost of afew more inches of steel plate is peanuts, compared to the lex- ‘bility of baseplate leveling with mounted equipment in emergency conditions. A machinist’ evel ean be placed on the acditional margin around the pump and driver, allowing the breseplate to beleveled, This snot the preferred method oflevel- ing, but it will work. im adjustment under driver feet NEW CONCRETE PREPARATION Freshly poured concrete must be allowed to cure before ‘epony grout is applied. As mentioned earlier, moisture will ruin the epoxy srout/conerete bond, even the small amount of mois