Installation

Seismic Analysis

When pumps are located in seismically active areas and for certain critical installations the pumps, supports and accessories should be earthquake-resistant. The design specifications to achieve earthquake resistance vary, depending upon geographical area, class of the equipment (defining how critical the survival of the equipment is) and the characteristics (acceleration response) of the structure or foundation supporting the pump.

Complete specifications for earthquake-resistance requirements should be supplied by the customer. This includes the following:

• The seismic criteria, such as acceleration, magnitudes, frequency spectrum, location and direction relative to pump
• The qualification procedure required, i.e., analysis, testing or a combination of these, and requirements for operability during and/or after test.

Leveling

1. Remove the supporting timbers, rope and any other equipment from the top of the foundation.
2. Disconnect the coupling halves between the pump and driver.
3. Lower the pump unit until the base plate is just above the foundation bolts.
4. Orient the pump so that the discharge outlet and suction inlet is in the desired direction and the holes in the base align with the foundation bolts.
5. Continue to lower the pump until the bolts just enter the holes in the base.
6. If the foundation is concrete, place the wedges under the base plate, adjacent to the bolt holes, one under each of the four sides.
7. For structural foundations (made up of I-beams or H-beams), use shims under the corners.
8. Continue to slowly lower the pump until the base of the base plate rests on the wedges or anchor bolts with washers and nuts.
9. By using the wedges or washers and nuts on the anchor bolts, adjust the pump suction flange center line to the correct elevation.
10. While maintaining the correct elevation, adjust the nuts and washers or shims to achieve the specified levelness of 0.005" per ft. [0.4 mm per m] in both directions. The levelness should be measured by placing a precision level on the machined face of the discharge flange.
11. Place a machinist's level on the discharge flange, orienting it parallel with one of the edges of the base.
12. Move the wedges or add more shims until the level reading reaches 0.005" per ft. [0.4 mm per m].
13. Reorient the level on the same surface, 90 ° from the original position.
14. Again adjust the wedges or shims until a 0.005" [0.12 mm] level reading is reached, taking care not to upset the levelness is the first direction.
15. After each adjustment, check for levelness in both directions.
16. Push in or add to any loose shims to distribute the weight evenly.
17. Fit nuts on the foundation bolts and tighten them gradually and uniformly.
18. Check the level readings in both directions.
19. If necessary, loosen the foundation bolts and readjust the wedges or shims, tighten the bolts again and check the level readings.

Grouting

After the base plate is at the correct location and leveled with a precision level, the base plate needs to be grouted to the foundation.

Grout compensates for unevenness in the foundation and base plate and minimizes vibrations levels during operations. It prevents the unit from shifting after mounting and alignment.

Only non-shrinking grouting material should be used for grouting the base plate to the foundation. Foundation bolts should not be fully tightened until the grout is hardened, usually about 48 hours after pouring.

1. Prepare the foundation surface according to the grout manufacturer's recommendations.

2. Locate the foundation bolts by the use of a template frame and provide anchorage. See the outline drawings furnished with each pump for the exact location of the foundation bolts.

3. Build a dam on the foundation, enclosing an area around the base plate that includes all alignment wedges. Allow for a grout thickness of 0.75 to 1.50" thickness [19.05 mm to 38.1 mm].  

4. Pour the grout through the holes provided in the base plate or through open ends of steel channel base plates. While pouring, tamp liberally in order to fill all cavities and prevent air pockets. If tamping does not eliminate all air pockets, drill small vent holes through the base surface.

5. Level off the grout flush with the top of the dam.

6. Allow the grout to cure at least 48 hours before tightening the foundation bolts or starting the pump.

Tighten pipe connections to suction and discharge flanges.

Check the pump alignment.

When the grout has thoroughly dried, paint the exposed edges to prevent air and moisture from coming in contact with the grout.

Inspection

All pump parts were carefully inspected before leaving the factory, but may have become soiled or damaged in shipping and handling or storage at site. The installer must therefore check that all parts are clean and undamaged before installing them.

Use appropriate solvent to wash off any protective coating from the shaft sections and wipe thoroughly clean and dry.

Dirt, sand, etc. in the system will cause premature wear on the critical pump internal surfaces, resulting in reduced pump performance.

Pumps and drivers mounted on a common base plate were accurately aligned before shipment. All base plates are flexible to some extent and, therefore, must not be relied upon to maintain the factory alignment.

Realignment is necessary after the complete unit has been leveled on the foundation and again after the grout has set and foundation bolts have been tightened. The alignment must be checked after the unit is piped and rechecked periodically as outlined in the following paragraphs. To facilitate accurate field alignment, we do not dowel the pumps or drivers on the base plates before shipment.

Engine Preparation

Safe and efficient operation of a pumping unit driven by an diesel engine, requires the installation to satisfy the following requirements:

1. It is recommended that the operator become familiar with the installation and service manual supplied by the engine manufacturer or Peerless Pump
2. Be well ventilated in order to keep the ambient temperature as low as possible. Taking 60 °F [15.6 °C] as a datum point, every 10 °F [-12 °C] rise in temperature reduces the horsepower of the engine by approximately 1 %.
3. Provide ample air for proper combustion.
4. Provide the engine with an efficient exhaust system so that the combustion gasses discharge with a minimum of backpressure.
5. Provide for a fuel system of adequate capacity that meets the local codes.
6. Provide ample accessibility to service engine.
7. Provide correct rotation of the pump. Engine rotation is determined at the factory. No change of engine rotation can be made in the field. 

Leveling

Flat surfaces that might capture air during grouting should be vented to prevent voids between the surface and the grout. The base plate should be leveled by use of wedges or by use of leveling screws supported on rectangular metal blocks.

The leveling screw threads should be covered with a non-binding material such as grease, putty or tape before grouting, to facilitate their removal.

If shims are used, they should be placed to isolate from the initial application of grout. After the initial grout has cured, the forms and shims may be removed and the void filled with a second application of grout.

A gap of about 0.75 to 1.5" [19.05 mm to 38.1 mm] should be allowed between the base plate and the foundation for grouting. 

Grouting

The grout material that supports the base plate is a critical element of the pump support structure and should be carefully selected. The product warranty is void if this Instruction is not followed.

If the grout cracks or fails, the structure will be compromised. When the alignment is correct, the foundation bolts should be tightened evenly but not too firmly. The unit can then be grouted to the foundation. It is not recommended to grout leveling pieces, shims or wedges in place because they introduce discontinuities and stress concentrations that may cause the grout to crack. Foundation bolts should not be fully tightened until the grout is hardened, usually about 48 to 72 hours after pouring. Jacking screws should be removed after the grout has hardened and the holes filled with an appropriate sealing material.

Doweling

Contact Peerless Pump for more information.

Pipe Supports, Anchors or Joints

Suction and discharge piping should be anchored, supported and restrained near the pump to avoid application of forces and moments to the pump in excess of those permitted by Peerless Pump.

In order to achieve optimum operation and minimum noise and vibration, consider vibration dampening of the pump.

Noise and vibration are generated by the revolutions of the motor and pump and by the flow in pipes and fittings. The effect on the environment is subjective and depends on correct installation and the state of the remaining system.

Elimination of noise and vibrations is best achieved by means of a concrete foundation, vibration dampers and expansion joints.

The pump should also be inspected internally for foreign matter that may have entered the pump. 

Vibration Dampers

To prevent the transmission of vibrations to buildings, isolate the pump foundation from building parts by means of vibration dampers.

The selection of the right vibration damper requires the following data:

• Forces transmitted through the damper
• Motor speed considering speed control, if any
• Required dampening in %.

The selection of vibration damper differs from installation to installation. In certain cases, a wrong damper may increase the vibration level. Vibration dampers should therefore be sized by the supplier of the vibration dampers.

If you install the pump on a foundation with vibration dampers, always fit expansion joints on the pump flanges. This is important to prevent the pump from "hanging" in the flanges. 

Suction Piping

The suction and discharge piping should be of sufficient size and be internally free of foreign material.

Considerations for suction piping to achieve optimal performance are:

1. When operating under suction lift, line must be kept absolutely free from air leaks.
2. When operating under suction lift, must be at least one pipe diameter larger than the pump suction nozzle. In order to prevent eddies and vortices, the end of the suction pipe must be at least two pipe diameters below the free liquid surface. If a foot valve is used to facilitate priming, the foot valve must have a minimum flow area 1.5 times the area of the suction pipe. The suction at all points and should not contain loops or high spots in which air can be trapped.
3. When operating under suction pressure, pipe may be equal to, but never less than the suction nozzle size.

Failure of the suction piping to deliver the liquid to the pump in this condition can lead to noisy operation, swirling of liquid around the suspended pump assembly, premature bearing failure and cavitation damage to the impeller and inlet portions of the casing.

Contact Peerless Pump for further information. 

Suction Valves & Manifolds

Block valves may be installed to isolate the pump for maintenance.

Foot valves are specially designed non-return valves sometimes used at the inlet to prevent backspin caused by rapidly draining water in the discharge pipe. 

Discharge Valves

A non-return valve and an isolation valve should be installed in the discharge pipe. The non-return valve serves to protect the pump from backflow and excessive backpressure. The isolation valve is used when starting and stopping the pump.

We recommend closing the isolation valve before stopping or starting the pump.

Pump backspin and hydraulic shock can cause severe damage to pump and motor. Install at least one non-return valve in the discharge pipe, not more than 25 ft. [7.5 m] after the discharge flange to help prevent this.

Operating some pumps at shutoff may cause a dangerous increase in pressure or power. If increasers are used on the discharge side of the pump to increase the size of piping, they should be placed between the non-return valve and the pump.

If expansion joints are used, they should be placed between the pipe anchor and the non-return valve. 

Nozzle Loads

The piping should be aligned with the pump nozzles to minimize pump nozzle loads. Contact Peerless Pump for allowable nozzle loading for your given design. 

Setting the Impeller Clearance

To achieve optimal performance and reduce radial loading, the impeller should be centered in the volute passageway of the casing. For new pumps, this is done at the factory.

Auxiliary (Driver, Coupling, etc.)

Engine Drivers

Engine driven unit are typically supplied with pump and drive on a common base plate. For units that are supplied separate, contact Peerless Pump.

1. Check the axial misalignment between pump and engine.
2. Check parallel alignment.
3. Check the angle between the pump shaft and driver when coupled has a Maximum angle of 3 degrees. Consult manufacturer.
4. At least 3/4 of the key is engaged with the coupler and the shaft.
5. Installation of universal drive see manufacturer's instructions.

Stopping the Unit/ Reverse Runaway Speed

A sudden power and/or discharge valve failure during pump operation against a static head will result in a flow reversal, and the pump will operate as a hydraulic turbine in a direction opposite to that of normal pump operation.

If the driver offers little resistance while running backwards, the rotational speed may approach the pump-specific speed.

This condition is called runaway speed and causes mechanical problems. Contact Peerless Pump for aid in preventing this condition.