Installation methods and requirements for pump sets

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Installation methods and requirements for pump sets: 1. When the product itself has specific technical requirements regarding its installation, the installation shall be carried out in accordance with the specifications outlined in the product’s technical documents； 2. The pump set can be installed with shims or without them, depending on the conditions of the equipment ； 3. The axis of the pump shaft should be horizontal, and its elevation must meet the design requirements ； 4. The radial displacement between the axis of the pump and the axis of the motor must meet the specified standards ； 5. The sealing parts of the pump must be tight, with no leakage allowed ； 6. The pump must be firmly connected to the base, and the base must be firmly connected to the foundation; there should be no looseness ； 7. When installing the pump body, its orientation in the longitudinal, transverse, and horizontal directions must meet the specified requirements ； 8. The clearance between the impeller and the pump casing must comply with the specifications outlined in the equipment’s technical documents. There should be no sticking or abnormal noises ； 9. Before installing the machine base, place the shims as required. The foundation surface at the location where the shims are placed (within about 50 mm around it) should be leveled, with an allowable deviation in levelness of 2 mm/m. The shims should make even contact with the foundation, and the contact area should be no less than 50%. The allowable deviation for the levelness of flat shims is 2 mm/m. The surface of the shims should be smooth, free of oxide scale, burrs, etc ； 10. When lifting the pump body, attach the lifting slings according to the lifting point markings specified by the manufacturer. After the pump base is in place, perform initial leveling and insert the foot bolts. The bare portion of the anchor bolt should be free of oil and oxide scale; a small amount of grease should be applied to the threads. The anchor bolt must be vertical and not tilted, and it should not touch the bottom of the hole. The distance between any part of the bolt and the wall of the hole must be at least 15 mm. Once the requirements are met, grout the reserved holes within 24 hours. Before grouting, it is necessary to ensure that all debris such as gravel and soil, as well as standing water, in the bolt holes are completely removed. The grouting material should be one grade higher than that of the pump set foundation; H40 grouting material shall be used uniformly, and the grouting process must be carried out continuously. When compacting the concrete in the reserved holes, do not allow the anchor bolts to become skewed or cause the machine to shift. The anchor bolts can be tightened only after the strength of the grouted concrete in the bolt holes reaches 75% or more ； 11. After the completion of the initial grouting curing period, level and align the equipment; place one set of shims on each side near the foot bolts, with no more than four layers per set, and the height of the shim sets is generally 30–70 mm. The elevation of the top surface of each shim set should match the actual installation elevation of the machine’s floor. If the distance between shims exceeds 500 mm, additional shims must be added. After the machine is leveled, the shims should protrude 10–30 mm from the base. For the shims on either side of the foundation bolts, the length of each shim that extends into the ground beneath the machine base should exceed that of the foundation bolt itself, in order to ensure even distribution of forces on the machine base. If the contact width between the bottom surface of the machine base and the shims is insufficient, the shims should be placed in such a way that the base sits in the center of the bearing surface provided by the shims. The overlap length of the paired shims should be no less than 3/4 of their total length, and the skew angle between them should be no more than 3°. After the machine is leveled and aligned using shims, check the tightness of the shim set by tapping it with a 0.25 or 0.5 kg hammer; there should be no looseness. Use a 0.05 mm feeler gauge to check the gaps between the shims as well as between the shims and the base; the total length that can be inserted from both sides at the same cross-section of a shim shall not exceed 1/3 of the shim’s length (width). After passing the inspection, perform inter-layer spot welding on both sides of the shim set using electric welding to secure it ； 12. During the machine leveling process, the selection of the installation reference and the allowable deviation in levelness must comply with the relevant provisions of the \"special specifications\" or the machine’s technical documents. The allowable deviation for general lateral levelness is 0.10 mm/m, while the allowable deviation for longitudinal levelness at the installation reference point is 0.05 mm/m. Leveling shall not be adjusted by using adjustable foot bolts (the three-point leveling method is generally used for leveling). 13. The standard measurement points for installation should be selected from the following locations: a. For pumps installed as a whole, the inlet and outlet flanges or other horizontal reference surfaces should be used as the basis ； b. For pumps that are disassembled for installation, use the machined surface of the pump body as a reference ； c. Vertical pumps, referenced to the coupling or motor base ； d. Reciprocating pump, using the machine frame slideway, bearing housing, exposed shaft parts, or other machined surfaces as references ； Allowable installation tolerances for centrifugal pumps used in the chemical industry (mm)
Item No. | Item | Allowable Tolerance | Inspection Method
1 | Centerline position | 5 | Checked with a steel ruler
2 | Elevation | ±5
3 | Levelness of the pump – vertical and horizontal directions | 0.05/1000 | Checked with a level
Overall installation: Vertical direction – 0.05/1000; Horizontal direction – 0.10/1000
14. Tighten the foot bolts symmetrically and evenly, leaving 1.5–3 threads exposed. At the same time, check the horizontality of the pump in both vertical and horizontal directions; it should not change. If there is any change, adjustments need to be made ； 15. After leveling and alignment of the pump base, perform secondary grouting using H40 grouting material ； a. Before the second grouting, debris and oil stains on the foundation surface should be removed, and the foundation should be moistened ； The base surface should be roughened, with the depth of the roughness generally being no less than 10 mm. The density should be 3 to 5 points per square decimeter ； b. Secondary grouting should be carried out within 24 hours after the concealed works have passed inspection and after the machine has been leveled and aligned; otherwise, re-measurement of the leveling and alignment data must be performed prior to grouting ； c. Before the second grouting, tighten the foot bolts to the required torque. This tightening should be carried out once the concrete in the pre-drilled holes has reached 75% or more of its design strength, and the tightening force must be even ； d. Grouting must be carried out continuously, and the grouting layer must be compacted to fill the bottom of the base. The height of the secondary grouting layer is generally 30–70 mm ； e. The distance between the formwork used for secondary grouting and the outer edge of the equipment should be no less than 60 mm. After the formwork is removed, finishing work must be carried out; the outer surface of the secondary grouting finish layer should be smooth, with a slight outward slope on the upper surface, and its height should be slightly lower than that of the upper surface of the equipment’s support structure ； 16. The alignment of the wheels shall be carried out in accordance with the requirements for rotor shaft alignment specified in Section 5.7 of the SH/T3538-2005 standard.