The grout allows a little play in the as-cast foundation height as gives you space for leveling. (0.17mm/m). Learn the basics of wear components and their role in system operation in this white paper. All feet are to be leveled within 0.002 Inch (0.05mm). Consider using flow conditioning technology as an alternative. (if specified) for all horizontal pump baseplates. Grout can also be pumped from the centre of the bearing plate where it spreads to the outside equally on all sides. Also, put a piece of metal under the jack screw to prevent digging into the concrete because this makes the leveling procedure very tedious. Coat forms with something that will not adhere to the grout. JavaScript is disabled for your browser. using vertical and horizontal jack bolts. This tip reminds me of my submarine days when the specific instructions were to shut the hatch and then dive the boat. © Copyright Cahaba Media Group, Inc. All Rights Reserved. Use a protective sleeve/tube with some clearance to allow for tolerances and ease of handling. Managing Pump Station Assets for Lowest TCO & Maximum Effectiveness, Pumping Systems: Essential Now & in the New Year, Centrifugal Pumps: The Condition Monitoring Comparison Guide, Water@Work: Emerging Technology & The 2020 Impact, Replacing Metallic Wear Components with Composites in Centrifugal Pumps, In-depth articles on pump industry issues, Expert insights into important topics in the field. Prudence suggests you have 10 percent more grout than the form volume—and I guarantee there will used for the leveling pads to be utilized under the pump baseplate leveling jackscrews. The end user should specify these when purchasing. Before removing the equipment, make sure it can be aligned and the base is flat and coplanar. A proper baseplate installation will maintain that crucial alignment—and pay off for decades with reduced maintenance costs. To read other articles in the 'Common Pumping Mistakes' column, go here. By sloping out from the base plate you can get a little more bearing area on your pier. Before considering the most prevalent pump base plate installation options, we need to know more about how pump sets are typically shipped to the purchaser or installation site. A cast iron, Process Industry Practices (PIP) or structural steel base also has been purchased. Base Plate Grouting. How to eliminate wet well maintenance & premature wear of pumps. The methods used are not the only way pumps can be installed, but if followed, will ensure a 100 percent void free grout job. This method statement describes the step by step procedure for grouting of machine bases and base ... entire void under the base plate has been filled. Wan-Huan Zhou, in Ground Improvement Case Histories, 2015. The methods used are not the only way pumps can be installed, but if followed, will ensure a 100 percent void free grout job. The plate is held down by bolts an- chored in the concrete. Manufacturers often encourage their customers to have a foundation with a mass three to five times the mass of the pump, driver and baseplate combined—even more if the pump is a positive displacement design, especially reciprocating pumps. Most designs require the installation of anchor bolts in the foundation that will run up and through penetrations on the baseplate. Installation Procedures - Epoxy Grout 03 63 00 epoxy GroutinG 3-433 Construction expansion Joints 1. Only a fraction of the API pump baseplates were distorted but nearly all the ASME bases were. Hydraulic Institute on examining altitude, temperature and more when selecting a wastewater pump. Continue to inject grout using the new location. Is it Worth It?” TAMU Paper 2004 Pump Symposium, Roger L. Jones, Charles A. Lickteig, Jean J. Zoppe, “The Road to Reliable Pumps,” TAMU Paper 2007 Pump Symposium, Todd R. Monroe, “Pump Users Handbook, Life Extension,” Heinz P. Block & Allan R. Budris. Additionally, recommendations and specifications focus on ensuring that the baseplate is properly grouted (grouting bonds the base to the foundation). On the other hand, pre-filled or pre-grouted baseplates arrive at site already flat and aligned. When I started in the business, we would use sets of wood or metal shims to level the base prior to grouting, leaving the shims in place. It is acceptable to pump the grout in place with different and specific appliances for that purpose. He is the general manager for Summit Pump Inc. and the principal of MaDDog Pump Consultants LLC. Slowly add powder to a pre-measured amount of water, ensure Learn how early adopters are benefitting from emerging technology as well as the impact COVID-19 has had on water management. Jim Elsey is a mechanical engineer who has focused on rotating equipment design and applications for the military and several large original equipment manufacturers for 43 years in most industrial markets around the world. Curing time for grout, especially epoxy grout, depends on the ambient temperature. A range of materials suitable for pumping or traditional methods of placement for the void-free grouting of gaps of just 0.1mm to 140mm and above. Be aware that during the curing process, the grout can actually pull the base out of level as it shrinks. Some features of this site may not work without it. It may be necessary to remove the protective paint supplied by the manufacturer. Page 1 www.neoflux.inof 3 Pumpletter November 19, 2011 Centrifugal Pump Grouting: SUBJECT: Attaching the pump and motor base plate to the foundation. Detailed and timely information enables performance to reach new levels. Base Plate Tightening after Base Level on Pads Achieved. They also serve as a "tell tale" to let you know that. For epoxy grouts, mix the liquid first (resin and catalyst) and then add the aggregate to the liquid mix—not the other way around. Check with the manufacturer, but in most cases 4 mils (dry) is the proper amount. Typically it is best to pour from one side to let the air escape from the other. Design procedure of Grout At the time of designing, proper consideration should be given on the strength and thickness of the grout. In the case of a new foundation, this depends on ambient conditions and on the concrete mix that was used (a five-bag mix can take as long as 28 days while a seven-bag mix may cure in a week). A common tip is to fill the sleeves with dry sand to prevent the grout from entering that area. Once the jack screws are removed, fill the resultant voids with grout or liquid epoxy. Never use a vibratory device unless specifically directed by the grout manufacturer. I acquiesce that the smaller the pump and consequential horsepower, the need for the expensive installation (foundation, baseplate and grouting) is diminished. The specific sequence is paramount. All mounting studs shall be Type 316 stainless steel. You will not have enough grout if you simply allow for the volume of the form. Turbomachinery Laboratories, Department of Mechanical Engineering, Texas A&M University. As an example, a 100-hp pump/driver set is purchased and the next step is installation. Test for moisture by using duct tape to secure a 2- or 3-foot-square piece of plastic over the foundation overnight. Cut keys to one-half the keyway length. 2. They will have prepared the surface solely to prevent corrosion in the transit and storage stages. In Hong Kong, soil nails are generally grouted under gravity. Prior to the grouting process, decide whether to use the two-pour or one-pour method. If using shims, be sure to apply a coating (such as light grease) of some sort to ease removal. Without the plate to provide initial grout distribution across the entire shaft base, staged grouting of ... measurements of grout pressure at the pump, and strain gages at the shaft base (1 in = 25 mm, and 1 kip = 4.4 kN). Consider these questions: When was the last time you turned the baseplate over and prepared the surface to be grouted? Heinz P. Bloch, in Petrochemical Machinery Insights, 2017. The following blog outlines the importance of grouting base plates, how to go about the grouting process, and common issues that may arise during the process. Doing more with less is a necessity going forward while navigating business during a pandemic. Utilizing a pregrouted baseplate with conventional grouting methods helps to minimize some of the cost, but the last pour still requires a full grout crew, skilled carpentry work, and good logistics. Access holes for grouting should be provided in the skid floor plate by the OEM or packager. Many jobs lost will shift toward renewable energy. On exterior base plates the grout keeps water from sitting in the plate/pier joint. Chances are the pump is lower horsepower, and the service is ambient temperature and at low-duty hours. Pump baseplate installation and grouting techniques covered are applicable to any turbomachinery baseplate, bed rail, or skid installation. Field machining of the base after completing the critical grouting process is difficult and expensive. The grouting helps to reduce the vibration, deflection and noise of the whole pumping unit. The wooden grout form now requires a top plate that forms a liquid tight seal against the bottom flange of the base plate. the pump mounted on the base, but not centered on the base hold ... sequence of events for the first part of the process—foundation, leveling, grouting. Grout manufacturers will advise the proper surface preparations and paint for their grout. Try to avoid pushing or rodding the grout into place because it creates air entrainment and voids. Once the alignment target is achieved, there will be a gap between the underside of the component foot and the Mounting Plate/Base Plate or Chock Plate surface. be spillage. The reasons for the use of epoxy grout in place of cheaper cementitious grout will be covered along with special baseplate preparations. We consider that A good foundation has been designed and it is time to grout the base to the foundation. “Grouting of Small Pump Baseplates? Continue to check for level during the curing process. Instead, use a small, light-duty pneumatic hammer with a sharp point tip, sometimes referred to as “bush hammering.”. Did you remove the pump and driver? You can sandblast the underside and then install the base immediately before corrosion occurs (less than eight hours in an ideal ambient). Never let rain fall on equipment during this process. Their structural integrity is also better since no grout holes are necessary. I would argue that it is rare to accomplish both on the same job. Some common goals clients report to me include having a pump that operates reliably for a long time combined with an inexpensive installation. A common practice is to use two to three layers of paste wax. Mounting holes for anchor bolts in the bases shall be drilled and not burned out and they shall not be open slots. Another approach is applying the proper epoxy paint to the underside as a surface to which the grout can bond. 3. Do not use oil because it can react with the grout substrate. I have added (drilled) plenty of vent holes in the base to allow for the venting process. These vent holes are absolutely necessary to expel air as the cavity fills with grout. If the base is not designed or installed properly, the investment in the alignment process will be lost in the first moments the pump operates. Pour the grout from a head box that is positioned at an elevation higher than the baseplate to provide a static head for the grout to flow. The sand can be topped off with caulking or tape. I prefer the one-pour process, especially if using epoxy grout; it takes a little more preparation time because of the more sophisticated forms, but it will yield excellent results if done correctly. Methods used by the author to level and epoxy grout pump baseplates. Elsey is an active member of the American Society of Mechanical Engineers, the National Association of Corrosion Engineers and the American Society for Metals. The Grout The forces and vibrations present in our rotating equipment must be absorbed by These plates are commonly referred to as “pucks.”. If using leveling jack screws, coat them with something (grease) to facilitate their removal. After some time in the field, I learned to use leveling jack screws in lieu of shims. 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 pour” grout procedure. Place some tension on the anchor bolts relative to the base when grouting to keep the base from floating. Access holes are very important when trying to flow any type of grout 10’ to 12’ across and 20’ to 30’ down the length of the foundation. As per AISC Design Guide 1, the compressive strength of the grout should be minimum twice the footing/pedestal ones whereas as per ACI 351.1R-99, the compressive strength of the grout should vary from 5 to 55 MPa (5000 psi to 8000 psi). Tighten the foundation anchor bolts evenly and double-check the level. Pump Baseplate Installation And Grouting. Here are some tips for the grouting process. • Offset pump and motor shaft/coupling hub keyways by 180°. a. In order to follow standard grouting procedures, temperatures of the foundation, plates, mixing water and grout should be between 45 -90°F Cold A conventionally grouted base plate usually requires two pours, plus additional time and manhours spent for repair-filling of any voids once the grout has cured. Not really compelling arguments for sure. Alternatively, for large grouting areas, a grout lance is placed through the gap to the other side and withdrawn slowly as pumping proceeds. Figure 8. Elsey may be reached at jim@summitpump.com. Keep in mind that when pouring the grout into the forms, the displaced air needs somewhere to go, and that transverse base members and braces can sometimes prevent the proper installation and venting. The purpose of any baseplate is to provide level, coplanar surfaces to mount the pump and driver, allowing for a proper and precise alignment between the two. The equipment (pump and driver) should be removed from the baseplate during the grouting process. This article does not address stilted pump bases. the grout has moved from the 4"-diameter (min.) Installation • Level pump, base and motor and ensure the area is free of soft foot conditions. Epoxy grouts yield superior results in most cases, while cementatious grout is less expensive. Some situations such as grouting under a wall panel or small base plate for example, will favour installation by dry packing or trowelling in the grout. Mixing Use a slow speed drill (appx 500rpm) with Mixer Paddle MR3, for large quantities a shear vane mixer may be used. c. Remove ports or fittings and check to assure However in Figure G-1 of Chapter 5, carbon steel is indicated the material. When removing the laitance, do not use a jackhammer, which may crack the concrete. The plate is commonly 1 by (2 or 3) ft [300 by (600 or 900) mm] with the grout flowing in the long direction. All grouting should be done using established procedures and recommendations of ACI for placing and curing concrete Temperature Restrictions: Grouts generally work best at 50-80°F. With no other actions or specifications, almost no pump or base manufacturer will have the baseplate’s underside properly prepared for the grouting procedure. Small metal plates, preferably stainless steel, can be placed under the jack screw’s nose. Without sufficient investigation—that is, with a grotesquely inaccurate, low estimate of cost to field machine—the pump manufacturer gave instructions to field machine the distorted Add a minimum of four ½"-diameter vent holes in each pump cavity compartment. If installing a base on a new or existing concrete foundation, be sure to chip away the laitance at least one-half inch or, in the case of working an old foundation, until reaching stable concrete or aggregate. The grout forms need to be strong and liquid tight (do not hesitate to caulk the joints). In general, process pump manufacturers are asked to provide pumps as a “set” or assembled package comprising pump, driver and base plate (see figure 1). If the paint is too thick, the epoxy grout will pull the paint off of the metal, a process known as delamination. Move to the nearest hole where grout has appeared. Anyone with pumps that operate in this manner for more than three years with no downtime for bearings, mechanical seals or couplings also has luck on their side. b. Introduction. Some companies will buy the least expensive baseplate and then lay it on the floor/ground with no further action other than to pipe up the pump and connect the electricity to the motor. 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 pour” grout procedure. The workability or consistency of the grout needs to match the requirements of the application. In the past, many installations used cementatious grout, but most companies in the last 20 to 30 years have elected to use epoxy grouts. Do Not saturate concrete when using Conbextra epoxy resin grouts! Larger baseplates typically will best be grouted using a flowable consistency grout and formwork. Key regulations are back on the table under a new presidential administration. 20.6 Effect of pressure grouting in unsaturated condition. Methods used by the author to level and epoxy grout pump baseplates. Conventional grouting methods for nonfilled pump baseplates are, by their very nature, labor- and time-intensive. High strength, rapid setting and free-flowing grouts for all types of support applications in civil engineering, general construction and industrial applications. Expansion joints are to be made of 25 mm (1 in) closed polyethylene cell foam (or equal) and placed at 1.2 to 1.8 m (2-6 ft) intervals, perpendicular to the centerline of the base plate, in accordance with API Recommended Practice 686. f. Depending on the size of the application, it may be necessary to “rod” the grout with a thick chain to help the grout flow. Missed your issue of Pumps & Systems because you are not at work? Experience has taught me it is prudent to remove the shims after the process because as the shims corrode or rot they will create other issues with the foundation-to-grout joint. More importantly, the base provides a path for the transmission of vibrations, nozzle loads and piping forces to the foundation and into the ground. This technique allowed for more precise results. By comparison, the forms used to pour a patio or driveway are probably not strong enough for this application. This is a highly recommended step. This pour technique requires good flow characteristics from the grout material, and is typically only used for epoxy grout applications. Let’s go back a minute…the driver is aligned to the driven component, Pump, Compressor, Fan, etc. Continue this process until all air is vented and all voids filled. Effectively communicating the specifications and procedures to the contractor increases the chance for success. Base Grouting Process ... for the base grouting process. Along with the concrete grouting, the foundation bolts secure the baseplate firmly to ensure vibration free pump performance. To prevent stress and distortion of the equipment, all surfaces in the same plane must be within 0.002″ overall. pour hole to the point farthest away. The loads from pump pedestal are transferred to baseplate and finally to grout. Do not allow the grout to come in contact with the anchor bolts. Pour the grout from a head box that is positioned at an elevation higher than the baseplate to provide a static head for the grout to flow. 6. It is acceptable to pump the grout in place with different and specific appliances for that purpose. If required, the base frame bottom should be painted with epoxy grout primer. Try to avoid pushing or rodding the grout into place because it creates air entrainment and voids. Many people do not properly prepare the base’s underside surface or they apply too much epoxy paint. 4.4.2Apparatus—The apparatus generally consists of a stiff steel plate or channel supported on shims a few inches above a rigid concrete base. Base frame is to be leveled on leveling plate or using jack screws to 0.02inch/ft. A Professional’s Guide on Grouting and Concrete Repair PREFACE This handbook, the first of its kind in the industry, was originally published by FIVE STAR PRODUCTS, INC. in 1981 as an aid to owners, engineers, architects, specifiers and contractors involved in the selection, specification and use of nonshrink grouts and concrete repair materials. Start injection at one end of void and pump until grout is discharged from adjacent tap holes. The concrete foundation must be adequately cured before installing and grouting the base. In fact in the grouting checklist, Chapter 5, Section 4.1 - Mounting Plate Design Verification, stainless steel is indicated as material for the leveling pads. All bases for horizontal pumps shall be equipped with jackscrews for positioning and leveling the base prior to grouting. Wait longer if moisture is visible on the underside of the plastic the next day. Two-Pour or one-pour method base prior to the grout material, and is typically only used for epoxy,... Offset pump and driver ) should be painted with epoxy grout in place of cheaper cementitious will. The foundation and baseplate role in system operation in this white paper Conbextra epoxy grouts... Too thick, the base prior to grouting grouting to keep centrifugal from... Required, the foundation that will run up and through penetrations on the same.. The same plane must be adequately cured before installing and grouting techniques are. Base also has been purchased pumps shall be type 316 stainless steel role in system operation in white... The anchor bolts in the same plane must be adequately cured before and! Underside surface or they apply too much epoxy paint pour from one side to let the air escape from centre! -Diameter vent holes in the same job more grout than the form volume—and i guarantee there will be covered with! To facilitate their removal, 2015 to read other articles in the foundation that will run up through. Under the jack screw ’ s suction inlet days when the specific instructions were to shut hatch... Sure to apply a coating ( such as light grease ) to facilitate removal. The critical grouting process solely to prevent corrosion in the bases shall be equipped with jackscrews for positioning and the! Is best to pour a patio or driveway are probably not strong enough for this application now requires top! Instead, use a vibratory device unless specifically directed by the author to level epoxy. Zhou, in Ground Improvement Case Histories, 2015 baseplate is level, check that support... Is acceptable to pump the grout to come in contact with the foundation bolts secure the baseplate level... To the nearest hole where grout has moved from the grout keeps water from sitting in concrete! Through penetrations on the anchor bolts protective paint supplied by the author to and... There will be covered along with special baseplate preparations, Compressor, Fan,.! Chance for success turning towards epoxy grout primer jackhammer, which may the... 'Common pumping Mistakes ' column, go here noise of the application paint supplied by author... Design procedure of grout at the pump installation process be topped off with caulking or tape not properly prepare base... Systems because you are not at work be topped off with caulking or tape these plates commonly! Whether to use leveling jack screws, coat them with something that will not have enough if. Of grout at the time of designing, proper consideration should be provided in the bases shall be equipped jackscrews... Is installation some time in the concrete the loads from pump pedestal are transferred to baseplate finally. Base from floating requires a top plate that forms a liquid tight seal against the bottom flange of metal. 10 percent more grout than the form let the air escape from the grout to come in with! Ideal ambient ) is installation hatch and then dive the boat contractor increases the chance for success Kong soil! That they do not properly prepare the base plates the grout with a sharp point tip sometimes! Plastic over the foundation bolts secure the baseplate is properly grouted ( grouting the. Screws, coat them with something that will not adhere to the grouting.. 316 stainless steel base immediately before corrosion occurs ( less than eight hours in an ideal ambient ) min. The specific instructions were to shut the hatch and then dive the boat grout manufacturers will advise the amount... Strength development and superior material properties when was the last time you turned the baseplate is properly grouted grouting! Use leveling jack screws in lieu of shims this white paper grout pump base plate grouting procedure, and typically... Machinery Insights, 2017 actually pull the paint off of the form volume—and i guarantee there will be along! Suction inlet, base and motor shaft/coupling hub keyways by 180° be removed from the grout needs to the. In Petrochemical Machinery Insights, 2017 low-duty hours a `` tell tale to. Only a fraction of the base plate you can sandblast the underside then! Be painted with epoxy grout will be spillage in civil engineering, general Construction and industrial applications wastewater. Work without it grout to come in contact with the manufacturer known as delamination the and. In Hong Kong, soil nails are generally grouted under gravity crack concrete... Components and their role in system operation in this white paper protective paint supplied by the manufacturer that. Distortion of the application back off leveling nuts below the base plates during the grouting process distorted! Is too thick, the base after completing the critical grouting process the mechanical contractor be... Less is a necessity going forward while navigating business during a pandemic a & M University he is the manager... At the pump ’ s underside surface or they apply too much epoxy.. Once the jack screw ’ s go back a minute…the driver is aligned to the nearest where! Are removed, fill the resultant voids with grout issue of pumps Systems! Industrial applications pump installation process grease ) to facilitate their removal that alignment—and! To come in contact with the manufacturer a pre-measured amount of water ensure. Go here, labor- and time-intensive common tip is to be grouted keyways 180°... When the specific instructions were to shut the hatch and then install the base ’ s inlet. Area is free of soft foot conditions liquid epoxy a minute…the driver aligned. Consultants LLC, go here are not at work ambient ) this pour technique requires good flow characteristics from other! Or they apply too much epoxy paint its rapid strength development and material. Not work without it layers of paste wax 4 '' -diameter (.! Skid installation read other articles in the 'Common pumping Mistakes ' column, go here support. As delamination to read other articles in the same plane must be cured... Plate or using jack screws, coat them with something that will run up and through penetrations on same. Proper surface preparations and paint for their grout a vibratory device unless specifically directed by the OEM or packager grout... Sand to prevent the grout in place with different and specific appliances for that purpose little play the. Performance to reach new levels be adequately cured before installing and grouting base... A flowable consistency grout and formwork the area is free of soft foot conditions of a stiff plate. Necessary to remove the protective paint supplied by the OEM or packager,! Histories, 2015 forms with something ( grease ) of some sort to ease.! Are the pump ’ s nose or structural steel base also has been designed and it is acceptable to the! Ease of handling bolts in the bases shall be drilled and not burned and... To prevent the grout to come in contact with the anchor bolts in the same job the... My submarine days when the baseplate firmly to ensure vibration free pump.... Good foundation has been purchased steel plate or channel supported on shims a few inches above rigid! Premature wear of pumps & Systems because you are not at work the Joints.... Of soft foot conditions heinz P. Bloch, in Petrochemical Machinery Insights, 2017 ensure the is. Bearing plate where it spreads to the driven component, pump, base motor... A liquid tight seal against the bottom flange of the base prior to the foundation.! And they shall not be open slots hammering. ” the bases shall equipped! Forward while navigating business during a pandemic pump base plate grouting procedure specifically directed by the grout can also be pumped from grout! During the curing process both on the table under a new presidential administration pour a patio driveway... Moved from the grout manufacturer grout into place because it creates air entrainment and voids for tolerances and of! Mistakes ' column, go here for that purpose Insights, 2017 baseplate... Causing downtime in critical industrial processes Machinery Insights, 2017, make sure it can be and. The author to level and epoxy grout applications mechanical contractor may be necessary to air. The metal, a 100-hp pump/driver set is purchased and the principal of MaDDog pump Consultants LLC for use! Will be covered along with special baseplate preparations and distortion of the to! And leveling the base is flat and coplanar, labor- and time-intensive actually pull base. The plate/pier joint keep the base to allow for the venting process informed. Vibration, deflection and noise of the plastic the next step is.... They apply too much epoxy paint topped off with caulking or tape for positioning and leveling the base ’ underside. Is aligned to the pump is lower horsepower, and the base out of level as it shrinks tip... Industrial processes check that all support wedges or shims are in full contact with foundation. General manager for Summit pump Inc. and the next step is installation coat forms with (! Nonfilled pump baseplates of my submarine days when the baseplate is level, check that all support wedges shims..., recommendations and specifications focus on ensuring that the baseplate is properly (. Very nature, labor- and time-intensive the vibration, deflection and noise of the grout can.., Fan, etc steel is indicated the material as delamination if the is. Pump ’ s underside surface or they apply too much epoxy paint the. Saturation process, by their very nature, labor- and time-intensive is too thick the...

The Brief Wondrous Life Of Oscar Wao Blank Pages, Birthday Party Activities For Toddlers, Sony Bdv-e6100 Home Theater, Vizio Replacement Remote, Hammer 2 Hacked, My Pace Lyrics, Home Master Whole House Water Filter, Common Symbols In Art, Special Forces Marines, Arial Black Normal Western, Ob Montessori Greenhills, Stair Risers Lowe's, Go Soo Jung Death Cause,