CAUTION: Based upon the publication date, this document may not contain the latest

guidance. The user is strongly advised to contact the Technology Manual Sponsor to
determine the appropriate subject matter expert for consultation on applicability to the
users specific case.

1000 Pump Installation

Abstract

Contents
Introduction

1020

Installation Checklist

Page
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1000-2
1000-7

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Revision History

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1010

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This section contains general guidelines and checklists for installation of new
pumps and reinstallation of existing ones.

January 1991

1991 Chevron U.S.A. Inc. All rights reserved.

1000-1

1000 Pump Installation

Pump Manual

1010 Introduction
Although these guidelines focus on new installations, many aspects also apply to
existing installations where equipment has been repaired, rerated, retro-fitted, etc.
Proper pump installation helps ensure trouble-free startup and long term reliability.
If installed improperly, even the best pump can be a source of costly maintenance.
For example, a pump running perfectly in a well-designed installation may experience many problems if moved to a poorly designed installation. The opposite is also
true. Additionally, an unreliable pump installation can affect plant availability, even
if fully spared. Two fully spared but poor installations never equal a single, reliable
installation.
This section discusses general items that should be considered to ensure reliable
pump installations.

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Although the items on the checklist in Section 1020 are simple, it is surprising how
often they are not checked or not properly followed. Typical examples include:

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Baseplates improperly grouted. This leads to excessive deflection and vibration,

shortening pump and driver life.
Pump and driver shafts improperly aligned. This shortens bearing, seal, and
coupling life.

Excessive pipe cold-springing. This distorts the pump case and baseplate, shortening bearing, seal, and coupling life.

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These problems can be expensive. For example, the cost of three or four seal failures may equal the original pump purchase price. There is a significant economic
incentive to achieve good, reliable pump installations from the start.

1020 Installation Checklist

The attached checklist covers most common onshore and offshore pump installations. Where appropriate, installation items specific to certain types of pumps are
listed separately. This checklist does not include specific acceptance criteria (alignment tolerance, pipe forces, etc.). These criteria should be developed for the specific
application according to the manufacturer's service manual, applicable industry
standards, and local practices.
The following checklist assumes that there are no problems inherent in the equipment. This means that the pump design matches the intended service, materials are
correct, and the pump has been properly manufactured. It also assumes that the
associated process and auxiliary piping system, foundations, and baseplate are properly designed and built.

1000-2

1991 Chevron U.S.A. Inc. All rights reserved.

January 1991

Pump Manual

1000 Pump Installation

Pump Installation Checklist

Initial

Date

Properly Completed Data Sheets

________

________

Pump Cross Section/Performance Curves

________

________

Shaft Seals/Packing

________

________

Coupling

________

________

Auxiliary Systems (lubrication, sealing, cooling)

________

________

Shop Performance/Mechanical Test Results

________

________

Service Manual (covering all major pump train components)

________

________

________

________

________

________

Performance/Vibration History (existing pumps)

________

________

Spare Parts List

________

________

Concrete properly cured before grouting

________

________

Concrete surface properly roughened and cleaned

________

________

Mounting plate metal surface clean/properly painted

________

________

Mounting plate corners properly rounded

________

________

Proper grout material/thickness

________

________

Coupling disconnected before levelling

________

________

Mounting plate levelled

________

________

Pump mounting pads horizontal and at same elevation

________

________

Grout properly cured

________

________

No hollow areas in grouting

________

________

Anchor bolts properly tightened

________

________

Mounting plates located at load bearing support beams

________

________

Shims of non-corrosive material

________

________

Baseplate/skid properly levelled

________

________

Bolting properly tightened

________

________

General - All Pump Types

1. Data Sheets (Pump & Driver)

Safety Instruction Sheets

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Maintenance History (existing pumps)

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Drawings:

2. Foundations and Grouting

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Concrete Foundations:

Other Foundations:

January 1991

1991 Chevron U.S.A. Inc. All rights reserved.

1000-3

1000 Pump Installation

Pump Manual

Pump Installation Checklist (continued)

Initial

Date

Storage protection requirements met

________

________

Internal/external cleanliness checked

________

________

Rust preventative/lubricant compatibility acceptable

________

________

Baseplate/skid straight and flat

________

________

Pump feet free of burrs

________

________

Pump and driver not bolt-bound

________

________

Nozzle gasket surface finish acceptable

________

________

Pump and driver rotates freely by hand (no excessive radial or lateral play)

________

________

Alignment shims (number, material, condition) acceptable

________

________

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3. Equipment Condition (Before Installation)

Coupling condition acceptable

________

________

________

________

________

________

________

________

________

________

________

________

Proper blinding & tagging suction/discharge lines

________

________

Suction screen location and orientation correct

________

________

Check/block/bypass valves location and orientation correct per P&ID

________

________

Correct gasket design/material installed

________

________

Relief valves properly set

________

________

Piping/pump flanges parallel

Rotation arrow permanently marked, checked

Oil level marked, checked
Alignment jack screws

4. Process Piping Systems

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Seal leak free (static or running test)

________

________

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P&ID Check

Check for cold spring with indicators

________

________

Correct piping supports (hot and cold) installed

________

________

Expansion joints properly adjusted

________

________

Piping strain acceptable (hot service check)

________

________

Check ANSI Class on flanges for correct rating

________

________

Eccentric reducers - flat side up, angled side down

________

________

Suction piping sloped to prevent vapor traps

________

________

Piping clean as dictated by installation

________

________

1000-4

1991 Chevron U.S.A. Inc. All rights reserved.

January 1991

Pump Manual

1000 Pump Installation

Pump Installation Checklist (continued)

Initial

Date

Piping properly braced

________

________

Piping cleaned

________

________

Piping proper size and material

________

________

Piping properly sealed/socket welded

________

________

Piping properly traced and insulated

________

________

Proper thread lubricant used

________

________

Check instrumentation per any available drawing

________

________

5. Auxiliary Piping Systems

General:

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Seals:
Flush properly connected

________

Flush system orifice/strainer/cyclone separator correctly located

________

________

Quench properly connected/plugged

________

________

________

________

________

________

________

________

________

________

Lube oil cooler connected

________

________

Pump pedestals connected (hot services)

________

________

Piping properly cleaned/water-free

________

________

Proper orifices installed (pressure systems) and tagged

________

________

Housings flushed with correct oil

________

________

Screwed piping properly assembled (without tape)

________

________

Oil levels correct

________

________

No bends/kinks between housing & oiler (purge mist)

________

________

Oilers properly vented (at bearing cap)

________

________

Oil sump bottle non-vented (purge mist)

________

________

Oil sump bottle vented (pure mist)

________

________

Oil mist fittings - proper sizes

________

________

Oil mist - check flow

________

________

Vent properly connected/plugged

Drain properly connected/plugged
Packing:

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________

Cooling:

Lubrication:

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Stuffing box properly connected

Lantern ring location/flush connection correct

January 1991

1991 Chevron U.S.A. Inc. All rights reserved.

1000-5

1000 Pump Installation

Pump Manual

Pump Installation Checklist (continued)

Initial

Date

Vent properly piped

________

________

Drain properly piped/plugged

________

________

Warm-up connection properly piped for hot pumps

________

________

Ports properly connected for Sundyne pumps

________

________

Alignment shims entirely under each pump foot

________

________

Soft foot checked

________

________

Avoid spring effect due to an excessive number of shims

________

________

Case Vents/Drains:

Correct axial spacing between pump & driver shafts (hot and cold)

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6. Couplings and Alignments

________

________

________

________

________

________

________

________

________

________

________

________

________

________

Pump/driver cold aligned & bolting properly tightened

________

________

Coupling hub runout checked

________

________

Cold alignment to manufacturer's recommended tolerances

________

________

Hot alignment checked

________

________

Pump/driver properly dowelled

________

________

Coupling guard installed

________

________

Proper packing installed, gland not cocked

________

________

Special tools available

________

________

Driver rotation checked (prior to coupling)

________

________

Instrumentation, alarms, and shutdown in proper condition

________

________

Pump/driver properly protected during idle period

________

________

Axial float of motor driver checked

Proper coupling interference fit

Coupling lube holes properly positioned
Gear coupling properly greased and gaskets installed

7. Miscellaneous

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Flexible coupling shim packs properly installed

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Motor driver properly positioned (limited end float coupling)

1991 Chevron U.S.A. Inc. All rights reserved.

January 1991

Pump Manual

1000 Pump Installation

Pump Installation Checklist (continued)

Initial

Date

Curb ring properly leveled and grouted

________

________

Pump assembly within acceptable vertical deviation (proper lift with axial
setting)

________

________

Internal cleanliness checked

________

________

Belts and sheaves properly aligned

________

________

Matched belt sets used

________

________

Belts properly tensioned

________

________

________

________

________

________

________

________

________

________

________

________

________

________

________

________

Belts properly tensioned

________

________

Belt guards installed

________

________

Plunger/piston/packing correct size

________

________

Rod straightness/runout/surface condition acceptable

________

________

Packing properly installed and lubricated

________

________

Packing gland properly adjusted (initial)

________

________

Correct bladder pressure/fluid level in pulsation dampers

________

________

Lubricators operating correctly

________

________

Author

Technology
Lead

Other Specific Pump Types

1. Vertical Centrifugal

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2. Rotary Pumps

Suction strainer cleanliness checked

Jacket piping properly connected

Belt guards installed
3. Reciprocating Pumps

Belt and sheaves properly aligned

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Matched belt sets used

Baseplate/foundation bolts retightened

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Pressure gage installed before/after strainer

Revision History
Date
January 1991

January 1991

Description
Initial release

1991 Chevron U.S.A. Inc. All rights reserved.

1000-7