Wallace E.

(Ed) Wilcox is a Staff

Machinery Engineer with Chevron Energy
Technology Company, in Houston, Texas.
He worked for more than 10 years with
Conoco and Citgo as a Rotating Equipment
Engineer, and he has authored papers on
vibration analysis and performance testing.
Mr. Wilcox has a BSME degree fromthe
University of Missouri Rolla, and an MSME
degree fromOklahoma State University. He
has also done postgraduate work at the Georgia Institute of
Technology in the areas of lubrication, rotordynamics, and
vibration. He is a Vibration Institute Level 111 Vibration Specialist
and a registered Professional Engineer in the State of Oklahoma.
Mike White is the Manager of Field
Services for Sulzer Pumps (US) Inc., in
Portland, Oregon. He is responsible for the
startup of new equipmentpumps, drivers,
supporting systems. He supervises and
trains the startup group for Sulzer. Mr.
White has worked for 35 years at Sulzer
Pumps, in manufacturing, pump assembly,
service center, nuclear seals, and field
services departments.
Gordon Parks is a Senior Field Engineer
for Sulzer Pumps (US) Inc., in Portland,
Oregon. He has more than 30 years of
experience with Sulzer Pumps and has
worked as a Field Services Representative,
Field Service Manager, Service Center
Manager (in USA and Asia) and Resident
Engineer at a refinery.
Mr. Parks has a BSc degree from
Portland State University.
ABSTRACT
Installation and startup of centrifugal pumps and drives can be
a stressful time. It involves a coordinated working relationship
with several craftsfoundation contractors, pipefitters, welders,
millwrights, startup engineers, electricians, and information
technology (IT) technicians. Also the startup routine is the last
event in the long process from ordering equipment to installation.
By the nature of being last in the process, any delays in the
upstream processes are expected to be mitigated by a quick
uncomplicated startup. With these pressures in place a firm dedication
to following procedures is required. The steps from installation to
startup are described and in their proper sequential order.
INTRODUCTION
An example of startup events not in proper order is the case of
the pump mounted on the base, but not centered on the base hold
down holes in the pedestals. The driver is then rough aligned to the
pump and signed off. Next the piping is made up to the pump. It is
noticed at this time that the pump is bolt bound. As this is an
unacceptable condition, the piping is released, the pump is
centered, the driver realigned to the pump, and the piping is
realigned to the pump nozzle flanges sometimes resulting in
cutting and welding of these large bore pipes. All the extra work is
time consuming and costly, not to mention the toll it takes on
morale in having to do the job again. Figure 1 shows the proper
sequence of events for the first part of the processfoundation,
leveling, grouting. Figure 8 likewise shows the ordered sequence of
steps that occur after the base is set, and grout cured. The steps
shown are an overview in order to emphasize the overall order of
the process. A more detailed explanation of these events can be
found in API 686 (1996).
INSTALLATION SEQUENCE CHECKLIST
Figure 1. Foundation/Grouting Checklist.
75
COMMISSIONING AND START-UPS OF NEW UNITS (PUMPS)
by
Wallace E. (Ed) Wilcox
Staff Machinery Engineer
Chevron Energy Technology Company
Houston, Texas
Mike White
Field Service Manager
and
Gordon Parks
Senior Field Engineer
Sulzer Pumps (US) Inc.
Portland, Oregon
R FOUNDATION CONSTRUCTION
The method shown in Figure 2 can be used to determine whether
a pump foundation is sized adequately.
Figure 2. Top Surface Foundation and Foundation Area to Mass
Ratio Diagram.
R PREPARE FOUNDATION
Figure 3. Surface to Be Rough Chipped and Clean.
R CLEAN UNDERSIDE OF BASEPLATE
Cleanliness is essential (Figure 4). The bottom of the base
should be painted with epoxy grout primer if required.
Figure 4. Under Side of Base Plate.
R SET BASEPLATE OVER
FOUNDATION BOLTS
The base is equipped with anchor bolt holes (Figure 5), leveling
holes, 5 in (127 mm) grout holes, and 0.5 in (12.7 mm) air holes.
Figure 5. Location of Anchor Bolts on Side Rails of Base Plate.
R LEVEL BASEPLATE USING
JACK SCREWS AND LEVELING PADS
The leveling jackscrew is reacting on a stainless steel button that
will be grouted in permanently (Figure 6). For this reason the top
surface is rounded to prevent point loading leading to stress risers
in the grout.
Figure 6. Anchor Bolts and Leveling J ackscrew.
The overhang of the base pad allows leveling of the pads without
removal of the pump (Figure 7). Today both removal of the pump
and leaving it in place are acceptable. Traditionally all the
machines were removed from the base for leveling. Due to costs
and complexity of auxiliary attachments it is desirable to leave the
equipment in place.
Figure 7. Overhang of Base Pad.
PROCEEDINGS OF THE TWENTY-FIFTH INTERNATIONAL PUMP USERS SYMPOSIUM 2009 76
R SNUG-UP FOUNDATION
ANCHOR BOLT NUTS
Figure 8. Base Plate Tightening after Base Level on Pads Achieved.
R CHECK LEVELING OF BASEPLATE
This step is to ensure that during the prior step of snugging the
anchor bolts, the base level has not changed (Figure 9).
Requirements for level are 0.002 in/ft (0.17 mm/m). Each foot must
be level to themselves and the other feet within 0.002 in (0.05 mm).
Figure 9. Base with Straightedge and Machinist Level.
R MOUNT DRIVER (IF FIELD MOUNTED)
Many times the motor is delivered to the field directly which
means the mounting process normally done at the factory is done in
the field (Figure 10). In this situation the motor is set on the motor
pads. The coupling alignment including the distance between shaft
ends (DBSE) is made. After completion, a scribe is used to scratch
the circular outline of the Hold down bolt on the base pad. This is
done by reaching into the motor hold down holes and scribing the
base pads using the holes as a guide. Lift the motor off, then drill and
tap the base pads. The motor can then be repositioned on the base.
Figure 10. Base with Motor Mounted in the Field, not in the Factory.
R CHECK FOR SOFT FEET,
PUMP AND DRIVER
First ensure all the hold down bolts are tightened. They do not have
to be torqued. Soft feet are discovered by setting up a magnetic base
to the pump/motor pedestal. The dial is attached with the button on
the top of the foot (Figure 11). The hold down bolt is then loosened.
If a soft foot exists the foot will raise up. The amount is read on the
dial indicator. The maximum 0.002 inches (0.05 mm) is allowed.
Figure 11. Pump Feet with Dial Indicator.
RALIGN DRIVER TO PUMP
This alignment (Figure 12) is to ensure that coupling alignment
can be made prior to grouting of the base. Should there be problems
in achieving alignment there the base may have to be reworked.
Once grouted, options are severely limited. First the machines are
centered in the hold down holes. Side to side alignment is made.
Vertical alignment is not made at this time. It is important to note
however that the driver is lower by approximately 0.130 inches (330
cm). It is standard practice to shim the driver and leave the pump
feet free of shims. The lower driver pads ensure this is the case.
Figure 12. Rough Alignment.
77 COMMISSIONING AND START-UPS OF NEW UNITS (PUMPS)
Bases are provided with sufficient number of grout holes 4 or 5
inch in diameter, to allow the grout to access all areas (Figure 13).
Note the small vent holes on the perimeter of the base.
Figure 13. Base with Grout Holes Through Motor Pad.
Voids are detected using a hammer on the deck plate. The most
critical areas to be concerned about are under the pedestals. These
are also the hardest places to get the grout to flow to. Drill and tap
the deck plate to match the threads on a high pressure gun (grease
gun). Epoxy grout can then be pushed into voids. Trapped air is
discharged through air holes in the deck plate. Additional holes
may have to be provided.
R GROUT BASEPLATE
It is now time to grout the base (Figure 14).
Figure 14. Grouting.
R FINAL TORQUE FOUNDATION
BOLTS AFTER GROUT CURES
A practice seen more and more is to use cementatious grout in
the bottom of the base and finish off with epoxy grout (Figure 15).
There are grouting handbooks available that go into the specifics
of this process. One point to be made here is the need to allow
epoxy grout to cool sufficiently. Epoxy grout is done in three pours
allowing for cooling of each pour. This minimizes the risk of the
heating causing distortion to the fabricated base.
Figure 15. Initial Grout Pour.
Once the grouting has cureda matter of daysthe equipment
if removed from the base is returned. Rough alignment is made.
EXAMPLE OF IMPROPER
GROUT APPLICATION
Figure 16 is an example of a foundation cracked. It may be due
to water freezing heaving up the concrete. This photo also shows
there is no grouting under the sole plate or anchor bolts present.
Figure 16. Discharge Head Vertical Pump.
R INSTALL MAIN PIPING
The main piping is now attached to the pump (Figure 17).
Figure 17. Main Piping.
R CHECK FOR PIPE STRAIN
Once the fitters have welded up the main piping, it should be
rechecked for excessive strain on the pump nozzles (Figure 18).
Note the stanchion welded to the base is not good practice. Piping
supports should not be on the base and clear of the foundation.
Figure 18. Check for Pipe Strain.
PROCEEDINGS OF THE TWENTY-FIFTH INTERNATIONAL PUMP USERS SYMPOSIUM 2009 78
R FINAL ALIGNMENT
Coupling alignment guidelines are shown in Figure 19. Always
ensure the machines are centered in the hold down holes and the
air gap (DBSE) is proper before finishing the final alignment.
Many times one or both of these items is left out, which causes this
process to be repeated.
Figure 19. Coupling Alignment Guidelines.
R FINAL ALIGNMENTTHERMAL OFFSETS

Power pumps and API pumps are typically centerline design

machines where the pump foot is at or near the shaft horizontal
centerline. Vertical thermal growth is minimal.

Motors are foot mounted and frame temperature soak from the
shaft centerline relates to vertical thermal offset.

Fixed gears have more complex coupling alignment offset

requirements. Again, significant growth is vertical due to thermal
soak in the frame. Additionally there is a thermal growth that
occurs side to side.

There is a mechanical offset requirement also due to the action

of the pinion gear moving up on the bull gear. All these offsets in
gears can be obtained from the gear manufacturers. It is normally
found on the mass elastic diagram.

Steam turbines being hot and foot mounted also have significant
vertical offset requirementsmore than motors.

Gas turbines have vertical offsets and many times have an

angularity offset in the vertical plane. This is due to the fact that the
hot engine portion is in the back and the much cooler compressor
section is near the drive-end. The coupling will end up open at
the bottom.
Figure 20 is an example of how thermal offsets are communicated
today. Note the DBSE/DBCFF are set up to accommodate axial
growth. The preset amount is the coupling spacer length plus the
thermal growth distance. When the machines are running and at
temperature, the shafts have grown closer together providing the
exact coupling center member is fit into the DBSE.
Figure 20. Thermal Offset Map as Supplied by OEM.
R FILL SYSTEM
Figure 21. Pump Flooded with Product.
PRE STARTUP CHECKLIST
A pre startup checklist is shown in Figure 22.
Figure 22. Field Service Rep Checklist.
The following explains the steps in detail.
R Leveling and Grouting of Base
R Check Train for Soft Feet (Figure 23)
79 COMMISSIONING AND START-UPS OF NEW UNITS (PUMPS)
Figure 23. Checking for Soft Feet.

Check pump and motor pads for flatness, etc.

Soft foot creates 1frequency vibration.

Base level is always spoken of relative to the machined pads, not

deck plate.

Deck plate is sloped for drainage and is not a precision surface.

Check pads with the use of a precision straightedge, machinist

level, and shim stock.

Optical transit equipment can also be used.

R Strainer in Suction

Figure 24 is a startup strainer.

Typical screen is #8 mesh (0.063 wire with 0.125 spaces

between).

Stops large objects from entering pump. Not intended to be a

fine filter

If required as part of the process, a permanent, more elaborate

filtering product should be installed.
Figure 24. Suction Strainer.
R Minimum Flow Orifice
RWarm-up Orifice
A minimum flow diagram is shown in Figure 25.
Figure 25. MinimumFlow Diagram.
All pumps need protection should the application the pump is in
have low demand periods. The requirement for a minimum flow
line is not universal. Some applications do not need this protection.
An example would be flood water, injection service where demand
is steady or the pump is turned off.
R Suction Gauge
R Discharge Gauge
R Pipe Strain
Pump nozzle loads are shown in Figure 26.
Figure 26. Pump Nozzle Loads.
The pump manufacturers provide allowable moments and forces
on the suction/discharge nozzles. The values are to ensure
proper operation should loads suddenly be applied, or to handle
cold loads that dissipate after startup due to thermal changes. It
is inappropriate to allow unnecessary loading due to these
allowable levels.
R Bearings Removed and Cleaned
R Check Bearing Clearance with Plastigauge (if rated operating
speed is over 4000 RPM)
R Check Coupling Hub Runout (pump and motor)
PROCEEDINGS OF THE TWENTY-FIFTH INTERNATIONAL PUMP USERS SYMPOSIUM 2009 80
A bearing assembly nondrive-end is shown in Figure 27.
Figure 27. Bearing Assembly NDE.
Cleaning of bearings is almost always required. It depends on
the length of time between manufacture and startup, and the
environmental conditions around the pump during this period of
time. The startup group should always at least disassemble a
representative bearing to make sure there is no water, corrosion, or
particulate matter present.
R Lube System Flushed
R Oil Level Checked and Pressure Switches Set
A lube oil system is shown in Figure 28. Heating of the oil is
required to help in the cleaning process. The immersion heater is
used to heat up the reservoir. Another method is to run hot product
through the cooling side of the heat exchanger.
Figure 28. Lube Oil System..
R Distance Between Shafts
R Rotation and No Load of Drive have been Checked
The coupling spacer or an inside micrometer is used to set the
DBSE (Figure 29). This should be set as close as possible plus or
minus 0.010 in (0.25 mm).
Figure 29. DBSEDistance Between Shaft Ends.
R Hot ServiceSet Aligning Blocks (Figures 30 and 31).
Remove .002 Shim and Torque Outboard Pump Hold Down Bolts
to Torque Value
R Final or Hot Alignment in Accordance with IOM
Figure 30. Hot Alignment Keys and Blocks Barrel Pump.
Figure 31. Hot Alignment Blocks Horizontal Split Pump.
81 COMMISSIONING AND START-UPS OF NEW UNITS (PUMPS)
Multistage horizontal pumps grow thermally along the shaft
axis. The drive-end is pinned to lock in the coupling alignment. A
guide key arrangement is used on the nondrive-end to allow the
pump to expand and contract due to the operating temperatures.
Typically these features are only used on pumps 250F or higher.
Figure 32 shows a startup checklist and Figure 33 shows a pump
prepared for first start.
Figure 32. Startup Checklist.
Figure 33. Pump Prepared for First Start.
Contaminants can gather under the mechanical seal gland
bushing due to the area being open to atmosphere. This bushing
runs a close running clearance0.025 in (0.64 mm) diametrical to
the seal sleeve. In normal operation this clearance is not lubricated
and if clean and centered presents no problem. After sitting the
clearance can become dirty. Always flush the bushing using the
pipe taps on the seal gland at the 10 oclock or 2 oclock position
prior to startup. Keep a small stream of water going under the
bushing during initial startup. This lubricates and cools the bushing
preventing a pick-up and seizure that can gall the seal sleeve.
Worse, with enough heat the shaft will bend. After a short time,
about 30 minutes of running time, the water can be shut off.
New systems have to be completely vented. In one instance a 10-
stage pump was started up and ran well for a few minutes. The
suction line was very long, 1000 ft to a storage tank. Unknown was
a large air pocket half way. When it reached the pump, the pump
continued to operate but the discharge gauge once steady began
swinging. The air pocket filled the first stage impeller creating a
dry run situation. On touch the pump case was burning hot.
Fortunately the steam turbine service rep standing by understood
the situation and immediately turned off the turbine salvaging the
pump from seizure.
FINAL PRE STARTUP CHECKS

Walk through the startup sequence with the operators.

Witness flooding and venting of the pump and seals.

Verify:
Oil pressures (lube oil system, LOS) and flows through the
bearings.
No leaks are present on lube oil and seal piping.
Proper warmup of the pump (hot service).
By hand that pump turns freely.
OPERATIONAL CHECKS

Record suction and discharge pressures.

Monitor and record bearing temperatures (housing and with

handheld gun).

Check temperatures on seal inlet and outlet lines.

Monitor suction differential pressure on suction screen (if

equipped).

Take vibration readings.

Monitor lube oil reservoir temperatures.

When obtaining operating data, ensure there is no leakage
undetected through the minimum flow line or another main line
that is supposed to be blocked off. Undetected flows correspond to
a pump that seems to be low in performance when taking data.
Verifying pump performance is shown in Figure 34, and checking
vibration is shown in Figure 35.
Figure 34. Verifying Pump Performance.
PROCEEDINGS OF THE TWENTY-FIFTH INTERNATIONAL PUMP USERS SYMPOSIUM 2009 82
Figure 35. Checking Vibration.
POST STARTUP MEETING

Identify outstanding actions or issues.

Discuss maintenance of equipment.

Spare part strategy

Local service shops

IOM up-to-date
CONCLUSION
The end product from the commissioning and startup of
pumping systems determines the health of the system for years. It
is therefore important to allocate the proper amount of time and
resources to it. Care and thoroughness should be the watch words
for successful completion.
REFERENCES
API Standard 686, 1996, Machinery Installation and Installation
Design, American Petroleum Institute, Washington, D.C.
BIBLIOGRAPHY
Harrison, D. M., 2000, The Grouting Handbook: A Step-by-Step Guide
to Heavy Equipment Grouting, Gulf Professional Publishing.
83 COMMISSIONING AND START-UPS OF NEW UNITS (PUMPS)