3-Field Service Installation and Start-up Checklist (Horizontal Pump) SC-044-2.pdf

IPG PRO SERVICE CENTERS

Field Service Installation and Start-Up Checklist

Horizontal Pump

Form # SC- 044 Rev #: 1 Date: 11/14/03 Page 1 of 5

Customer: Goulds Pumps Serial No.

Customer Equipment No.

Pump Model: Pump Size: Stages:

NOTE: Use this checklist in conjunction with the standard instruction manual furnished with the equipment. Initial each item completed or write N/A if not applicable. Once you have completed this checklist, please forward a copy to EPD Field Service for entry into our Field Action Reports.

Section 1:

System and Installation Inspections and Checks

1) Verify pump baseplate is level to within .005 inch per foot. Note that API units the level requirement .002 inch per foot. Maximum out of level from one end to the other should not exceed 1/32”.

2) Inspect foundation to determine whether it appears adequately designed to handle the weight and loading of the pump. General rule is the foundation should be three times the mass of the equipment mounted on it including process fluid for centrifugal machines and five times the mass for reciprocating machines. Note that Pro Service does not design foundations and is not responsible for foundation inadequacies, however, they should be noted as foundation integrity will affect equipment life.

3) Make sure baseplate is properly grouted using high quality non-shrink grout. This can be verified by “ringing” the baseplate for “hollow” sounds indicating voids.

4) Make sure all anchor bolts are torqued evenly to their proper torque values.

5) Verify alignment is within specification. Insure there are no “soft” feet on pump or motor and all hold down bolts are tight. Goulds recommended alignment criteria is as follows:

A. Reverse dial indicator method alignment tolerance is 0.0005” per inch of dial indicator separation.

B. Rim and face method the alignment tolerance is 0.002” in the horizontal and vertical planes.

Horizontal Pump

Form # SC- 044 Rev #: 1 Date: 11/14/03 Page 2 of 5

6) Connect piping and check for pipe strain.

A) Piping installation criteria.

1) The distance between the flanges should be no greater than 0.031” plus the gasket thickness.

2) The parallelism between the flanges should be 0.002” per inch of pipe diameter with a maximum of 0.030” regardless of flange diameter.

3) Concentrically, the bolts should be able to be installed by hand.

7) Recheck alignment per #5.

8) Make sure all valves operate freely and are properly installed for the direction of flow. Also insure that they have the proper pressure rating.

9) In conjunction with your contact or customer’s rep, verify where the pumpage is going and that the system is properly “lined up” for the test. NOTE: It is the customer’s responsibility to get fluid and power to the pump and correct and correct any errors found in the system.

10) Verify pumpage supply will be continuously available for the duration of the test. It is very important that the initial run is at least ten minutes in duration in order to completely “flush” the pump. Also verify pumpage and system conditions are consistent with the order specs.

11) If possible, verify the cleanliness of pumpage and piping. If on hand during the installation, insure that the supplied pumpage and piping are clean. On multi-stage units or close clearance alloy construction pumps, always recommend using start-up strainers.

Horizontal Pump

Form # SC- 044 Rev #: 1 Date: 11/14/03 Page 3 of 5

Section 2:

Pump Assembly Pre-Start Inspections and Checks

1) Verify that pumps and drivers (electric motors, turbines, gears, etc.) are properly lubricated before start-up. Lubrication information can be found in the appropriate IOM'’. Verify that oiler settings are correct and the oil rings are in place if the pump is equipped with them. Make sure oil mist in units is working properly and all lines are open.

2) On pumps equipped with oil rings, make sure the rings are in the correct location.

3) On pumps with lube systems, make sure all valves are open.

4) Determine the allowable number of cold/hot starts with the motor vendor. This is very important especially during the initial start-up when numerous “bugs” have to be worked out of the system and controls. The general rule of thumb is two cold or one hot start per hour.

Exceeding the recommended starts breaks down the motor’s insulation and can cause failure.

Megger the motor if possible before start-up.

5) Prior to coupling driver to pumps, verify proper rotation of driver by “bumping” it. In addition to verifying rotation, run uncoupled to insure that the driver runs smooth and sounds normal. If customer refuses to allow a check of rotation, make a notation in Section 4B and have customer sign and date.

6) Only after verifying correct rotation of driver, proceed with coupling pump to driver. If required, perform total impeller travel check and get impeller clearance in accordance with applicable instruction and operation manual. Lube coupling if required per manufacturer’s recommendations.

7) On units with packing, do not over-tighten packing gland. Excessive leakage should be eliminated over time and not all at once. Normal leakage is 60 drops/minute.

8) Units equipped with mechanical seals should be inspected to make sure:

A) Seal auxiliary piping is properly hooked up, all flush lines and return/drain lines are open.

B) Clips are removed when units are equipped with cartridge seals.

C) Shaft is not binding by rotating it. Listen for any rubbing sounds, seal drag is normal and varies with seal configurations.

9) On sealless pumps make sure all environmental controls are hooked up and operating. Make sure all condition monitoring devices are hooked up and working. NOTE: If condition-monitoring devices are not hooked up, it must be noted. Pumps Must Not Be Run Dry.

Horizontal Pump

Form # SC- 044 Rev #: 1 Date: 11/14/03 Page 4 of 5

Section 3:

Starting Unit

1) After all checks in Section 1 and 2 are completed, conduct a start-up meeting with customer to discuss actual procedures required during commissioning. Also verify with customer that their “system” is ready for pumpage. Review Sections 1 and 2 and correct any discrepancies.

2) If pumpage temperature is greater than 200º F, a pre-start warm-up procedure will be required.

Pumps should be raised in temperature 50º F per hour. The pumps will be ready to start when they are within 50º F of the operating temperature. Allow pump temp to stabilize prior to starting.

A) Prior to starting the pumps, alignment should be checked.

3) Make sure suction valve is wide open, open discharge valve 10%-15% of wide open. Start the pump and open discharge valve to meet the design point if required, otherwise open to pump BEP point.

4) On units with mechanical seals, make sure all environmental controls are working properly.

Make sure all cooling devices are working and correct flow rates are established.

5) Verify that the pumps are running smoothly with no unusual noise, vibration or overheating of pump and bearings. The pump should run at least ten minutes to flush out the system.

6) On pump equipped with lube systems, make sure systems are operating properly.

7) Run pumps a minimum of one hour or until bearing frame temperature stabilizes.

8) Begin mechanical run test. Establish baseline performance and vibration readings.

Horizontal Pump

Form # SC- 044 Rev #: 1 Date: 11/14/03 Page 5 of 5

Customer: Pump Serial No.

Customer Equipment No.

Pump Model: Pump Size: Stages:

NOTES:

Goulds Pump Representative Date

Customer Representative Date