This is a general guide to show the reason for the man-hours attributed to the mechanical installation of a pump. In this instance the procedure refers to a slurry type pump either Z drive of direct coupled with no oil cooler or disassembled drives. A typical 8×6 or 10×8 pump say. The procedure will cover a wide range of sizes and types as it is consonant across types and sizes.

Go get: Pumps will be in a laydown area at the site each unit will need to be collected and taken to the installation point, this will require a mobile crane and a driver and Dogman to walk the item into position. In many cases the installation frames for the pumps are a separate item and need to be found, matched to the pump and bought to the incitation point also.

In some cases the frames are placed on the pump plinth and the pump installation done insitu in others the pump and frame are assembled ready for a single lift into position.

Hold down bolts: In my experience two possible problems occur, firstly if the hold down bolts are cast in there is a chance the alignment may be out with that of the pump frame, if not it’s an easy process if there is misalignment modifications and in some instances replacement of one or some of the bolts may be required. Secondly if the plinth does not have cast in bolts and requires Chemical anchors then core drilling for each hold down bolt is required. Simple percussion drill will not work as the plinths are full of steel reinforcing bar so Diamond core drilling is required.

Lifting in: Each pump will be lifted into position on the support plinth using a suitable crane, as long as lifting calculations and experienced riggers are used this is an easy and generally trouble free procedure. In some cases this is what a few people believe is installing a pump.

Packing and levelling and alignment: Each pump requires levelling with steel packers and alignment with the other systems to achieve a plumb installation in some cases where the area is wet during operation of chemicals are present stainless steel packers are needed instead of mild steel. These will be a selection of generally 50mm x 50mm steel plates ranging from 20mm thick down to 1mm thick.  The normal allowable packing space is between 25mm minimum and 40mm maximum but this can vary dependant on the specification for your project. I have seen packing up to 60mm when alignment and levels were out of spec, this should always be a last resort, unfortunately removing and replacing a large cast in concrete pump plinth or cutting and realigning tank nozzles can be prohibitive in cost and in most cases time impact (schedule).

Bolting down: The pump hold down bolts may not be a perfect length. Firstly tighten each bolt and nut to a first pass torque generally by feel of the installer and in a pattern that tensions bolts diagonally across the base frame, like flanges you do not just tension each bolt in a single path around the flange you tension across the flange. Once you have the frame aligned and pre-tensioned, torque each bolt according to the required specification. There will be a minimum and maximum thread protruding from the torqued bolt a minimum of 1.5 threads to a maximum of 2.5 threads or as per the specification document. You may have to cut some bolts down to achieve this; this also implies a requirement to treat the cut ends for corrosion.

Pipe alignment: If the suction and discharge piping is available I would recommend a test fit-up to confirm alignments at this stage to avoid modifications latter on, if there are problems deal with them before they become critical

Drive alignment: The alignment will be either the belt pullies and tensions or a direct drive coupling, in either case the safety guards must be removed and the preliminary alignment done by the mechanical fitter. The Safety guards are to be left off and the drive belts off or coupling undone as the electrical pre-commissioning will require a test bump of the drive motors to ensure correct connection and drive direction. Until this is complete the final alignment and replacement of guards remains undone.

Gland water connection: I would consider the connection of the flexible gland water pipe to the hard pipe from the gland water panel a mechanical item and make sure it is completed during the pump installation. Just like the completion of instrument air lines is that last piece of flexible tube from the hard pipe to the instrument is considered and instrumentation process not piping.

Re- assemble: Once Test bumping is complete, complete an electrical lock out procedure ion the pump as the litem is no live. Complete the alignment of the drives and re-fit the guards and complete a pump installation check sheet to get sign off on the installation.