Most installers are reluctant to remove the OSHA guards when they see them. They believe they are too cumbersome and that it will take too much time. They believe removing the guards is way more hassle then the immediate rewards offer and consequentially do nothing.

What they don’t realize are the benefits of recreating the alignment to the factory workbench standards really are. Not only are they crucial to long life and a satisfied customer but a repeat customer.

Proper installation of base mounted pumps will provide long life to the customer. Anything less will reduce the life expectancy of the bearing frame assembly and the motor. It will also cause coupling insert failures and lead to owner dissatisfaction.

In this issue we remind our readers how to align a base mounted pump and assembly of an OSHA guard. Before we begin let me remind everyone by stating, Armstrong base mounted pumps are factory aligned but must be re aligned in the field to the factory standard. This is common to all pump manufacturers and is stated in the Hydraulic Institute Standards.

Location:
Locate the unit as close as practical to the liquid being pumped, with a short, direct suction pipe. Ensure adequate space is left around the unit for operation, maintenance, service and inspection of parts. Electric motor driven pumps should not be located in damp or dusty location without special protection.

Foundation and Mounting:
The following text and illustrations are offered as general suggestions for the preparation of a satisfactory foundation.

Foundation should be sufficiently substantial to absorb any vibration and permanently support the baseplate at all points. This is essential in maintaining the alignment of a direct coupled unit.

The most satisfactory foundations are made of reinforced concrete and should be at least 2.5 times the shipping weight of the pumping unit. The foundation should be poured well in advance of the installation to allow proper time for drying and curing. Foundation bolts of suitable size should be embedded in the concrete located by a drawing or template. Pipe sleeves, 2.5 times the size of the anchor bolts, should be embedded in the concrete, to permit adjustment of the bolts after the concrete has been poured.

If the unit is to be mounted on fabricated steel work or similar structure, the unit should be set over, or as near as possible to, the supporting beams or walls and to be so supported that the baseplate cannot be distorted nor the alignment disturbed by any yielding or springing of the structure or base.

When the unit has been placed on the foundation, disconnect the coupling. Do not re-connect the coupling until after the unit has been piped, finally aligned and checked for correct direction of rotation.

Place pumping unit on foundation and insert metal wedges on either side of the foundation bolts under base plate leaving approximately 3/4” space for grouting. Carefully level the unit by adjusting the wedges until shafts of pump and driver are leveled. With the proper gauge, check coupling faces and suction and discharge flanges of the pump for vertical position.

Slight misalignment at this point may be corrected by adjusting the wedges.

When the baseplate is completely level, the foundation bolts should be tightened evenly and firmly. After unit has been in operation for about a week, check the leveling. Any misalignment may be corrected by placing shims between base and driver or pump feet.

Grouting:
Construct a dam around the foundation with grout forms, as shown in the illustration and enclosed ends of baseplate. Use a good mixture of non-shrinking grout. The grout should be the consistency of heavy cream. Holes are provided in the base plate to permit pouring of the grout and stirring. The holes also act as air vent holes. Fill under the base completely, stirring to assure proper distribution of the grout. Check to see that the grout flows under the baseplate evenly. When the grout has hardened thoroughly, (usually after 48 hours) tighten the anchor bolts and remove the grout forms.

1. Install foundation bolts.
2. Install grout forms.
3. Fill in base with grouting.

Pump Piping - General:
Guidelines for piping are provided in the Hydraulic Institute Standards.

• Never connect a pump to piping or draw piping into place by forcing at the flanged connections of the pump. This may exert strain on the pump and cause misalignment between pump and motor. Pipe strain will adversely effect the operation of the pump resulting in physical injury and damage to the equipment.
• Always start piping from the pump. Piping must be supported independently of, and line up naturally with, the pump flanges.
• Use as few bends as possible and preferably long radius elbows. Install good supports under suction and discharge piping with anchors near but independent of the pump. Suction and discharge pipes may be increased at pump nozzle to suit pump capacity and particular conditions of installation.
• Do not connect piping to pump until grout has hardened and pump and motor anchor bolts have been tightened.
• It is suggested that expansion loops or joints be properly installed in suction and/or discharge lines when handling liquids at elevated temperatures, so linear expansion of piping will not draw pump out of alignment.
• Use eccentric reducers on suction connection. Lay out the suction line with a continual rise towards the pump without high points, thus eliminating possibility of air pockets that may prevent the pump from operating.
• A strainer of three or four times the area of the suction pipe, installed in the suction line, will prevent the entrance of foreign materials into the pump. 1/8” diameter perforations in the strainer are typical.
• Test suction line for air leaks before starting; this becomes essential with long suction line or static lift.
• Install, at pump suction, a straight pipe of a length equivalent to 4 or 6 times its diameter; this becomes essential when handling liquids above 120°F (49°C). Armstrong suction guides may be used in place of the straight pipe run and in line strainer.
• Install isolation valve(s) in both suction and discharge lines on flooded suction application; this is used mainly to isolate the pump for inspection or repair Install a non-slam check valve in the discharge line between pump and isolation valve to protect pump from excessive back pressure and to prevent water running back through the pump in case of driver failure. Armstrong Flo-Trex valve may be used in place of check valve and isolation valve on pump discharge.

Caution: Discharge valve only must be used to reduce the pump flow, not the suction valve. Care must be taken in the suction line layout and installation, as it is usually the major source of concern in centrifugal pump applications.

Alignment:
Note: Proper alignment is the responsibility of the installer, operator and owner of the unit.

Although the pumping unit is accurately aligned at the factory prior to being shipped, all baseplates are flexible to some extent and should not be relied upon to maintain factory alignment.

Realignment is necessary as follows:

• After the unit has been set level on the foundation.
• After the grout has set and the foundation bolts final tighten.
• After the pipes have been connected.

Accurate alignment is absolutely essential. Proper mechanical operation of the equipment cannot be guaranteed unless the factory alignment is reproduced in the field. All alignment should be made by moving or shimming the motor. The flexible coupling compensates for temperature changes and permits end movement of shafts without them interfering with each other; it will not compensate for misalignment. Faulty alignment will result in noisy pump operation, reduced bearing life, excessive coupling wear and wasted power.

To verify alignment, place a straight edge across the coupling as shown in the following illustration; this must rest evenly on both rims at top, bottom and both sides. With a pair of inside calipers or thickness gauge, check distance between coupling halves at points where straight edge was used; distance must be equal at all points.

This is our Standard Procedure for OSHA GUARD Assembly:

1. Always ensure power supply is locked out before beginning any work on a pump.
2. Bearing Cap is designed to accept the OSHA Guard and is used with all Bearing Assemblies manufactured by Armstrong.
3. Mount Piece # 1 to the bearing Cap using two 3/8” cap screws # 911121.
4. Mount Piece # 2 to the bearing Cap using two 3/8” cap screws # 911121.
5. Put the Vibration Insulating pads on Piece # 3 & 4 facing to the Motor.
6. Mount Piece # 3 & 4 together using two 3/8” cap screws # 911121 and two 3/8” Nuts.
7. Make sure you use the washers for mounting the 4 pieces as supplied.
8. Use the side slots to tighten the bolts to the Bearing Cap firmly.
9. Make sure that the assembled 4- pieces Guard is rigid.
10. Make sure that the Guard Assembly does not touch the coupler & the two shafts.