API 610 BASEPLATE AND NOZZLE LOADING CRITERIA. by dames E. Steiger Lead Design Engineer United Centrifugal Pumps San Jose, California James E, Steiger ts a Lead Design Engineer with United Centnfuga! Pumps of San Jose, Calfornia. Prior to Joining United, he was involued with centrifugal ‘pumps forthe nuclear industry ot Pcie "| Pumps. He has on M.S. desree in Me- {| chanical Engineering from Brigham | Youna University, andi oreisteredpro- ©) fessional engineer in the State of California, ABSTRACT ‘The baseplate and nozzle loading criteria in the December 11985 draft version of API610 7th Eaitionissubstantilly diferent from the criteria found in the 6th Editon, The optional heavy duty baseplate criterion has been eliminated, an ungrouted ‘baseplate stifiness criterion has been added so that designs can ’be easly verified by a relatively Inexpensive test in the manufac- turer's shop, and Append, Effect of External Nozale Forces and Moments on Piping Design, has been retitled and rewritten. ‘These changes and others have been made 0 clarity the intent of the document, and to make the design criteria both achievable for the manufacturer and enforceable by the purchaser. ‘Shortcomings found in sub-sections 2.4, 3.3.1, and Appendix € of the 6th Edition are discussed as is the’ corresponding modified text found in the proposed 7th Editon of API 610 Standard. Results are provided of routed and ungrouted pump: baseplate stifness tests, An evaluation chart and baseplate checklist are also included. INTRODUCTION ‘eally a baseplate is a structure, generally fabricated from ‘tae, 10 which shaft coupled pieces of rotating equipment are ‘mounted and heldin alignment or kouble free operation, Proper design, manufacturing, handling and installation are key ingre- dents necessary f0 provide reliable service. When one of the pieces of equipment is a pump that is subjected to externa) loadings viathe attached piping, maintaining shaft alignmentand ‘minimizing equipment distress can become more complicated. Recognizing this, API Standard 610 puts more emphasis on ‘external piping loads and baseplate design than any other rolating equipment standard, Thies justified, due tothe number of centrifugal pumps used in a refinery and the economic- rehabiity trade-off associated with the magnitude of allowable Piping loads. Pump manulacturers and rotating equipment engineers con. ‘cerned with maintaining the shaft alignment of coupled equip. ‘ment for operational reliability, prefer small piping loads. Several ‘arguments can be made'a defend this postion. Field experience Indicates that design or calculated piping loads can be sign cantly different from the loads actually imposed on the installed ‘equipment. The pump-baseplate assembly represents a complex us structure whose response to piping loads dificult topredict with a high degree of certainty ‘Contractor and piping designers prefer langer piping loads “which result simpler and significantly less expensive piping configurations. The argument is that the pump manufacturers {and rotating equipment engineers areto0 conservative and the higher piping loads which have been proven by past experience do not usually lead to significant operability problems. ‘Before the 6th Edlion of API610 was published, there were no industry accepted standards or allowable piping loads acting on central pumps [1] (The 5th Edition only addressed pumps: with discharge noses four Inches and smaller in diameter [2). Each pump manufactures, contractor and user had their own standards which frequently complicated plant design, The 6th Edition addressed this problem by establishing two sels of standards, one for the pump manufacturer (Table 2 of API610, presented herein as Figure 1), and suggested values for the Diping designer (Appendix C). Besides providing standardized allowable piping loads, the 6th Editon of API 610 defines two stifness criteria for pump-baseplate and support assemblies (Standard-2.43 and Heavy Duty-2.4.6). These criteria were added to establish uniformity to the structaal design of pump- baseplate assemblies. The 1985 Pressure Vessel Research Com: mittee (PURC) Pump-Piping Interaction Experience Survey Indicates that API was right on target with the intent of their document [3]. The survey Indicates that there is a significant _pump-piping!nteraction problem and thatit has an upper annual Impact on the order of one-half bilion dollars ‘Although the intent of the 6th Edition was good, a careful review ofthe text found in Section 2.4 and Appendix C indicates thatthe specified design criteria are often vague, and, thereore, subject to intenpretation, In most instances, there Is not a cost ‘effective method of proving that the design ctteria are being met. Pereeeees Si emer ae pr dr muni Figure 1. Table 2—Noazle Loadings (1)4 PROCEEDINGS OF THE THIRD INTERNATIONAL PUMP SYMPOSIUM With such complicated structures, analytical methods are only as valid as the assumptions that are made concerning the behavior, of the equipment. The standard baseplate sifness criteria is lificultto achieve and frequently results in designs thatcannotbe ‘economically justified except by the knowledgeable user. In most Instances, the heavy duty baseplate sifines criteria can only be achieved on paper by making appropriate assumptions. As a result of these problems, the intent ofthe 6th Edition concerning baseplate and nozzle loading criteria is not being achieved. ‘With so many purchasers and users buying equipment to the API 610 6th Edition specifications, pump manufoctures are forced into advertising compliance fo remain in business. As a result of the previously mentioned shortcomings, there are wide variations in the structural design of pump-baseplate assemblies ‘among pump manufacturers, For some manufacturers, the 6th Edition had a significant impact on the structural design of their [pump cases and baseplates[4]. On the other hand, some of the ‘pumping equipment being sold appears to be of the Sth Edition Vintage, with no modifications whatsoever. In other instances, ‘manulacturers have apparently made different interpretations as to the meaning ofthe sifess criteria found in Section 2.4, The ‘Ith Edition Task Force has made significant changes tothe new 610 Standard (December 1985 Draft) in order to eliminate ambiguity of text and to make the sifiness requiternents realise ‘and economically enforceable [5) ‘The intent herein is to make the reader more knowledgeable about API 610 baseplate and nozzle loading criteria, so that better pumping equipment willbe selected. Shortcomings ofthe 6th Edition Standard have been critqued and the new 7th Editon Standard is presented. Grouted and ungrouted stifiness test data for end suction overhung pumps, along with pertinent ras been shattened fo one paragraph of text. Subsections that deal with casing design are now found in Section 2.2 (Pressure Casings), while the requirements for baseplates are found in Section 3.3 (Mounting Plates). Section 2.4 is shown herein along ‘with the related figures, table and referenced subsections, Table 2 (Figure 24) incorporates the same component nozzle loadings that appear in the 6th Edition Standard (Figure 1). An allowable resultant force and moment for each nazae size is also provided ‘These resutant values are used by the piping designer and are calculates irom the tabulated component loads. A note has also been added to Table 2 (proposed 7th Edition), clarifying that each ofthe loads shown represent an allowable range that varies from plus to minus the specifed value. Significant changes found In Section 2.4 and subsection 2.2.8 have been italiczed. Due to the previous remarks concerning the shortcomings of the 6th Edition Standard, these changes are believed to be sell explanat- cory. Subsections 3.3.1 Sand Appencix Fare essentially new and therefore comments follow the text. Section 2.4—External Nozale Sorces ‘and Moments (7th Edition) Pumps with noes 16 inches and smaller in size and ‘with casings constructed of steel or alloy steel shall be Figure 24, Table 2—Nozle Loadings {5} capable of satisfactory operation when subjected tothe fores and momenis shown in Table 2 (Figure 24 herein). The vendor shall submit nozzle loadings for pump anges layer than 16 inches and for pump Casings consiructed of materials other than steel or alloy tee. The range of allowable forces and moments ‘given in Table 2 (see Figure 1 through 5for orientation, ie. Figure 25 herein ae to be used by the vendor (see section 2.2.8 and 3.3.1.5) for parmp and baseplate design and by the piping designer (see Appendix M) to establish acceptable piping configuration. Two effec of noze loading are considered: distortion of the pump casing see2.2.8) and misalignmentof the pump and driver shafts (see 3.3.1.5), Vertical and vertical inline pumps driven by integrally mounted electric ‘motors whose shaft alignment isnot affected by exter nal norée ioads may be subjected to forces and moments that ae double the values shou in Table 2 Bl Figure 25. Figures 1-5 [5} ‘Section 2.2—Pressure Casings 7th Edtion Subsection 228 22.8 The pump pressure casing shall be capable of withstanding double the forces and moments in Table 2, applied simultaneously to the pump through each ‘nozzle, plus internal pressure, without distortion which would impair operation of the pump or sea! [5]126 PROCEEDINGS OF THE THIRD INTERNATIONAL PUMP SYMPOSIUM Pump Shaft Displacement. Loading Condition Inches Microseters Direction Mr 0.003 % Me 0.007 178 NOTE: Ny and WZ equal the sum of the Towable suction and discharge rozzle wonents fron Table 2. We = OM suctiow * (MY prscHARGE He = UEsuction * “2 orscHaRGe Figure 26, Table 10—Stifness Criteria for Ungrouted Base. plates. Subsection 3.3.1—Baseplates for Horizontal Pumps Subsection 3.3.1.5 3.3.5 To minimize misalignment of pump and driver ‘Shafts due tothe piping load effects, baseplatesshallbe constructed with sufficient structural stifness to limit pump shaft dsplacementat the drive end of theshaftor al the register fit of the coupling bub to the values shown in Table 10 (Figure26, herein). Grout or bearing housing supports (wobble plates} shall not be used asa means of obtaining the required stifness. Its recog rized that grout can signifcantly increase the stifiness of the baseplate assembly, by neglecting this effect, base: plate construction can easily be verified by testing atthe vendor's shop (see 3.3.1.6) [5} ‘Subsection 3.3.1.6 3.3.1.6 lispealled, the vendor shalltestto demonstrate that the pump and its baseplate assembly, when an- cchored at foundation bolt hole locations with any bearing housing support disconnected, are in com pliance with the requirements of 33.1.5. The pump Easing shall be subjected to moments MYc and MZe, so thatthe coresponding Zand Y shaftdisplacementscan bbe measured and recorded. The shat displacement measurements shall be absolute (not relative to the baseplate). For record purposes, the vendor’ test data shall include a schematic drawing ofthe test setup, the calculated momantioads (MYc and MZ), the applied ‘moment loads, and their corresponding displacements at the drive end of the pump shaft [5] AAs can be seen, Subsections 3.3.1.5 and 3.3.1.6 represent significant and needed departures from the pump support assembly sifinss criteria found inthe 6th Edition, Thisis dye to the fact that the design and compliance tet criteria do not take creitfor grout, even though twill be placed when the baseplates are installed at the jobsite, With this departure, the criteria ‘become economically enforceable. A simple test rig that can be used to measure pump shaft displacement as required by Subsections 33.1.5. and 3.3.1.6 is strated in Figures 27 and 228. The weight hanging from the suction nozzle pipingcreates the applied moment (force X distance). Notice that the shaft dis- placements ate being measured with respect to the floor and not with respect to the baseplate structure. Ten 3id.n concrete anchors have been used to hold the bateplate (API Standard "Number 8) to the shop floor Plotted test data for this ungrouted Figure 27. MZC Loading Technique forthe Ungrouted Baseplate ‘Compliance Test. Figure 28. MYC Loading Technique for the plate Compliance Test 7] gems A Figure 29, Plotted Deta foran Ungrouted Boseplate Compliance Test.TUTORIAL ON BASEPLATES AND FOUNDATIONS 127 ‘compliance fest are show tn Figure 29. Approximately four to twelve huss time is needed to set-up, conduct and document this type of a test The more sophisticated apparatus shawn in Figures 11-12 could also be used to apply loads to pump casing Dial indicators or proximity probes can be used to measure shaft sisplacement “The design and acceptance criteria for 7th Eaton pump baseplate assembles are based on two (MYZ and MZY) of the eighteen previously discussed displacement constants (Figure 26). The fsteriterion (MY loadingand2 displacement) provides ‘a measure ofthe torsional rigidity ofthe pump pedestal support ‘assembly while the second eriterion (MZ loading and Y displace- rent) reflects the bending sfness ofthe support pedestals and the torionalsifness ofthe pump feet. tis interesting to see how these criteria vary with pump size (Figure 30). Sifiness constants (KYZ and KZY) which are the resipracals of the displacement ‘constants (MYZ and MZY) increase the pump size. As indicated, ‘12x14 pump denoted by a value of 30 on the horizontal axis ‘must be nine times sifer than 233 (abscissa value of five) due to the variation in allowable piping loads (Table 2), Alsoindicated fn Figure 30, ate test points for four 6th Edition pumps. These test points demonstrate that the new requirements are indeed. realistic and achievable PUMP & BASEPLATE STIFFNESS CHARGE NOZZLE SIZE, INCHES Figure 30. Ungrouted Pump-Baseplese Stfiness Criteria [5, (Table 10) Figure 31. Drip Pan Type Baseplate with Tivo Inch Rounded Corners. Figure 32. Drip Rim Type Baseplate with Two Inch Rounded Comers Subsection 33.1.9 3.3.1.9 The outside corners of the baseplate in contact With the grout shall have at least2-ineh (50-milimeter) radi (in the plan view? [5] This new requitement has been added to reduce the stress concentration associated with square corners and thereby pre vent grout crackage. Baseplates with rounded corners are ilus- trated in Figutes 31 and 32 ‘Appendix F—Criteria For Piping Design ‘APPENDIX F (called APPENDIX B herein) consists of three ‘main sections 1) F1—Horizontal Pumps with Grouted Basep- lates, 2) F2—verteal inline Pumps, 3) F3—Sample Problems {indluded to demonstrate the intent and use of the equations contained within the Appendix). Section F2 and F3 wil not be presented nor discussed herein. Secton F1 was eure aking, into account the relaxation of the pump baseplate sifiness exiteria, The sifness requirements (shown in Figure 26) resltin ‘ump equipment that § approximately 50 persent of what was Speded for 6h Edition standard baseplates. To clr to the Piping designer and the user the effects of piping loads greater than Table 2 values upper bounds for anticipated shat dsplace- ‘ment have been provided. Subsection E1.2's very similar othe piping oad eri found in Appendix Cfo standard baseplates. Subsections 12.1 and 1.2.2 ae equivalentto the old Appen- dix C erteria for nozde sizes eight inches and small. Above eight inches, Subsecton F12.1 permis larger resultant piping Toads on the individual nozles. Subsection F:1,2.2 contos stress and strain in the pump easing. Suosedin F1.2.3 is new and limits the magritude of load that can be imposed on the pump isl. This erteron contels the magnitude ofthe shal displace: ment due to fexbiity inthe pump baseplate assembly. Without ‘Subsection FJ.2.3, pump shat cisplacements in the 0,020 in range would be possible. It should be understood thatthe shaft displacement values cited in Appendix F assume that bracket support is not present. With bracket supports, shaft displace: ments would be substantially les. CONCLUSIONS ‘AP! 610 6th Edition baseplate and nozzle loading citeriahave been examined and found to be vague and subject o interpreta tion, The grouted baseplate test program developed by the API 610 7th Edition Task Force demonstrated thatthe standard and heavy-duty baseplate sifness criteria found in the 6h Edition of ‘Standard 610 were not being achieved and that there was a need, for more realistic criteria that could be enforced with a simple,128 PROCEEDINGS OF THE THIRD INTERNATIONAL PUMP SYMPOSIUM Inexpensive compliance test. The proposed 7th Edition of API Standard 610 (December 1985 Draft) addresses this problem and the other major shortcomings found in the 6th Eaition APPENDICES APPENDIX A. wee ayer EES eE Se zi i @ > i a a 5 & Fie e Appendix F Criteria For Piping Design Section 4.1—Horizontal Pumps with Grouted Baseplates NOTE: These criteria do not apply to pumping equipment purchased in accordance with 1.1.2 of this standard F1 Hortontal Pumps with Grouted Baseplates E11 Acceptable piping configurations shall not cause exces sive distortion ofthe pump casing and shall not cause excessive ‘misalignment between the ends of the pump and driver shafts. Piping configurations that produce component nozae loads that lie within the ranges specified in Table 2 willmit casing distortion to one-half the vendor's design criterion (see 2.2.8) and will ‘ensure pump shaft displacements of less than 0.010 inch. 1.2 Piping configurations that produce loads outside the ranges specified in Table 2 are aso acceptable without consulta- tion with the pump vendor, provided the conditions specified in F.L2.1 through F..2.3 ave satisfied, Satisfying these conditions will ensure that any pump casing distoriton will be within the vendor's design criteria (see 2.2.8) and thatthe displacement of the pump shaft wil be less than 0.015 inch, 1.2.1 The individual component forces and moments acting ‘on each pump nozzle lange shallnot exceed thaerange specified In Table 2 by a factor of more than 2 1.2.2 The resultant applied force (FRSq, FRDg) and the resultant applied moment (MRS, MRD,) acting on each pump nozzle flange shall satisfy the appropriate interaction equation (Equations F-1 and F-2) (FRSy/1SFRSr2) +(MRSq/1.5MRSre)<2 (Fl) (FRDg/1.SFRDze)+(MRD\/L.5SMRDrel=2_(F-2) 1.2.3 Theapplied component forces and momentsacting on ‘each pump nozde lange must be translated and resolved to the center ofthe pump. The magnitude ofthe resultant applied force (FRC,), the resultantapplied moment (MRC4),and the applied ‘moment (MZC,) shal be limited by Equations F-3, F-4, and F-5, (The sign convention shown in Figures 3-5 and the righthand tule should be used in evaluating these equations.) FRC,<15(FRSr2+ RD) 3) MZCq<2.0(MZSq2-+MZDy2) ray MRC y<1.5(MRStp-+MRDr2) (5) where FRCq= [(FXCa)? + (FYCa)? + (FZCq)*18? FXCq™ FS, + FAD, FYCa=FYSa+FYDs, FZCq=F2Sq+FZDy MRC = (MC)? + (MYC + (MZCay MXCq=MXSq + MXDg ~ (FYSall¢8) + (FYD4)@D) = (F2Sq)(98)~ (FD UDA MYC a=MYSq+ MYDa + EXSal¢S) + FXD§I2D) ~ (P28) x8)~ (FDA IDIVIZ -MZSq + MZDx— (FXSq) VS) + (EXDa)yD) (PS AS) FYD AD IIAZ MZCa, 1.3 Piping configurations that produce loads greater than those allowed in Faa or E12 shall be mutually approved by the purchaser or the vendor ‘Nomenclature F force, in pounds. FR resultant force. (FRS, and FRD, are calculated by the squate-root-of-the-squafes method us: ing the applied component forces acting on the noule flange. FRSrp and FRDry are extracted from Table 2 using the appropriate nozzle size.) 'M moment, in foot-pounds. [MR resultant moment. (MRS, and MRD, are cal- culated by the square-root-ofthe-squares ‘method using the applied component mo- ‘ments acting on the nozzle flange. MRSro and ‘MRDr2 are extracted from Table 2 using the appropriate nozde size.)‘TUTORIAL ON BASEPLATES AND FOUNDATIONS 129 center of the pump, as defined by the ntersec- tion of the pump shaft centerline and the sup- port pedesial centerline (see Figures 3-5). § suction now. D discharge nozie, Subscript A. applied loads. Subscript T2 loads extracted from Table 2 x, ¥,2 location coordinates of the novale flanges with respect to the center of the pump. X, ¥,Z direction of the loads (see Figures 3-5). APPENDIX C Baseplate Checklist (5) 1. Will the baseplate assembly be lifted with all equipment ‘mounted? ‘a. Ave the structural members properly zed? ’, Ave attachment welds adequate? Are liting lugs provided and properly located? 4d. Are spreader bars required for lifting? ‘e. Will any piping that runs the length of the baseplate be damaged during liting? 2. Will the baseplate be grouted in place? a. Will the footprint ofthe baseplate conform to the standard dimensions found in Appendix H? '. Are grout holes of adequate size and properly located? Ate 1/2 inch vent holes properly located? 4. Are cross members properly located, attached and shaped. 10 lock pesiively into the grout? fe, Have vertical leveling screws been spectied? Ae there they properly located and of adequate size? {Are the outside corners ofthe baseplate rounded to prevent grout cracking due to stress concentration? 19. Willepoxy grout be used? Isa suitable primer being appled to all groutable surfaces of the baseplate? ‘3. Should the optional stifness test be spexfied? ‘a. What is the soverty of the service? '. What ate the construction features of the pump-baseplate assembly? 1. Thickness of tendon connecting pump casing to foot pad? 2, Size and number of pump hold-down capscrews? 3, Size, shape, height and thickness of support pedestals? seals and where ar the support pedesis atached the aseplate? . What ate the construction features of installed pump ‘easeplate assemblies in similar service? Do they have good maintenance records? d. Does the vendor have witnessed sifiness test data for similar equipment? @ What will tre vendor charge to perform the optional stifness test? 4, Whats the operating sped and the length ofthe couping spacer ‘g. What is the magnitude of the calculated piping loads? fi Are the calculated piping loads realistic? Is the pump handling hot product? Wil there be operating conditiors that cause temperature swings? }. Will the equipment be realigned when itis hot? 4, Have alignmert positioning screws been provided? 5. Does the baseplate drain rim or pan have adequate slope? 6, Does the baseplate extend under the pump and drive ‘elements to contain leakage? REFERENCES 1, American Petroleum Institute, "Centrifugal Pumps for Gen: eral Refinery Services,” API Standard 610, Six Editon (1981), 2. American Petroleum Institute, “Centrifugal Pumps for Gen- eral Refinery Services,” API Standard 610, Fith Edition ag) 3, Payne, JLR,, “PVRC Pump Piping Interaction Experience Survey,” Pressure Vessel Research Committee- Welding Re- search Council (February 1985), 4, Steiger JLE,, “Horizontal Process Pump Modifications to Comply with API 610 Six Edtion Forces and Moments” Proceedings othe Fist international Pump Symposium, ‘Texas A&M Univers, College Station, Texas, pp. 47-55, (May 1984) 5. American Petroleum Insitute, “Centrifugal Pumps for Gen- eral Refinery Services,” Proposed API Standaré 610, Sev: enth Edition (December 1985 Dra 6. “Boller and Pressure Vessel Code," Section ViPressure Vessels Divison 1, p. 187 (1983). 7. James, WH,, “ry Spring Mounted Pumps," Hycrocarbon. Processing, pp. 247-250 (September 1978) 8. Hortll, WR., "Free Baseplates Reduce Cost and Increase Rebabily,” Hydrocarbon Processing, pp. 177-180 (Apri 1981). 9. Jones, WB. and Hayrapetin, V, “API Nozze Loading Data Reduction Program,” Pacic Bumps Division, Desset Indus- tries (September 12, 1984), 10. Bussemaker FJ, “Design Aspects of Basepates for Oil and Petrochemical industy Pumps,” Thensitution of Mechan\- ‘al Engineers 45/1. pp. 135-641 (1981). 1. Muay, Je, M.G., Better Pump Grouting.” Hydrocarbon Processing, pp. 100-104 (Februery 1974)