SPECIFICATION

LEVELING AND INSTALLING OF PACKAGE BASES

Data
Control SPECIFICATION NO. ES 9-414 ISSUED: 12/16/99; PRD 66541-6
Level (Date and PRD No.)

1 REVISION: E

(Letter, Date and CR No.)

Release A; 09/05/03; CR8405
Stamp B; 05/10/05; CR11594
C; 10/10/06; CR14996
D; 09/03/13; PR 38170

Rev ECN Signature and Title Date Pages Affected

Edited by: Mark Mulock
Engineer, Mechanical Analysis 01/30/2015

E Approved By: Frank Peterson

Group Manager, Mechanical Analysis 01/30/2015
87057 All
Approved By: Chris Patterson
Group Manager, Commissioning 01/30/2015

Approved By: Jon Windt

Manager, Package Development & Integration 01/30/2015

ATTENTION
This copyrighted work and the information herein is proprietary to Caterpillar Inc., Solar Turbines
Incorporated, and/or subsidiaries of either. Without express, written proprietor permission, any
copying, disclosure, or use except that for which it is loaned, is prohibited.

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CONTENTS

Section Page

1.0 Purpose ........................................................................................................................... 1

2.0 Reference Information ..................................................................................................... 1
2.1 Flow Chart for Leveling & Installing Single Frame Pkg without Gimbals or AVMs ............ 3
2.2 Flow Chart for Leveling & Installing Split Frame Pkg without Gimbals or AVMs ............... 4
2.3 Flow Chart for Leveling & Installing Single Frame Pkg with Gimbals or AVMs ................. 5
2.4 Flow Chart for Leveling & Installing Split Frame Pkg with Gimbals or AVMs .................... 6
2.5 Flow Chart for Leveling & Installing Split Frame Pkg on Sub-base ................................. 7
3.0 Package Elevation and Leveling Details .......................................................................... 9
3.1 Confirm Pattern and Distance between Frame and Foundation ................................. 9
3.2 Foundation Elevation and Leveling ............................................................................ 9
3.3 Extending Jacking Bolts ............................................................................................. 9
3.4 Frame Elevation and Leveling ................................................................................. 10
3.5 Sub-Base Elevation and Leveling ............................................................................ 11
3.6 Special Note for Non-Sub-Base 3-Point Mounted Packages.................................... 12
3.7 Bolt Package Frame Interface ................................................................................. 12
3.8 Shim or Grout under Datum -C- ............................................................................... 14
3.9 Shim under Datum -E- ............................................................................................. 15
3.10 Jackscrews .............................................................................................................. 15
3.11 Fasten Tie-Down Hardware ..................................................................................... 15
3.12 Soft Foot Check ....................................................................................................... 15
3.13 Place Temporary Supports ...................................................................................... 16
3.14 Remove Temporary Supports .................................................................................. 16
3.15 AVM Uplift Snubbers ............................................................................................... 16
4.0 Alignment Check ........................................................................................................... 17

Figure Page

1 Reference View for Definition of Terms ........................................................................ 2

2 Locations to Measure for Package Level .................................................................... 11
3 Package Frame Match Marks ..................................................................................... 13
4 Recommended Torque Sequence .............................................................................. 13
5 Generic Shimming Practice………………………………………………………………… 14

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 Specification No. ES 9-414

1.0 Purpose

To describe the procedure to place Solar Turbines packages on their foundation, establish vertical
elevation, level package, and prepare for drivetrain alignment.

2.0 Reference Information

2.0a Applicable Documents

• Project Specific Mechanical Interface Drawing (MID)

• Fastener Installation and Torque Values, ES 9-54
• Package Tie-Down Options, PIL 181
• Turbomachinery Package Installation Guideline (TPIM) 1000, 1010, or 1020
• Shaft Alignment Handbook, 3rd Edition, John Piotrowski

2.0b Definition of Terminology

• Package Frame Interface – The location where the driver and driven frame are bolted
together on a package that is constructed with separate frames. Machined pads on both
portions of the package frame form the bolted joint.
• Machined Equipment Mounting Pads – The machined upper pads on the package frame
onto which the equipment is mounted. These include pads for the Engine spring mounts
and trunnions (depending on package type), Gearbox (if applicable), and the Generator or
Compressor.
• Frame Foundation Pads – The thick steel pads at the lowest part of the package frame
that are used to attach the package frame to foundation. These pads have a slot for the
tie-down bolt to pass through, and threaded holes for the jacking bolts to pass through.
• Frame Jacking Pads – Steel pads at the lowest part of the package frame that are used
for jacking purposes only. These pads are smaller than the Frame Foundation Pads, and
are often located near the package frame interface.
• Site Watermark – An immovable location at site that should be chosen as the reference
point to which all equipment is positioned. Careful use of a consistent Site Watermark will
aid in the interfacing of equipment.
• Datum -C- – The plane that is formed by the underside of the Frame Foundation Pads or
the bottom of the frame I-beam in the case of typical PG frames. Solar uses this plane as
the “benchmark” during the design process to assign the vertical relationship of all
component interfaces including ancillary, hydro-mechanical hook-ups, and electrical
connections. It is critical that a relation be established between this design datum, and a
Site Watermark for the installation and set-up of the package.
• Site Elevation Point – A reference point that should be chosen at site to use for package
elevation purposes. The Site Elevation Point should be positioned higher than the Site
Water Mark by a distance equal to the distance between Package Datum -C- and Datum
-D-. Please refer to the Solar Mechanical Installation Drawing for this relationship.
• Datum -D- – The plane that it formed by the machined surfaces located on the tops of the
package lifting bollards/gussets. These points are a reference plane that should be used to
measure the vertical elevation of the package in relation to the Site Elevation Point. These
points are also useful for preliminary package leveling operations, but must not be used for
final package leveling.

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• Gimbal Mounts and Anti-Vibration Mounts (AVMs) – Gimbal mounts are designed to
lessen the influence of platform/deck deflections on offshore packages while AVMs are
intended to reduce the amount of vibration to and from the package. The mounts will
attach to the Frame Foundation Pads or Sub-base. These mounts are optional and will not
be supplied with every package.
• Datum -E- – The plane that is formed by the underside of the Gimbal Mounts or AVMs on
a package that is supplied with these mounts. This datum functions the same way as
Datum -C- does on a package without Gimbals or AVMs.

The above listed terms are shown pictorially in Figure 1 for clarification.

•
•
•
•

Figure 1: Reference View for Definition of Terms

2.0c Use of Flow Charts

The flow charts are intended to make it easier to level and install package bases. They are also used
to remove duplication of pages within this specification. Each flow chart will have shapes for a
predefined process, process, decision, and terminator. Every predefined process refers to a specific
section. This specific section will give more details about the predefined process. Each flow chart is
based on the frame type with or without 3-point package mounts. All of the flow charts are kept to one
page except for the sub-base installation.

Five flow charts are given:

• Single frame package without Gimbals or AVMs,
• Split frame package without Gimbals or AVMs,
• Single frame package with Gimbals or AVMs,
• Split frame package with Gimbals or AVMs, and
• Sub-base (which always includes a Split frame package with Gimbals or AVMs).

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2.1 Flow Chart for Leveling and Installing Single Frame Pkg without Gimbals or AVMs.

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2.2 Flow Chart for Leveling and Installing Split Frame Pkg without Gimbals or AVMs.

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2.3 Flow Chart for Leveling and Installing Single Frame Pkg with Gimbals or AVMs.

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2.4 Flow Chart for Leveling and Installing Split Frame Pkg with Gimbals or AVMs.

Confirm foundation hole pattern and distance

between mount locations matches MID and/or frame
(see section 3.1)

Check foundation elevation & levelness

(see section 3.2)

Tack weld sole plate to the

Place package over
YES foundation or deck
Using split frame package as mounting location with Remove hardware between
(Protect the package by
template to locate sole plates? mounts and sole plates mount and sole plate
ensuring proper grounds are
attached to frame
in place before welding.)
NO

Place each mount at foundation location with

¼” shim under mount

Place ¼” shim on Finish welding around sole plates Remove package from over
each sole plate (weld size determined by customer) mounting location

Place temporary supports

(see section 3.13)

Place each frame at it’s corresponding mounting location

Fasten the mounts to the frames,

if not already done in previous step

Bolt package frame interface Shim under datum -E-

(see section 3.7) (see section 3.9)

Check elevation & levelness Adjust height of temporary supports,

(see sections 3.4 & 3.6) if necessary

NO
Is the package at the Loosen bolts at
proper elevation & level? frame interface

YES

Fasten the mounts to the foundation or deck

Remove temporary supports

(see section 3.14)

Check elevation & levelness

(see sections 3.4 & 3.6)

NO
Is the package at the Shim under datum -E-
proper elevation & level? (see section 3.9)

YES

For AVMs, adjust uplift snubbers Alignment check

(see section 3.15) (see section 4.0)

Package is ready for final alignment

Sheet 1 of 1

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2.5 Flow Chart for Leveling and Installing Pkg on Sub-base with Gimbals or AVMs.

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2.5 Cont. Flow Chart for Leveling and Installing Pkg on Sub-base with Gimbals or AVMs.

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3.0 Package Elevation and Leveling Details

The goal is to move the package to its proper elevation and levelness before going into final drivetrain
alignment. Packages may consist of a single frame or split frame or a sub-base. Each frame
configuration can be mounted directly to the foundation or deck or may use a set of Anti-Vibration
Mounts (AVMs) or gimbals. A sub-base will always include a driver and driven split frame package
with AVMs or gimbals.

3.1 Confirm Pattern and Distance between Frame and Foundation

Before lifting the package into position, confirm that the foundation has been laid out properly,
and that all tie-down holes in the foundation also match the Solar Mechanical Installation
Drawing (MID). Next, measure the distances between the tie-down foot slots on the package
frame and confirm that they match the distances listed on the Solar MID. This process of
checking is to confirm that the tie-down locations in the frame and the foundation will line up
once the package is lifted into position. It is preferable to do this as early as possible, so that
any foundation misalignments can be rectified before expensive lifting equipment is brought to
site.

3.2 Foundation Elevation and Leveling

The next step for the installation of any package is the verification of the foundation onto which
the package will be mounted. It should be verified that there are no high spots in the
foundation between the mounting pads or Sole Plates that could possibly contact the underside
of the frame. The foundation pads or Sole Plates should be at least level with, if not higher than
the rest of the foundation. Each foundation pad or Sole Plate should be installed flat within
0.030”/ft (2.5 mm/m) and coplanar to 0.120” (3.0 mm) to the other pads.

3.3 Extending Jacking Bolts

On some of the larger Solar packages, it is very difficult to raise the package upward using the
package jacking bolts. As the package is lifted into position, the package jacking bolts should
be extended or threaded through the package tie-down foot so that they protrude from the
underside of the foundation feet as far as possible. The package jacking bolts can then be
backed off more easily to lower the package into the level position. Obtain confirmation from
the customer that the area beneath the package jacking bolts has sufficient strength to hold the
package.

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3.4 Frame Elevation and Leveling

It is imperative that a machinist’s level or a measuring tool of equivalent resolution (laser

beacon or transit) be used to measure the levelness of the frame. Frame level must be
measured on the machined equipment mounting pads of the frame, and not the surfaces that
make up Datum -D-. (Datum -D- is only to be used for site elevation.) The tops surfaces of the
frame I-beam are not Engineering-controlled surfaces and a package will not be considered
level if these surfaces are used to measure the levelness of the package.

Caution

Datum -C- on the Solar MID drawing refers to the underside of the driver and
driven frame foundation feet, and not the top surface of the foundation. In the
case of a package that is equipped with AVM or Gimbal mounts, then Datum
-E- is the underside of the AVM or Gimbal. Datum -C- or Datum -E- MUST be
positioned using a consistent relationship with the same Site Watermark that
is used to position all other equipment including ancillary, enclosure, piping,
and electrical. Failure to do so could result in equipment misalignments
during assembly.

Package jacking bolts have been provided in the package tie down feet and package jacking
feet for vertical adjustment for single frame packages and split frame packages without mounts.
Lower the package using the package jacking bolts, and use a surveyor's transit or equivalent
measuring tool to set the elevation of the package leveling datum points to a previously defined
Site Elevation Point. Packages with mounts must use hydraulic jacks to adjust the package
height. The individual Datum -D- surfaces should only be used to level and coplanar to the Site
Elevation Point within 0.060” (1.5 mm).

Once the package is considered to be at the correct elevation using Datum -D-, then the
leveling process can begin. Make sure that the drivetrain equipment hold-down hardware is
fully loosened before attempting to level the base. This includes the hardware used to bolt
down the engine, gearbox, and the generator or compressor. It is possible to constrain the
base in a deflected condition with the drivetrain equipment hardware; the hardware must be
loosened to ensure the package frame is leveled properly. For separate frames, level the
driven package first and then the driver package.

Note:
Final leveling must be done using a calibrated machinist’s level, or instrument of
equivalent resolution on the machined equipment mounting pads of the package.

With the frame interface hardware still loose, all machine mounting pads must be leveled to
within 0.005”/ft (0.42 mm/m). This includes the engine mount pads, gearbox mount pads (if
applicable), and the driven equipment pads. This level criteria is for both the forward to aft as
well as side-to-side direction. Measure the pad level next to the tie-down points of each
piece of equipment as shown in Figure 2, and get all pads within the level criteria.

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= areas on the machined pads where frame level criteria must be held to 0.005”/ft (0.42 mm/m).

Figure 2: Locations to Measure for Package Level

3.5 Sub-Base Elevation and Leveling

Use a surveyor's transit or equivalent measuring tool to set the elevation of the sub-base to a
previously defined Site Elevation Point. Sub-bases must use hydraulic jacks to adjust the
package height. The top of the foundation pads on the sub-base located in the vertical plane
above the mounting locations should be used to level and coplanar to the Site Elevation Point
within 0.060” (1.5 mm).

Also ensure the top of the foundation pads on the sub-base are coplanar within 0.030” (0.76
mm). If sub-base needs leveling, use a hydraulic jack to raise sub-base and add needed shims
under datum -E-.

Note:
This step establishes and maintains all pads in a horizontal plane for the driver
and driven frame installation. This center support is required to limit
deflection and assure proper load distribution of package during assembly.
Additional supports can be added along the sub-base side beams to
ensure a rigid base.

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3.6 Special Note for Non-Sub-Base 3-Point Mounted Packages

It is not always possible to have the forward to aft level within tolerance on all of the machined
pads on a package that is mounted on 3 points. The package will sag under its own weight,
and the machined pads at the forward and aft end of the package will end up being sloped
downward toward the center of the package. Depending on the package size and weight, the
forward to aft slope may be outside of the 0.005”/ft (0.42 mm/m) tolerance. In this case, the
gearbox mount pad becomes the critical point of measurement and this pad must be leveled
within 0.005”/ft (0.42 mm/m) in both the forward to aft, and side to side directions. All
machined pads still must be leveled within 0.005”/ft (0.42 mm/m) from side to side.

Note:
For non-sub-base supported packages with foundation mounting points spanning
more than 35’ (10.7 m), the package sag (mid span deflection) can be as much
as 0.25” (6.4 mm). This is expected and not a reason for concern.

3.7 Bolt Package Frame Interface

Once the two sections of the package are considered level, obtain the proper equipment to
torque the interface bolts. Use the match marks at the package interface pads (when provided)
to ensure the elevation of the bases has been retained in relation to each other. The match
marks are shown below in Figure 3. The elevation between the two sections of the package
should have been set very closely during the prior elevation of Datum -D-, but it needs to be
confirmed that correct elevation has not been lost during leveling. If one of the sections of the
package is higher than the other, then it must be determined which one should be moved. This
must be done evenly and carefully to retain the level of the package.

For packages that do not have match marks or do not match up, these package sections
should be elevated or lowered so the holes in the interface plate align with each other. The
connecting bolts should be able to move freely; they should not be bolt bound. Remove or fill
the incorrect match marks. Make match marks on both Driver and Driven frames and this will
become the new match marks.

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Interface
Match Marks

Figure 3: Package Frame Match Marks

Ensure that both sections of the package are still within the level criteria, and then torque the
interface bolts to their full torque spec. The interface bolts should be re-tightened in the
pattern shown below:

Figure 4: Recommended Torque Sequence

Monitor the level of each package section during the torque sequence, and make sure the
package sections are not moving in relation to one another. Make sure all machined pads have
remained level after the interface bolts have been torqued. If the combined package is not
level, use the package jacking bolts or hydraulic jacks to get the package back within the level
spec. If level cannot be achieved simultaneously on all pads, then the two sections of the
package were shifted during the interface bolt torque-up, and the joint must be loosened again,
and the process must be repeated.

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3.8 Shim or Grout under Datum -C-.

Once the frame is in the level position it must be shimmed or grouted properly to minimize any
possible movement as the tie-down bolts are torqued.

Customer experience has shown the use of Non-Shrinking Epoxy Grout to be the most
successful method for mounting Solar packages on concrete foundations. If grout is chosen to
be used, then a grout contractor should be consulted.

The shims must contact the frame with at least 50 in2 (0.032 m2) of contact area. The shim
should encompass the tie-down bolt as well as possible, and be shaped so that it passes under
the nearest structural member such as the vertical web of the I-beam. The shim does not
need to cover the entire frame foundation foot.

In theory, every mounting surface is perfectly flat but in reality, that is rarely the case. Using a
feeler gage, the gap under each frame pad can be determined in multiple locations. Figure 5
shows a generic example of modifying standard shims to achieve support all the way around
the tie-down location. After placing the shims under the frame foundation pad and torqueing
down the tie-down bolt, physically check to make sure each shim is secure. If a shim is loose,
repeat the process under that specific frame foundation pad.

Figure 5: Generic Shimming Practice (dimensions shown in thousandths of an inch).

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3.9 Shim under Datum -E-

Datum -E- is under the Gimbal or AVM mount.

A 0.25” (6.4 mm) shim should be placed under datum -E-. This allows for vertical adjustment in
both directions. Various sizes of shims for the Gimbal or AVM should have been included.
Use these shims to elevate and level the package.

Additional shims may have to be placed between the base frame and temporary supports to
assist in elevation and leveling of the package.

3.10 Jackscrews

The jackscrews, used for vertical adjustment, must be backed off prior to torqueing the
package to the foundation. The customer can leave the jackscrews in a backed off position or
remove them entirely.

3.11 Fasten Tie-Down Hardware

Once the package is fully shimmed, then torque down the tie-down bolts. Know that the tie-
down hardware torque values are typically specified by the party responsible for the
foundation/deck design. If Solar Turbines is prime then the torque value should be given on
the MID or can be found in ES 9-54. For Solar guidelines on tie-down hardware see PIL-181.

Slight adjustments may have to be made to the shim packs to get the frame back within the
level criteria if the shim packs were crushed down as the tie-down bolt was torqued. If the shim
packs crush down enough to move the frame out of level, then not enough shim was used to fill
the gap.

Note:
Not having enough shim under a foundation pad can lead to the very
undesirable condition known as “soft foot”.

If the package came out of the level spec as the tie-down bolts were torqued, then the shim
packs should be adjusted slightly to bring it back within the level spec.

3.12 Soft Foot Check

Perform a “spring back” check on each frame foundation foot to ensure that there is no
occurrence of “soft foot”. The spring back check should be performed by zeroing a dial
indicator on the surface of the frame mount pad, and un-doing the tie down bolts one at a time.
If the frame tie-down foot moves more than 0.010” (0.25 mm), then the package shimming
needs to be reworked to eliminate the “soft foot”. Re-torque the tie-down bolt before moving to
the next frame foundation pad.

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3.13 Place Temporary Supports

Placing temporary supports are necessary for safety and ease of installation.

Caution

Ensure the foundation or deck can support the combined weight of the driver
and driven packages plus sub-base.

For split frames packages, place four temporary supports at the frame jacking pads near the
interface. Place additional hydraulic support jacks near the mounts to allow for vertical
adjustment and shim placement.

For sub-bases, place a temporary support on each side of the sub-base, centered between
the forward and aft mounts. If the temporary support contact area is less than the width of the
sub-base I-beam flange then center the temporary support under the sub-base I-beam. Place
additional hydraulic support jacks under the sub-base, located at the pads closest to the
driver/driven interface pads. Ensure that the structure under the temporary supports and
hydraulic support jacks can bear the loads. Add shims as necessary to fill gap and fully
support the sub-base. Slowly release the jack until the sub-base rests on the two temporary
supports.

3.14 Remove Temporary Supports

Use hydraulic jacks to raise the frame just high enough to remove the rigid temporary supports.
Remove the temporary supports then slowly lower the hydraulic jacks so the entire bolted
assembly is supported by the designed three-point mount system.

3.15 AVM Uplift Snubbers

After the AVMs are fastened to the frame and deck, then the uplift snubbers need to be
adjusted. Reference the Unpacking, Installation & Maintenance Procedures in the AVM crate.
Extra copies of the procedure can be requested from the supplier.

Caution

If the package ever needs to be moved or lifted (i.e. the load is going to be
removed from the AVMs) after installation, the uplift snubbers must be
unscrewed per the AVM procedures before removing the load. If the uplift
snubbers are not unscrewed before the package is moved or lifted, this could
damage the AVMs.

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4.0 Alignment Check

The package is now ready for a preliminary alignment check. Use the shims provided in the loose
ship kit and adjust rotating equipment as necessary. Fill the package oil tank to the level
recommended on the MID drawing before beginning the final alignment procedure.

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