HPS INSTALLATION & COMMISSIONING PROCEDURE

Main (Motor) Skid Shimming & Leveling:

Once the systems arrive on location the main (motor) skid should be set firstly onto the concrete
foundation. If an extension skid is part of the overall HPS assembly do not set this skid onto the
concrete foundation until the main skid is shimmed and leveled. See steps below.

Steps:

• Clean the concrete foundation of all debris

• Use a string line and run it from one end of the foundation to the other and verify the gaps
between the string and the top of the concrete foundation to note the high and low spots of the
foundation
• Install the 1” steel plates onto the concrete foundation
• Set the main (motor) skid onto the steel plates at each leveling and anchor location
• Make sure the main (motor) skid is centered onto the foundation and adjust if required
• Walk around the skid to note any gaps between the top of the steel plates and the bottom of
the C-channel of the main skid. Use a scale to measure the largest gap on both sides and
starting on the motor end use the jacking bolt to torque down onto the steel plate to bring the
skid upward to match the largest gap value measured. Repeat this along the length moving side
to side until all leveling/anchor locations are lifted.
• Starting at the motor end of the main (motor) skid, use steel shim plates and/or standard motor
shims to fill the gap between the skid and the steel plate.
• Once the gap is filled at this location release the jacking bolt to let the skid rest upon the shims
and steel plate. Check if the shims are loose and if so, add small shims one at a time until the
shim stack is tight between the skid and the steel plate.
• Move to the next leveling/anchor location and fill the gap and verify if the shims are tight once
the jacking bolt is released.
• Before moving to the next location go back to the first location and verify if the shims are still
tight. If so, proceed to the next location to fill with shim. If not, go back to the second location
to adjust the shims and verify tightness of the shims at both the first location and second
location before proceeding.
• Make sure to go back to check the previous shimming location to verify those shims are still
tight before proceeding. Repeat bullet points 8, 9, and 10 until all shimming/leveling locations
are completed and all shims are tight.
• Install anchor bolts
• Hand tighten with ¼ turn of a wrench
The next steps require the removal of the pump barrels from the skid and having the laser straightshot,
adapter, carpenter squares, magnetic bases, dial indicators, and bore sight/target.

TC Bracket Alignment Check to Skid Centerline on main (motor) skid:

• Install the laser adapter to the thrust chamber shaft and then install the laser straightshot (do
you have battery for laser)
• Install carpenter square with magnetic base on the discharge end with the edge of carpenter
square at the centerline of the skid
• Install carpenter square with magnetic base on the suction end between 1st and 2nd saddles with
the edge of carpenter square at the centerline of the skid
• Need to remove the runout of the laser so the dot is a tight circle before moving forward with
alignment
• Once runout is removed and the carpenter squares are in position the laser dot should be split
in half off the edges of the carpenter squares. If not, the TC bracket needs to be adjusted.
• Once adjusted and the TC bracket is on centerline of the skid check the height of the laser dot
on the scale of the carpenter square and make a note of that

Pump Extension Skid Shimming-Alignment to Main (Motor) Skid:

The extension skid has been installed onto the concrete foundation and shimmed and leveled at this
point. The anchor bolts should not be installed prior to the steps to follow below.

• Tighten the extension skid to the main (motor) skid with no shimming between the two skids
• Install the carpenter squares with mag bases on both ends of extension skid on opposite sides-
same as installed on the main (motor) skid
• Use the laser straightshot to check the extension skid straightness to the main (motor) skid.
• If the laser dot does not split the edges of the carpenter squares the skid needs to be adjusted
by adding shim between the main (motor) skid and pump extension skid.
• If shim needs to be added, loosen the hardware and insert the shim and re-tighten and look at
the laser dot location. Repeat the shimming process until the laser dot splits the edges of both
carpenter squares.
• Check the Centerline Height on the carpenter squares and compare to the value noted on the
main (motor) skid. If the Centerline Height needs adjusting, shims will need to be added to the
top half or bottom half between the main (motor) skid and pump extension skid to lift the skid
upward or downward
• If shim needs to be added, loosen the hardware and insert the shim and re-tighten and look at
the laser dot location. Repeat the shimming process until the laser dot is at the desired
Centerline Height
• Once the alignment and Centerline Height are correct need to check the shimming of the
extension skid to the steel plates to make sure all locations are tight. If not, add shim until tight
and check previous location to make sure those shims are still tight.
• Once shimming and leveling are verified and correct, install the anchor bolts and hand tighten
with ¼ turn with a hand wrench
Pump Saddle Alignment:

This step requires the bore sight/target.

• Starting at the last saddle on the discharge end place the bore sight/target with the flat face
facing the laser. There is a hole in the center of the bore sight in which the laser dot should pass
through if the saddle is line up correctly on centerline.
• If saddle is not aligned move the saddle side to side and vertically with the nuts underneath for
the adjustment. Once verified with the bore sight move to the next saddle and make the
adjustments until all of them are completed.

Once the main (motor) skid has been leveled and shimmed install the extension skid (if any) to “rough”
align it to the main (motor) skid. Use the same techniques to level and shim the extension skid but do
not tighten the two skids together at this time.

Install the Pump Barrels:

• Place the two jacks (not bottle jacks or hydraulic jacks) on the main skid (motor skid)
• Make sure the saddle nuts are hand tightened on each saddle that were loosened during the
alignment step
• Carefully install the first pump onto the skid and into the saddles and try not to bump the
saddles which will affect their alignment
• Once first pump is installed check the lateral movement and make note of it.
• Using the pump jacks carefully roll the pump towards the intake without the coupling installed
or o-ring installed on pump base
• The pump should roll freely into the bore of the intake/adapter plate and if not need to adjust
until pump base flange is square/parallel to the intake face
• Once pushed into the bore use a feeler gauge to sweep between the two faces to know if pump
needs further adjustment as the gap should be equal at 12, 3, 6, and 9 positions
• Once alignment is done start the shimming process- install the shim screw with shims that were
removed when laser was attached and tighten to shaft. Make sure to check for burrs once
tightened and if any use a round or flat file to remove the burr.
• Install the TC to pump coupling
• Slowly move the pump towards the coupling slowly and once close bring in slowly and try to
engage coupling to pump shaft by hand while turning the shaft back and forth.
• Once engaged slowly bring the pump towards the intake and use two screws to tighten the
pump base to the intake at 180 degrees apart
• Take the necessary shimming measurements from the head of the pump to know if the amount
of shims installed is correct or some need to be added or removed
• Once shimming is verified and correct install the pump base o-ring and bolt the pump to the
intake with all 12 screws and torque tighten
• At this point I hope you have two more sets of pump jacks to install on the pump skid
• Carefully install the second pump onto the skid and into the saddles and try not to bump the
saddles which will affect their alignment
• Once second pump is installed check the lateral movement and make note of it.
• The next steps are the same as the first pump except instead of bolting to intake you are bolting
to head of the first pump
 • Once second pump is also ready meaning shimmed properly to the first pump with o-ring and
coupling installed we are ready to bring up the lower pump saddles to touch the belly of the
pumps
• Once the pump saddles are touching use one of the magnetic bases with a dial indicator and
place underneath the pump and zero out the indicator. Using two people, cross-tighten the
saddles and watch the indicator as it will move when one person tightens and when the other
person tightens it should go back to zero. Do this for all saddles until completed.
• Install the mag base with dial indicator under the pump near the pump jacks and zero the
indicator. Release the pump jacks and watch the indicator as it should remain at zero. Do this
for all jacks installed.
• Install the top clamps and make sure the gaps on the sides are even and DO NOT OVERTIGHTEN
these.
• Install the discharge flange assembly and make sure o-ring is installed.

MOTOR to Pump Alignment:

• Verify the distance between shaft ends is correct for the spacer coupling length. If not, adjust.
• Perform the motor alignment and make sure we have SMILEY faces in both vertical and
horizontal
• Properly torque tighten motor coupling and make sure to tighten hub set screws to proper
torque value
• Install the coupling guard

At this point the suction and discharge piping can be installed but before tightening we need to make
sure the flanges are parallel to one another and no horizontal or vertical offset or angularity and if so
needs to be corrected.

Once piping is re-connected the system can be ready to start.

Once started and running for 15 minutes we can check the vibration levels and we still may need to
make adjustments if the vibration is not where we need it.