Pump Division. Type MPT Centrifugal Pumps

Transcription

1 Pump Division Type MPT Centrifugal Pumps USER INSTRUCTIONS: INSTALLATION, OPERATION, MAINTENANCE PCN= (E) These instructions must be read prior to installing, operating, using and maintaining this equipment. 1of 41

2 CONTENTS Page CONTENTS INTRODUCTION AND SAFETY General CE marking and approvals Disclaimer Copyright Duty conditions Safety Summary of safety markings Personnel qualification and training Safety action Products used in potentially explosive atmospheres Safety Labels Nameplates Warning labels Noise level TRANSPORT AND STORAGE Consignment receipt and unpacking Handling Lifting Storage Storage General Storage Long Term Recycling and end of product life DESCRIPTION General Design of major parts Pump casing Valve flap Impeller Wear plate Cover Plate Shaft Stuffing box (Seal housing) Shaft seal Bearing housing Pump bearings and lubrication Impeller adjustment Driver Flexible coupling..error! Bookmark not defined Coupling guards Baseplates Performance and operating limits Performance Pressure limits Flange loads Pump lubricant data Recommended bolting and screw torques Temperature limitations INSTALLATION Location Foundation Install pump units Mount baseplate Install baseplate Grouting Grouting foundation bolts Grouting baseplate Grouting baseplate prevents movement Initial alignment Thermal expansion Alignment methods Piping Protective covers Forces and moments on pump flanges Inlet pipe Flow and pump suction Fitting valves and easy maintenance Piping and fittings should be flushed before use Corrosive liquids Electrical Connections Qualified electrician Wiring motor Emergency stopping Rotation direction Final shaft alignment check COMISSIONING STARTUP, OPERATION, AND SHUTDOWN Making ready for operation Lubrication Pre-operation check list Starting the pump Start-up Priming plug Discharge line Correct rotation Check outlet pressure and flow Pressure Outlet valve Check the pump unit for vibration or overheating Running Mechanical seals Stop/start frequency Stopping and shutdown Close the outlet valve Stop the pump Prolonged shutdowns MAINTENANCE...20 Page 2 of 41

3 6.1 Maintenance schedule Routine inspection (daily/weekly) Periodic inspection (6 monthly) Lubrication data Oil lubricated bearings and mechanical seals Mechanical seals Dismantling General Dismantling the pump Genuine Flowserve parts Part numbers and identification Replacing coupling parts Complete disassembly Examination of parts Used parts Casing, impeller, wear plate, and seal housing Shaft, keys, and impeller setscrew Gaskets, O-rings, and lip seals Bearings Suction flange and flap valve Mechanical seal Assembly To assemble the pump consult the sectional drawings Prepare Bearings Mechanical seal Impeller Suction flange Coverplate/wear plate Back pull-out assembly/case Lubrication Final assembly Spare Parts Ordering of spares Pump details Genuine parts Recommended spares Storage of spares FAULTS; CAUSES AND REMEDIES PARTS LIST AND DRAWINGS Sectional Arrangement and Parts List Drawings MODEL Sectional Arrangement and Parts List Drawings MODEL Sectional Arrangement and Parts List Drawings MODEL Sectional Arrangement and Parts List Drawings MODEL Sectional Arrangement and Parts List Drawings MODEL Mechanical Seal Sectional Arrangement and Parts List Drawing 8.7 General Arrangement Drawing...Error! Bookmark not defined. 9 CERTIFICATION OTHER RELEVANT DOCUMENTATION AND MANUALS Supplementary Instruction Manuals Change notes...37 Page 3 of 41

4 1 INTRODUCTION AND SAFETY 1.1 General These instructions must always be kept close to the product's operating location or directly with the product. Flowserve s products are designed, developed, and manufactured with state-of-the-art technologies in modern facilities. The unit is produced with great care and commitment to continuous quality control, utilizing sophisticated quality techniques and safety requirements. Flowserve is committed to continuous quality improvement and being at your service for any further information about the product in its installation and operation or about its support products, repair, and diagnostic services. These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements and applicable safety and health laws/regulations. These instructions must be read prior to installing, operating, using, and maintaining the equipment in any region worldwide. The equipment must not be put into service until all the conditions relating to safety, noted in the instructions, have been met. 1.2 CE marking and approvals It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and, where applicable, Low Voltage Equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED), and Equipment for Potentially Explosive Atmospheres (ATEX). Where applicable, the Directives and any additional Approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable, this document incorporates information relevant to these Directives and Approvals. To confirm the Approvals applying and if the product is CE marked, check the serial number plate markings and the Certification. (See section 9, Certification.) 1.3 Disclaimer Information in these User Instructions is believed to be reliable. In spite of all the efforts of Flowserve to provide sound and all necessary information the content of this manual may appear insufficient and is not guaranteed by Flowserve as to its completeness or accuracy. Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested, and incorporated into the products to help ensure continued product quality and performance in use. As Flowserve cannot test parts and accessories sourced from other vendors, the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install, or use authorized Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by Flowserve s warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in their use. 1.4 Copyright All rights reserved. No part of these instructions may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without prior permission of Flowserve Pump Division. 1.5 Duty conditions This product has been selected to meet the specifications of your purchase order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions. The product must not be operated beyond the parameters specified for the application. If there is any doubt as to the suitability of the product for the application intended, contact Flowserve for advice, quoting the serial number. If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature, or duty), it is requested that the user seeks Flowserve s written agreement before start-up. Page 4 of 41

5 1.6 Safety Summary of safety markings These User Instructions contain specific safety markings where non-observance of an instruction would cause hazards. The specific safety markings are: This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life. This symbol indicates safety instructions where non-compliance would affect personal safety and could result in loss of life. This symbol indicates hazardous and toxic fluid safety instructions where non-compliance would affect personal safety and could result in loss of life. This symbol indicates safety instructions where non-compliance will involve some risk to safe operation and personal safety and would damage the equipment or property. This symbol indicates explosive atmosphere zone marking according to ATEX. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion. This sign is not a safety symbol but indicates an important instruction in the assembly process Personnel qualification and training All personnel involved in the operation, installation, inspection, and maintenance of the unit must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required, the operator may commission the manufacturer/supplier to provide applicable training. Always coordinate repair activity with operations and health and safety personnel and follow all plant safety requirements and applicable safety and health laws and regulations Safety action This is a summary of conditions and actions to help prevent injury to personnel and damage to the environment and to equipment. For products used in potentially explosive atmospheres section also applies. NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER (Lock out.) DRAIN THE PUMP AND ISOLATE PIPING BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous. FLUOROELASTOMERS (When fitted.) When a pump has experienced temperatures over 250 C (482 F), partial decomposition of fluoroelastomers (example: Viton) will occur. In this condition these are extremely dangerous and skin contact must be avoided. HANDLING COMPONENTS Many precision parts have sharp corners and the wearing of appropriate safety gloves and equipment is required when handling these components. To lift heavy pieces above 25 kg (55 lb) use a crane appropriate for the mass and in accordance with current local regulations. NEVER OPERATE THE PUMP WITHOUT THE COUPLING GUARD AND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED GUARDS MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL THERMAL SHOCK Rapid changes in the temperature of the liquid within the pump can cause thermal shock, which can result in damage or breakage of components and should be avoided. NEVER APPLY HEAT TO REMOVE IMPELLER Trapped lubricant or vapor could cause an explosion. HOT (and cold) PARTS If hot or freezing components or auxiliary heating equipment can present a danger to operators and persons entering the immediate area, action must be taken to avoid accidental contact (such as shielding). If complete protection is not possible, the machine access must be limited to maintenance staff only with clear visual warnings and indicators to those entering the immediate area. Note: bearing housings must not be insulated and drive motors and bearings may be hot. If the temperature is greater than 68 C (175 F), below 5 C (20 F) in a restricted zone, or exceeds local regulations, action as above shall be taken. Page 5 of 41

6 HAZARDOUS LIQUIDS When the pump is handling hazardous liquids, care must be taken to avoid exposure to the liquid by appropriate pump placement, limiting personnel access, and by operator training. If the liquid is flammable and/or explosive, strict safety procedures must be applied. Gland packing must not be used when pumping hazardous liquids. PREVENT EXCESSIVE EXTERNAL PIPE LOAD Do not use pump as a support for piping. Do not mount expansion joints, unless allowed by Flowserve in writing, so that their force, due to internal pressure, acts on the pump flange. ENSURE CORRECT LUBRICATION (See section 6.2, Lubrication Data.) NEVER EXCEED THE MAXIMUM DESIGN PRESSURE (MDP) AT THE TEMPERATURE SHOWN ON THE PUMP NAMEPLATE (See section 3.3, Performance and operating limits, for pressure versus temperature ratings based on the material of construction.) NEVER OPERATE THE PUMP WITH THE DISCHARGE VALVE CLOSED (Unless otherwise instructed at a specific point in the User Instructions.) NEVER RUN THE PUMP DRY OR WITHOUT PROPER PRIME (Casing flooded) NEVER OPERATE THE PUMP WITH THE SUCTION VALVE CLOSED It should be fully opened when the pump is running. NEVER OPERATE THE PUMP AT ZERO FLOW OR FOR EXTENDED PERIODS BELOW THE MINIMUM CONTINUOUS FLOW THE PUMP SHAFT MUST TURN CLOCKWISE WHEN VIEWED FROM THE MOTOR END It is absolutely essential that the rotation of the motor be checked before installation of the coupling spacer and starting the pump. Incorrect rotation of the pump for even a short period can unscrew the impeller, which can cause significant damage Products used in potentially explosive atmospheres Always check that the driver, drive coupling assembly and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are installed. See section 9, Certification. Measures are required to: Avoid excess temperature Prevent build up of explosive mixtures Prevent the generation of sparks Prevent leakages Maintain the pump to avoid hazard The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection. Both electrical and non-electrical equipment must meet the requirements of European Directive 94/9/EC Scope of compliance Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed. Where Flowserve has supplied only the bare shaft pump, the Ex rating applies only to the pump. The party responsible for assembling the pump set shall select the coupling, driver, seal and any additional equipment, with the necessary CE Certificate/ Declaration of Conformity establishing it is suitable for the area in which it is to be installed. The output from a variable frequency drive (VFD) can cause additional heating effects in the motor. On pump installations controlled by a VFD, the ATEX Certification for the motor must state that it covers the situation where electrical supply is from the VFD. This particular requirement still applies even if the VFD is in a safe area. Page 6 of 41

7 Marking An example of ATEX equipment marking is shown below. The actual classification of the pump will be engraved on the nameplate. Equipment Group I = Mining II = Non-mining Category 2 or M2 = High level protection 3 = normal level of protection Gas and/or dust G = Gas D= Dust II 2 GD c IIC 135 ºC (T4) c = Constructional safety (in accordance with En ) Gas Group (Equipment Category 2 only) IIA Propane (Typical) IIB Ethylene (Typical) IIC Hydrogen (Typical) Maximum surface temperature (Temperature Class) (see section ) Avoiding excessive surface temperatures ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE Pump liquid temperature Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate. These are based on a maximum ambient temperature of 40 C (104 F); refe r to Flowserve for higher ambient temperatures. The surface temperature on the pump is influenced by the temperature of the liquid handled. The maximum permissible liquid temperature depends on the temperature class and must not exceed the values in the table applicable below. The temperature rise at the seals and bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated. Maximum permitted liquid temperature for pumps Maximum Temperature limit of liquid Temperature surface handled (* depending on class to temperature material and construction EN permitted variant check which is lower) T6 T5 T4 T3 T2 T1 85 C (185 F) 100 C (212 F) 135 C (275 F) 200 C (392 F) 300 C (572 F) 450 C (842 F) Consult Flowserve Consult Flowserve 115 C (239 F)* 180 C (356 F)* 275 C (527 F)* 400 C (752 F)* Maximum permitted liquid temperature for pumps with self priming casing Temperature class to EN T6 T5 T4 T3 T2 T1 Maximum surface temperature permitted 85 C (185 F) 100 C (212 F) 135 C (275 F) 200 C (392 F) 300 C (572 F) 450 C (842 F) Temperature limit of liquid handled (* depending on material and construction variant check which is lower) Consult Flowserve Consult Flowserve 110 C (230 F)* 175 C (347 F)* 270 C (518 F)* 350 C (662 F)* The responsibility for compliance with the specified maximum liquid temperature is with the plant operator. Temperature classification Tx is used when the liquid temperature varies and the pump could be installed in different hazardous atmospheres. In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in the particular hazardous atmosphere. Do not attempt to check the direction of rotation with the coupling element/pins fitted due to the risk of severe contact between rotating and stationary components. Where there is any risk of the pump being run against a closed valve generating high liquid and casing external surface temperature, it is recommended that users fit an external surface temperature protection device. Avoid mechanical, hydraulic or electrical overload by using motor overload trips, temperature monitor, or a power monitor and perform routine vibration monitoring. In dirty or dusty environments, regular checks must be made and dirt removed from areas around close clearances, bearing housings, and motors. Additional requirements for self-priming casing pumps Where the system operation does not ensure control of priming, as defined in the User Instructions, and the maximum permitted surface temperature of the T Class could be exceeded, it is recommended that user install an external surface temperature protection device Preventing the build up of explosive mixtures ENSURE PUMP IS PROPERLY FILLED AND VENTED AND DOES NOT RUN DRY Ensure that the pump and relevant suction and discharge piping is totally filled with liquid at all times during the pumps operation so that an explosive atmosphere is prevented. Page 7 of 41

8 In addition, it is essential to make sure that seal chambers, auxiliary shaft seal systems and any heating and cooling systems are properly filled. If the operation of the system can not avoid this condition it is recommended that you fit an appropriate dry run protection device (for example liquid detection or a power monitor). To avoid potential hazards from fugitive emissions of vapor or gas to atmosphere, the surrounding area must be well ventilated Preventing sparks To prevent a potential hazard from mechanical contact, the coupling guard must be non-sparking for Category Maintenance of the centrifugal pump to avoid a hazard CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION The responsibility for compliance with maintenance instructions is with the plant operator. To avoid potential explosion hazards during maintenance, the tools, cleaning and painting materials used must not give rise to sparking or adversely affect the ambient conditions. Where there is a risk from such tools or materials, maintenance must be conducted in a safe area. It is recommended that a maintenance plan and schedule is adopted. (See section 6, Maintenance.) To avoid the potential hazard from random induced current generating a spark, the baseplate must be properly grounded. Avoid electrostatic charge. Do not rub non-metallic surfaces with a dry cloth; ensure the cloth is damp. The coupling must be selected to comply with 94/9/EC and correct alignment must be maintained. Additional requirements for pumps on non-metallic baseplates When metallic components are fitted on a nonmetallic baseplate they must be individually earthed Preventing leakage Pumps with mechanical seal. The pump must only be used to handle liquids for which it has been approved to have the correct corrosion resistance. Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves, which could cause dangerous excessive pressures to occur if there is heat input to the liquid. This can occur if the pump is stationary or running. Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump and auxiliary systems. Where there is the potential hazard of a loss of a seal barrier fluid or external flush, the fluid must be monitored. If leakage of liquid to atmosphere can result in a hazard, the installation of a liquid detection device is recommended. Page 8 of 41

9 1.7 Safety Labels Nameplates For details of nameplate, see the Declaration of Conformity and section Warning labels & tags Page 9 of 41

10 1.8 Noise level Attention must be given to the exposure of personnel to the noise, and local legislation will define when guidance to personnel on noise limitation is required, and when noise exposure reduction is mandatory. This is typically 80 to 85 dba. The usual approach is to control the exposure time to the noise or to enclose the machine to reduce emitted sound. You may have already specified a limiting noise level when the equipment was ordered, however if no noise requirements were defined, then attention is drawn to the following table to give an indication of equipment noise level so that you can take the appropriate action in your plant. Pump noise level is dependent on a number of operational factors, flow rate, piping design and acoustic characteristics of the building, and so the values given are subject to a 3 dba tolerance and cannot be guaranteed. Similarly the motor noise assumed in the pump and motor noise is that typically expected from standard and high efficiency motors when on load directly driving the pump. Note that a motor driven by an inverter may show an increased noise at some speeds. If a pump unit only has been purchased for fitting with your own driver then the pump only noise levels in the table should be combined with the level for the driver obtained from the supplier. Consult Flowserve or a noise specialist if assistance is required in combining the values. It is recommended that where exposure approaches the prescribed limit, then site noise measurements should be made. The values are in sound pressure level L pa at 1 m (3.3 ft) from the machine, for free field conditions over a reflecting plane. For estimating sound power level L WA (re 1pW) then add 14 dba to the sound pressure value. Typical sound pressure level, dba, L pa at 1 m (3.28 ft) reference 20 µpa (2.9x10-9 psi) Motor size and speed kw (hp) Pump and motor dba 3550 r/min 2900 r/min 1750 r/min 1450 r/min Pump only dba Pump and motor dba Pump only dba Pump and motor dba Pump only dba Pump and motor dba <0.55 (<0.75) (1) (1.5) (2) (3) (4) (5) (7.5) (10) (15) (20) (25) (30) (40) (50) (60) (75) (100) (120) (150) (200) (270) (1) (1) (1) (1) (1) 83 (1) (400) (1) 84 (1) 81 (1) Motors in this range are generally job specific and noise levels should be calculated based on actual equipment installed. For 960 r/min reduce 1450 r/min values by 5 dba. Pump only dba Page 10 of 41

11 2 TRANSPORT AND STORAGE 2.1 Consignment receipt and unpacking Immediately after receipt of the equipment it must be checked against the delivery/shipping documents for its completeness and that there has been no damage in transportation. Any shortage and/or damage must be reported immediately to Flowserve Pump Division and must be received in writing within ten days of receipt of the equipment. Later claims cannot be accepted. Check any crate, boxes or wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to side walls of the box or equipment. Each product has a unique serial number. Check that this number corresponds with that advised and always quote this number in correspondence as well as when ordering spare parts or further accessories. 2.2 Handling Boxes, crates, pallets, or cartons may be unloaded using forklift vehicles or slings dependent on their size and construction. 2.3 Lifting Pumps and motors often have integral lifting lugs or eye bolts. These are intended for use in only lifting the individual piece of equipment. Do not use eye bolts or cast-in lifting lugs to lift pump, motor and baseplate assemblies. To avoid distortion, the pump unit should be lifted as shown. Care must be taken to lift components or assemblies above the center of gravity to prevent the unit from flipping. This is especially true with belt driven units with the motor mounted above the pump Lifting pump components Casing [1100] Use either a sling or hook through each of the two lifting lugs located on the side of the casing Bearing Housing [3200] Insert an eye hook in the drilled and tapped hole at the top of the bearing housing. Use either a sling or hook through the eyebolt Power end Same as bearing housing Bare pump Use either a sling or hook through each of the two lifting lugs located on the side of the casing and around the outboard end of the bearing housing with separate slings. Choker hitches must be used at both attachment points and pulled tight. Make sure the completion of the choker hitch on the bearing housing is toward the coupling end of the pump shaft. The sling lengths should be adjusted to balance the load before attaching the lifting hook Lifting pump, motor and baseplate assembly To lift the pump, driver, and baseplate as a unit, the following procedure must be followed. V-belt guards should be removed if fitted. If the baseplate has lifting holes cut in the sides at the end, insert lifting S hooks at the four corners and use slings or chains to connect to a lifting eye. Do not use slings through the lifting holes. For other baseplates, sling around pump discharge nozzle, when equipped, and the outboard end of the motor frame using choker hitches pulled tight. When pump is not equipped with optional discharge nozzle, use user supplied eyebolt screwed and seated into discharge of pump. Insert lifting S hook in eyebolt and use sling. 2.4 Storage Store the pump in a clean, dry location away from vibration. Leave flange covers in place to keep dirt and other foreign material out of pump casing. Turn the pump shaft at regular intervals to prevent brinelling of the bearings and the seal faces, if fitted, from sticking. Page 11 of 41

12 The pump may be stored as above for up to 6 months. Consult Flowserve for preservative actions when a longer storage period is needed Storage General Normal packaging is designed to protect the pump and parts during shipment and for dry, indoor storage for up to six months or less. The following is an overview of our normal packaging: All loose unmounted items are packaged in a water proof plastic bag and placed under the coupling guard Inner surfaces of the bearing housing, shaft (area through bearing housing) and bearings are coated with Cortec VCI-329 rust inhibitor, or equal. Bearing housings are not filled with oil prior to shipment The internal surfaces of ferrous casings, covers, seal chamber, flange faces, and the impeller surface are sprayed with Cortec VCI-389, or equal Exposed shafts are taped with Polywrap Flange covers are secured to both the suction and discharge flanges or face. In some cases with assemblies ordered with external piping, components may be disassembled for shipment The pump must be stored in a covered, dry location Storage Long Term Long term storage is defined as more than six months, but less than 12 months. The procedure Flowserve follows for long term storage of pumps is given below. These procedures are in addition to the short term procedure. Each assembly is hermetically (heat) sealed from the atmosphere by means of tack wrap sheeting and rubber bushings (mounting holes) Desiccant bags are placed inside the tack wrapped packaging A solid wood box is used to cover the assembly periods after addition of lubricants, inhibitor oils should be used. Every three months, the pump shaft should be rotated approximately 10 revolutions. 2.5 Recycling and end of product life At the end of the service life of the product or its parts, the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and in accordance with local regulations. If the product contains substances that are harmful to the environment, these should be removed and disposed of in accordance with current local regulations. This also includes the liquids and/or gases that may be used in the "seal system" or other utilities. Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used. The safety specifications must be in accordance with the current local regulations at all times. 3 DESCRIPTION 3.1 General The Flowserve MPT single stage pump has a back pull-out rotating assembly with suction and discharge facings on the fixed casing to allow removal of the rotating element without breaking the pipe joints or moving the driver. Mounting feet are rigidly connected to the casing so piping strains allowed in section 2.3, Flange Loads, are readily transmitted to the foundation. No special tools are required for dismantling and maintenance. An example of the nameplate used on the MPT pump, which is always mounted on the casing, is shown below. This packaging will provide protection for up to twelve months from humidity, salt laden air, dust etc. Warranty for the pumps will normally be for 12 months. Extension of this period can only be achieved with the prior agreement of Flowserve and would necessitate inspection prior to putting the pump into service. Serial No. Equipment No. Purchase Order Model Size MDP Material After unpacking, protection will be the responsibility of the user. Addition of oil to the bearing housing will remove the inhibitor. If units are to be idle for extended Page 12 of 41

13 3.2 Design of major parts Pump casing The volute type casing with integral priming chamber is of rugged heavy duty construction for minimum wear under the toughest operating conditions. Removal of the casing is not required when performing maintenance of the rotating element. The pump is designed with radial o-ring seals allowing the rotating element and cover plate to be easily removed (back pull out) Valve flap The pump suction opening is fitted with a non-return flap valve. The flap is a solid one-piece design and is easily removed for cleaning or replacement Impeller A fully balanced semi-open two vane impeller is spigotted and screwed to the shaft. The back of the impeller has integrally cast clearing vanes Wear plate The casing is fitted with a reversible and renewable steel front wear plate which is a close clearance against the impeller vanes. If the wear plate becomes excessively worn, it can be reversed to present its unworn face to the impeller. The Model 80 wear plate is not reversible Cover Plate A large cover plate below the suction facing retained by two hand nuts is easily removed to access the impeller and wear plate for fast cleanout of clogged or tangled solids. A PRESSURE RELIEF VALVE IS FITTED TO THE COVER PLATE AND MUST NOT BE REMOVED, PLUGGED OR MODIFIED Shaft The shaft is of ample size to transmit the maximum power required and to minimize deflection and vibration even during intermittent stop-start operation. Keys are used to transmit the torque. The shaft drive end and keyway are in accordance with ANSI B Stuffing box (Seal housing) The seal housing is positively located, sealed and fastened to the bearing housing and forms an oil chamber in which the seal runs fully immersed. The oil cools and lubricates the seal faces and prevents seal damage if the pump is run dry. The oil level is monitored via the sight glass fitted high on the bearing housing allowing the pump to be shut down in the event of a seal failure indicated by a sudden drop in oil level or product showing in the oil. A vent is also fitted at the top of the housing to maintain even atmospheric pressure in the oil chamber. The seal housing is easily replaceable if wear from the impeller back sealing vanes becomes excessive Shaft seal The stuffing box is fitted with a double mechanical seal; the pump end has a hard faced balanced rotary unit to prevent liquid and grit entering the seal chamber. The outboard end separates the seal and bearing oil chambers Bearing housing The robustly designed bearing housing is rigidly bolted and sealed to the pump casing. The housing is fitted with oil breather/fillers and sight glasses to indicate fill and low oil levels. The end cover is fitted with a lip seal to exclude dirt and moisture. An eyebolt is fitted to the housing for back pull-out withdrawal Pump bearings and lubrication The pump is fitted with two different types of ball bearings. The thrust bearing is a double row angular contact ball bearing, and the radial bearing a single row deep groove ball bearing. The thrust bearing is fitted at the outboard end in all pumps except the MODEL 80, which has it fitted at the inboard end. Both bearings run in a common oil bath and are sized for a long service life Impeller adjustment The bearing housing (back pull-out assembly) is fastened to the casing with four locknuts; these locknuts pass through four adjustable spacers in the bearing housing flange. Accurate impeller setting is affected by adjustment of these spacer and locking with the locknuts. The correct adjustment is 0.38/0.25 mm (0.015/0.010 in.) clearance between impeller vanes and wear plate. Clearance between the impeller and seal housing is fixed and does not need adjustment Driver The driver is normally an electric motor. Different drive configurations may be fitted such as an internal combustion engine, turbines, hydraulic motors, etc driving via couplings, belts, gearboxes, drive shafts, etc. Page 13 of 41

14 If the driver is an internal combustion engine which has not been supplied by Flowserve, a torsional analysis must be undertaken by the supplier to select the correct type of coupling in order to avoid shaft failure Guards Fabricated heavy duty sheet steel or aluminum solid or vented guards are provided to suit customer specific needs Baseplates Standard baseplates are steel fabrications. Long coupled and v-belt driven arrangement are available. Horizontal driver alignment screws and baseplate vertical leveling screws are provided as an option. Special baseplates can be supplied to suit individual installation needs. 3.3 Performance and operating limits Performance MPT pumps are furnished for a particular duty and service conditions advised on your order (See section 1.5, Duty Conditions). Changes in the hydraulic system will affect the pump s performance Pressure limits The operating pressure has been selected to meet your specific requirements. See section 1.5, Duty Conditions for details. The pressure and temperature operating limits for the flanges are in accordance with the relevant National or International standards unless advised otherwise Flange loads The permissible flange loading has been listed in the table below. Suction Discharge Maximum forces (kn (lbf)) and Moments (kn. m (lbf. ft)) Pump Size Fx Fy Fz Mx My Mz MODEL ( ) ( ) ( ) ( ) 75.9 ( ) ( ) MODEL ( ) ( ) ( ) ( ) ( ) ( ) MODEL ( ) ( ) ( ) ( ) ( ) 330 ( ) MODEL ( ) ( ) ( ) 759 ( ) ( ) ( ) MODEL 80 ( ) ( ) ( ) ( ) ( ) ( ) MODEL 20 ( ) ( ) ( ) ( ) ( ) ( ) MODEL 30 ( ) ( ) ( ) ( ) ( ) ( ) MODEL 40 ( ) ( ) ( ) ( ) ( ) ( ) MODEL 60 ( ) ( ) ( ) ( ) ( ) ( ) MODEL 80 ( ) ( ) ( ) ( ) ( ) ( ) Page 14 of 41

15 F = External force, tensile or compression M = External moment, clockwise or counterclockwise Forces and moments may be applied simultaneously in any direction Values apply to all materials Higher loads may be acceptable, if direction and magnitude of individual loads are known, but these need approval Pumps must be on rigid foundations and baseplate fully grouted Pump/Baseplate should not be used as pipe anchor. Expansion joints must be properly tied If in doubt, contact Flowserve for information Pump lubricant data Pump bearings and mechanical seals are oil lubricated. The oil levels in their respective chambers are monitored via fitted sight glasses. The recommended oil is Mobil DTE Medium or Castrol Hyspin AWH Recommended bolting and screw torques Recommended Bolt Torques Non-lubricated Screw size Torque N. m (lbf. ft) #10 6 N. m (4 lbf. ft) 1/4in. 10 N. m (7 lbf. ft) 5/16in. 16 N. m (12 lbf. ft) 3/8in. 34 N. m (25 lbf. ft) 1/2in. 54 N. m (40 lbf. ft) 5/8in. 122 N. m (90 lbf. ft) 3/4in. 176 N. m (130 lbf. ft) Apply lubricant to threads before tightening Temperature limitations Working temperature The allowable pump working temperature range is 0 C to +75 C (32 F to +167 F) Ambient temperature These pumps are generally fitted with TEFC motors with an ambient temperature limit of 0 C to +40 C (32 F to 104 F). Specific pumps may be fitted wit h motors to suit the client s requirements with other ambient temperature limits see motor nameplate for details. 4 INSTALLATION 4.1 Location When selecting the location, be sure to install the unit as close as practicable to the source of the liquid to be pumped. Allow adequate space for access, ventilation and maintenance operations involving dismantling and inspection of parts. Headroom is an important consideration as an overhead lift of some type is required for installation and maintenance of the pump-set. 4.2 Foundation Install pump units There are many methods of installing pump units to their foundations. The correct method depends on the size of the pump unit, its location, and noise vibration limitations. Non-compliance with the provision of correct foundation and installation may lead to failure of the pump and, as such, would be outside the terms of the warranty Mount baseplate The baseplate should be mounted onto a firm foundation, either an appropriate thickness of concrete or sturdy steel framework. It should NOT be distorted or pulled down onto the surface of the foundation, but should be supported to maintain the original alignment. The location of the foundation bolts and size of bolt holes can be obtained off the General Arrangement Drawing (See section 8.7). Page 15 of 41

16 Low vibration levels and long pump life will be obtained when the foundations have an adequate mass. Best practice requires the mass of the foundation block to be five times the mass of the equipment Install baseplate Install the baseplate onto packing pieces (approx. 25 mm (0.984 in.) to 50 mm (1.969 in.)) evenly spaced and adjacent to foundation bolts. Level the baseplate to within 1 mm (0.039 in.) in every 3000 mm ( in.) using a machinist s level on the machined surfaces of the pump and driver pads, placing shims between baseplate and packing pieces. The pump and driver have been aligned before dispatch. Check alignment of pump and motor half coupling. If this is incorrect, it indicates that the baseplate has become twisted and should be corrected by re-shimming. 4.3 Grouting Grouting foundation bolts Where applicable, grout in the foundation bolts Grouting baseplate After adding pipe work connections and rechecking the coupling alignment, the baseplate should then be grouted in accordance with good engineering practice. Fabricated steel and cast iron base plates should be filled with grout. If in any doubt, please contact your nearest Flowserve service center for advice Grouting baseplate prevents movement Grouting provides solid contact between the pump unit and foundation, prevents lateral movement of vibrating equipment, and dampens resonant vibrations. 4.4 Initial alignment Thermal expansion The pump and motor will normally have to be aligned at ambient temperature and should be corrected to allow for thermal expansion at operating temperature. In pump installations involving high liquid temperatures, the unit should be run at the actual operating temperature, shut down, and the alignment checked immediately Alignment methods Ensure the pump and motor half couplings are disconnected The alignment MUST be checked. Although the pump will have been aligned at the factory, it is most likely that this alignment will have been disturbed during transportation or handling. Align the motor to the pump, not the pump to the motor. Alignment is achieved by adding or removing shims from under the motor feet and also moving the motor horizontally as required. In some cases where the alignment cannot be achieved, it will be necessary to move the pump before recommencing the above procedure For couplings with narrow flanges, use a dial indicator gauge as shown. The alignment values are maximal for continuous service. FINISHED GROUT LEAVE TOP OF FOUNDATION ROUGH. DO NOT FINISH WITH TROWEL GROUTING TO BE 25 TO 50mm DEEP CONCRETE Permissible misalignment limits at working temperature: Parallel alignment within 0.1 mm (0.004 in.) TIR Angular alignment within 0.05 mm (0.002 in.) TIR Page 16 of 41

17 Measure face gap Face gaps may be measured between the machined faces using feeler gauges, measuring wedge, calipers, or suitable micrometer. 4.5 Piping Protective covers Protective covers are fitted to the pipe connections to prevent foreign bodies entering during transportation and installation. Ensure that these covers are removed from the pump before connecting any pipes Forces and moments on pump flanges Maximum forces and moments allowed on the pump flanges vary with the pump size and type and are shown in section 3.3.3, Flange Loads. To minimize these forces and moments that may cause misalignment, hot bearings, worn couplings, vibration, and the possible failure of the pump casing, the following points should be strictly followed: Prevent excessive external pipe load Never draw piping into place by applying force to pump flange connections Do not mount expansion joints so that their force, due to internal pressure, acts on the pump flange Inlet pipe The inlet pipe should be one or two sizes larger than the pump inlet bore and pipe bends should be as large a radius as possible. On suction lift the piping should be inclined up towards the pump inlet with long eccentric taper pipes incorporated to prevent air locks. On positive suction, the inlet piping must have a constant fall towards the pump Flow and pump suction Flow should enter the pump suction with uniform profile to minimize noise and wear. It is preferable to have a straight length of suction pipe (approx. 8 to 10 times the pipe diameter) immediately upstream of the suction nozzle and a straight length of discharge pipe (approx. 5 to 8 times the pipe diameter) immediately downstream of the discharge nozzle. Do not attach a short radius 90 bend directly on the suction branch. A long radius suction bend may be used as long as the bend is perpendicular to the shaft center line of the unit. Do not install elbows at an angle other than perpendicular to the shaft axis. Elbows parallel to the shaft axis will cause uneven flow into the impeller eyes. Inlet strainers, when used, should have a net free area of at least three times the inlet pipe area and a differential pressure device fitted to check for blockage. Except in unusual circumstances, strainers are not recommended in inlet piping. If considerable foreign matter is expected, a screen installed at the entrance to the wet well is preferable Fitting valves and easy maintenance Fitting an isolator and non-return valves can allow easier maintenance. Never throttle pump on suction side and never place a valve directly on the pump inlet nozzle. If butterfly valves are used in the suction line, the spindle must be parallel to the pump shaft Piping and fittings should be flushed before use Corrosive liquids Piping for corrosive liquids should be arranged to allow pump flushing before removal of a unit Air Release Valve When a discharge check valve is applied an Air Release Valve should be placed between the pump discharge and the check valve. The Air Release Valve s function is to vent air from the pump during the priming cycle. Flowserve Air Release Valves are available. 4.6 Electrical Connections Qualified electrician Electrical connections should be made by a qualified electrician in accordance with the relevant local, national, and international regulations. It is important to be aware of the EUROPEAN DIRECTIVE on electromagnetic compatibility when wiring up and installing equipment on site. Attention must be paid to ensure that the techniques used during wiring/installation do not increase electromagnetic emissions or decrease the electromagnetic immunity of the equipment, wiring, or any connected devices. If in any doubt, contact Flowserve for advice. Page 17 of 41

18 4.6.2 Wiring motor The motor must be wired up in accordance with the motor manufacturer's INSTRUCTIONS (normally supplied within the terminal box), including any temperature, earth leakage, current, and other protective devices as appropriate. The identification nameplate should be checked to ensure the power supply is appropriate Emergency stopping A device to provide emergency stopping shall be fitted Rotation direction Check required direction of rotation before connecting the motor to the pump. Ensure that the motor over power protection device is set 5% above the maximum power that the pump unit is expected to absorb. 4.7 Final shaft alignment check After connecting piping to the pump, rotate the shaft several times by hand to ensure there is no binding and all parts are free. The above operation should be repeated with piping and pump completely filled with water. 5 COMISSIONING STARTUP, OPERATION, AND SHUTDOWN 5.1 Making ready for operation Lubrication Bearings and mechanical seals Pump bearings and mechanical seals are not lubricated by Flowserve. See section 6.2 for oil chamber filling instructions. Bearing housing requires approx. one liter (33.81 fl. oz.) of oil Mechanical seal chamber requires approx. 350 ml (11.83 fl. oz.) of oil Check oil level at the sight glasses provided before putting into service Driver bearing Driver bearing lubrication should be in accordance with the driver manufacturer s instruction manual Coupling lubrication Coupling lubrication, if required, should be in accordance with the coupling manufacturer s instruction manual Pre-operation check list Pre-operation Check List Checked by Date With pump uncoupled start the driver to ensure correct direction of rotation Check alignment of piping, valves, and motor pump assembly. Alignment shall be such that joints can be bolted without placing any stress on the piping or pump Check all fasteners for tightness Visually inspect footing for cracks, etc Examine motor shims to ensure that any vibration during operation will not cause them to dislodge. CHECK THAT ALL ELECTRICAL, HYDRAULIC, SEALANT AND LUBRICATION SYSTEMS (AS APPLICABLE) ARE CONNECTED AND OPERATIONAL Check pump and motor for lubrication ENSURE ALL TERMINAL BOXES AND GUARDS ARE IN PLACE Check all valves and fittings to ensure that they are installed to allow flow in the intended direction Prime the pump. Ensure that the pump casing and all pipe work are completely filled with liquid. Filling plug must be replaced after priming Ensure pump/driver-coupling alignment is within the limits specified in Check all piping, seals, joints, and fittings for leaks. Page 18 of 41