FLOWSERVE CORPORATION Mark 3 ANSI Pumps Product Training Program April 2017
Table of Contents Pump Description Nomenclature Operating Parameters Range Chart Standard materials of construction Feature/Function/Benefit Pump selection Markets Served and typical application Main customers Competition Design centers and Manufacturing locations Page 2
Mark 3 Product Family Standard Lo-Flo Sealmatic Guardian Mag-Drive Unitized Self-Primer Recessed Impeller Vertical Inline Page 3
Pump Description End Suction Overhung Radially split Single stage Wide flow and head range 200+ hydraulics High operation efficiency Low NPSH requirement Easy maintenance Page 4
Pump Description ASME B73.1M & H.I.1.1-1.5 Standards Horizontal End Suction Foot Mounted Single Stage Centerline Discharge 150 / 300 lb Flanges Back-pull-out Dimensions set by standard Page 5
Pump Description ASME B73.1M Pumps (continued) Designed for corrosives External impeller adjustment Limit exposed threads and crevices Mechanical seal protection Bearing isolation Wide range of materials Page 6
Mark 2 Mark 3 Mark 3A Mark 3 ANSI 3A Flowserve ANSI History Page 7
Mark 2 Power End Created in 1962 Bearing Cap Fixed Cork or EPR gasket Impeller Setting via shims between bearing snap ring and housing No Sight glass oil level set by Trico Oiler Oil Flinger required because oil level not visually set Bottom Vented Breather Bearing span setting required no I.B. Bearing shaft shoulder Standard Lip Seals Page 8
Mark 3 Power End Impeller adjustment via micrometer threaded bearing carrier Standard Lip seals Oil level set visually with ½ sight glass and Trico Oiler Oil Flinger not required Top Vented Breather GP2 & 3 shafts and power end interchangeable with MK2 Shafts machined with shoulders for bearing span location Gp1 shafts 1 3/8 through seal chamber Larger oil sump MK3 1J Power End created for MK2 replacement on GP1 using 1.125 Page 9
Mark 3A Power End Threaded carrier changed to use small dia. O-rings Threaded carrier uses cast lugs at hold down bolts for use of wrench to adjust Removed lugs on O.D. of carrier removing need for spanner wrench Larger Oil return slots provide in bearing Carrier Bearing housing designed for larger 1 bulls eye sight glass Oil sump increased over Mark 3 Standard lip seals Trico Oiler combination Watchdog style standard Page 10
Mark 3 ANSI 3A Power End Same Power end as MK3A with added features Labyrinth Bearing Isolator Flowserve Bearing Gard Inpro VBXX-D Oil Seals Magnetic Drain Plug Plugged bearing housing no breather No Trico Oiler Lifetime Power end Warranty Page 11
Nomenclature: Mark 3 Pump Size Code Example: 2 K 3 x 2( ) - 10A / 8.25 RV 2: Group2 K: Mark III 3: 3 suction 2: 2 discharge 10: Max. impeller dia. 8.25: Imp. trim RV: Reverse vane imp. HD: Heavy Duty Shaft ( ) = _: Standard M: Sealmatic R: Recessed impeller US: Unitized self-priming V: Vertical in-line LF: Lo-Flo L: Non-metallic H: High Silicon Iron T: PTFE lined E: Durcon S: Old style self-priming Page 12
Mark 3 Nameplate Information Standard Nameplate Serial No. Equipment No. Purchase Order No. Model Size MDP Material Date Secondary Nameplate Serial No. Capacity TDH RPM Impeller dia. Page 13
Nomenclature: Pump Group 1 Pump Size ANSI designation 1.5x1LF-4 --- 1.5 x 1-62 AA 3 x 1.5 62 AB 3 x 2 62 --- 1.5 x 1 82 AA 1.5x1LF-8 --- 3 x 1.5 82 --- Page 14
Nomenclature: Pump Group 2 Pump Size ANSI Desig Pump Size ANSI Desig Pump Size ANSI Desig 3x2-82 A60 3x2-10A A60 3x1.5LF-13 --- 4x3-82 A70 4x3-10 A70 3x2-13 A30 2x1-10A A05 4x3-10H A40A 4x3-13 A40 2x1LF-10 --- 6x4-10 A80A 4x3-13HH A40 3x1.5-10A A50 6x4-10H A80 6x4-13A A80 3x1.5-13 A20 Page 15
Nomenclature: Pump Group 3 Pump Size ANSI desig Pump Size ANSI desig 8x6-14A A90 8x6-16A A110 10x8-14 A100 10X8-16 A110 6x4-16 ---- 10X8-16H A120 10X8-17 A120 Page 16
Operating Parameters Flow: 0.3 to 2,270 m3/h (2 to 10,000 gpm) Head: up to 300 m (985 ft) Power: up to 373 kw ( 500 hp) Pressures: up to 31 bars (450 psi) Temperatures: up to 370 C (700 F) Suction nozzle sizes: 38 mm (1.5 in) to 305 mm (12 in) Page 17
Range chart MK3 max impeller max speed 60 Hz Page 18
Range Chart In-Line max impeller max speed 60 Hz Page 19
MK3 Standard Materials Pump Material Specification (PROS) Component DCI D/C D4 CD4MCuN D20 DC3 TI Casing Nodular Cast Iron (Ductile Iron) Nodular Cast Iron (Ductile Iron) 316 SS CD4MCuN Durimet 20 Chlorimet 3 Titanium Impeller Nodular Cast Iron (Ductile Iron) CD4MCuN 316 SS CD4MCuN Durimet 20 Chlorimet 3 Titanium Rear Cover - Seal Chamber Nodular Cast Iron (Ductile Iron) Nodular Cast Iron (Ductile Iron) 316 SS CD4MCuN Durimet 20 Chlorimet 3 Titanium Shaft Steel Steel ZH ZC20 ZC20 Stainless w/ DC3 Sleeve Stainless w/ti Sleeve Seal Bearing Housing- Adapter Bearings Mechanical Seal: Balanced/unbalanced/catridge/split or Gland Packing Cast iron - Ductile Iron (SS is optional) Antifriction grease or oil bath lubricated (optional oil mist) Application standard application Page 20
MK3 Standard Material Page 21
Mark 3 Features ANSI 3A Reverse Vane SealSentry Features Designed to Optimize the Seal Enviroment Page 22
True Back Pullout Design Page 23
Causes of ANSI Pump Failures 80 70 60 50 40 30 20 10 Features 0 Shaft seal Bearings Other Page 24
Reverse Vane Impeller Low NPSHR Low, unidirectional thrust loads Hydraulic balance holes Wear Surface is the Rear Cover, Not Casing Low, predictable seal chamber pressure Running clearance set to rear cover, not casing Impeller and seal setting performed in the repair shop, not under adverse field conditions. True Back Pullout Design. Page 25
Front Vane Open Impeller Optional Clearance adjusted between impeller and case (field adjustment) Recommended where there are fibrous, stringy materials in the liquid Page 26
Front Vane Open Impeller Page 27
Reverse Vane Impeller One setting to maintain: Performance Efficiency Thrust Seal chamber pressure Page 28
Reverse Vane Impeller Seal Ring wear has less than 1.5% effect on performance TDH vs. Radial Clearance 2K4X3-10 at BEP +/- 1.5% 400 390 TDH 380 370 360 350 0.03 0.05 0.07 0.09 0.11 0.13 Radial Clearance Page 29
MK3 Inducer Sizes Available 2K6x4-10 2 & 4 Pole 50/60Hz 2K6x4-10H 2 pole 50/60HZ 2K6x4-13 2 & 4 Pole 50/60 Hz 3K8x6-16 4 & 6 Pole 50/60 Hz 3K10x8-16H 4 & 6 Pole 50/60 Hz Guidelines Average 30-40% reduction from PROS/Flowselex NPSHa values Flow rates 90% of BEP and lower Contact Distribution Support Group for Application & Pricing Requests Competitive Advantage Don t Oversize Page 30
Rear Cover / Seal Chamber Designs Page 31
FML SealSentry Chambers Flow Modified Large Bore (FML) Turns centrifugal flow caused by the seal into axial flow by the ribs along the chamber Handle up to 60% solids Can be field machined to restore wear surface Vast Sealing Options Single, Double, Gas, Split Self-flushing, self-venting, selfdraining Can eliminate expensive piping plans Good solids handling capability Extends the overall life of the mechanical seal Page 32
FML SealSentry Chambers Flowserve Test of FML Design 50% Titanium Dioxide Slurry Heavy Erosion on Cover Surface Flow Modifiers remain intact Mode of Failure: Pressure Containment Dime size blowout on cover surface Seal Inspection Performed Little signs of wear No Leakage during testing Page 33
Features: FMS Flow modified Small gland and gasket circles Self-flushing, selfventing, self-draining Page 34
Features: CBL Cylindrical bore Large gland bolt and gasket circles Recommended when seal chamber isolation is desirable Page 35
Features: CBS Cylindrical bore Small gland bolt and gasket circles Recommended when seal chamber isolation is desirable Page 36
Jacketed Seal Chamber (standard bore - CBS) Page 37
Jacketed Seal Chamber (FM chamber) Page 38
Mark 3A Power End Standard Features Bearing seals Standard Lip seals Optional Isolators Deep, Groove Conrad Type Ball Bearings Top vented baffled breather Trico constant level oiler 1 Oil Sight glass Rigid adjustable foot piece Shaft shoulder for both bearings Oil return slots, both bearings Lifting Eye Side mounted oil drain plug Page 39
Features Micrometer Impeller Adjustment Very accurate Very easy Calibrated bearing carrier Maintains near perfect parallelism Threads protected Each notch equals 0.10mm (0.004 ) Page 40
Features Mark 3A Power End Options Labyrinth seals Magnetic seals Duplex Angular Contact Thrust Bearing Oil mist option Magnetic drain plug Bearing housing oil cooler Shaft options Page 41
Features Mark 3 Power End ANSI 3A Design Bearing isolators (Flowserve Bearing Gard or Inpro VBXX-D) Magnetic drain plug Clean room assembly Vent and oiler holes plugged Lifetime Power End warranty Bearings are normal wear item Extended oil change intervals Mineral Oil 18 mo. Synthetic 36 mo. Page 42
Features Inpro VBXX-D Bearing Isolator Page 43
Features Shaft Options Solid Hook Sleeve Composite Friction-Welded Page 44
MK3 Heavy Duty Power End Option: All Mark 3 Group 3 Pumps Pumps can be Field Converted 550 BHp rating vs 325 BHp of existing Mark 3 design Duplex Angular Contact Bearings Large Roller Radial Bearing Minimum 5 year L10 Bearing Life Cartridge Seals Only Heavy Duty 3 Steel and 2205 Duplex Solid Shaft Improved L3/D4 Shaft Coupling End dia. Matches Current GP3 Belt-Drive Capable Offers 3K10x8-16H Full Impeller Diameter Range @ 1800 RPM Page 45
Features Mark 3 Casing Integral Foot mount design Centerline discharge 150# flanges (300# optional) Flat Face Flange (RF optional) Single volute on most sizes Double volute on larger pumps Drain, Suction, Discharge taps available Page 46
Features Mark 3A Bearing Housing Adapter Mates wet end to housing Allows parts interchangeability reduced inventory Metal-to-metal fit to housing and to rear cover. Standard is DCI (ductile iron), alloy is available Integral on Group 1 pumps. Page 47
Jacketed Casings Provides temperature control Integral (as shown) Bolt-on jackets available Page 48
Features Centerline Mounting Casings Reduces loads caused by thermal expansion Cradle Design Std. Optional - Jacketed feet allow temperature control Page 49
High Temperature Applications Temperatures greater than 300 F (149 C) Grafoil impeller and casing gaskets ZH shaft Oil Lubrication ANSI 3A Powerend Temperatures greater than 350 F (177 C) C-face motor adapter Jacketed Rear Cover. Preferably CBL with throat bushing. Finned Oil Cooler Temperatures greater than 500 F (260 C) Centerline mounted Casing 316ss Bearing Housing Adapters Page 50
Features C Flange Adapter Holds alignment even with changes in temp. & pipe loads Eliminates foot mounting of the motor Page 51
Features C-Plus Precision Alignment System For alignment within 0.002 in (0.05 mm) Page 52
Features Baseplate Options Page 53
Type A Standard Typically in stock Multi-Drilled for several NEMA size motors Primer suitable for epoxy grout Dimensions to ANSI B73.1 Page 54
Type B Polycrete Low installed cost Superior vibration dampening Excellent corrosion resistance Material Options Available Designed to be flat with excellent rigidity Catch basins and grout holes Inserts give infinite configuration possibilities Page 55
Type C Stilt Base Multiple Stilt arrangements available Multi-Drilled for several NEMA size motors Dimensions to ANSI B73.1 Page 56
Type D Heavy Duty Base End Caps, Machine Pads, Full Drip Rim Options Multi-Drilled for several NEMA size motors Dimensions to ANSI B73.1 Page 57
Type E PIP Baseplate Ten Point Heavy Duty Design Meets the intent of API 610 and Fully complies with PIP RESP002 0.002 /ft mach coplanar pads Cross Member Support Continuous seam weld Tapped Leveling Holes Integral Lifting Lugs Integral Grout Anchors ½ Vent Holes 4 Grout Holes Integral Sloped Drip Rim with Drain Port Post-Type Motor Adjusters Page 58
Baseplate Considerations Type A Bent Form Baseplate No Welding on Group 1 and 2 size bases. Drip Rim Option non-sloping on pump end only 303ss Catch Basin is a good option. Less Money. Type B Non-Metallic for Foundation or Stilt Mounting Consider when corrosive environment or when request is for SS baseplate Type C Consider in High Temperature Applications above 300 F (149 C) Consider when Temperature range is greater than 100 F ( 38 C) Type D Adds extra bracing, lifting lugs, and leveling holes over Type A Offers End Caps, Machine Pads, Full Drip Rim Options Type E API style baseplate Page 59
Features Polyshield Traditional baseplate systems do not offer a full solution to our customers. Picture shows great pump and baseplate, but just look at the issue below (concrete pad). How does a customer address this problem? Page 60
Features Total Installed Cost Total installed cost comparison 7000 6000 5000 4000 3000 2000 Foundation Protection Installation cost Baseplate 1000 0 PIP Style Baseplate Steel Baseplate Polybase Baseplate Polyshield Page 61
Polyshield Quick Installation Reduction Total Install Cost Corrosion Resistance Material Options Reduces Vibration One-piece Construction Available heights Flat mounting surface One-piece motor mounting block 4 Grout Hole Integral Grout Anchors Integral Drain Basin and Connection Page 62
Features Standard Metal Coupling Guard Carbon steel, stainless steel, aluminum Clamshell design Trimmed for exact fit Heavy-duty support legs Page 63
Features ClearGuard and DurcoShield Page 64
Flowserve ClearGuard Constructed of yellow-tinted, UV stabilized polycarbonate Excellent corrosion resistance Provides physical safety barrier around coupling, protecting against: Person s body and/or clothing contacting rotating components Components flying off a damaged coupling Extremely tough Stronger than aluminum or steel guard Can support 370 lbs. Allows static and dynamic inspection without removal Allows rotational speed and direction inspection DurcoShield is also available Page 65
Features Envelopes area between housing & casing Deflects spray from a malfunctioning seal Provides protection from rotating shaft Very easy to install and remove Constructed of yellow (ClearGuard ) polycarbonate Allows visual inspection of seal area Application -70 o F to 300 o F (-57 o C to 150 o C) Available in PVDF Easy to drill or cut slots and holes for piping Patented design DurcoShield TM Page 66
Features Mark 3 Inline Pump Standard Mark III power end Minimizes floor space Lower installation cost. Better able to accommodate piping loads With Reverse Vane impeller, thrust is reduced Shaft alignment fully adjustable Page 67
Features Mark 3 Lo-Flo Low flow Heads to 985 feet (300m) Conforms to standard ASME B73 dimensions Standard Mark 3 power end Radial vane Pump out vanes Balance holes Maintains low seal chamber pressure Page 68
Features Lo-Flo Casing Reduces radial loads Reduces shaft vibration Circular Concentric Casing Expanding Volute Casing Page 69
Features Sealmatic Repeller Operating Dynamic sealing Eliminates the need for conventional seal Static FXP TFE Disc Seal Checkmatic lip seal Flexible graphite packing Dry-running lift-off gas seal Page 70
The FXP Seal is made up of a 316 SS Rotor, a stationary Glass Filled PTFE Disk, and a 316 SS Gland to retain the Disk. Figure 1 The Rotor face is tapered to provide a good match between the two parts and has concentric grooves machined into the sealing face. The concentric grooves provide sealing dams with high loading on each, providing consistent performance whether static or dynamic. The Disk is piloted to insure good concentricity of the sealing surfaces, thereby minimizing leakage. FXP Seal - Large-Bore Box Page 71
Features Sealmatic Applications Hard to seal services (Caustic, slurry) Where water flush is undesirable (Evaporator feed, sulfuric acid) Continuous duty Page 72
Features Self Priming Compact Motor and pump out of pumped liquid Better alignment than cantilevered pumps Relatively inexpensive Easy installation and maintenance Unitized casing includes priming chamber air separator volute Page 73
Features Applications Sump Services Waste water Tank car unloading Dike Sumps Coal Pile Run Off Suction Lift: 25 feet Air bleed line required Priming time varies by application Page 74
Features Self-Priming Tank Makes any pump self-priming Materials Steel 316SS FRP Proper sizing required Operates under vacuum. Not suitable for pressure. Page 75
Features Recessed Impeller Vortex Maintains integrity of solids Pumps large solids Minimizes shear, abrasion, clogging Impeller clearance set at rear cover Tangential discharge casing Standard Mark 3 Power End Pump out vanes control seal pressure and minimize solids in the seal chamber Page 76
Features Recessed Impeller Applications Solids Slurries Corrosives Abrasives Waste streams Shear-sensitive liquids Less than 20% solids contact impeller Page 77
Features High Silicon Iron The most universally corrosion resistant alloy in the pump industry Low mechanical shock resistance (treat like glass) Low thermal shock resistance (keep temperature change within 100F per hour) Page 78
Features Guardian ANSI B73.1 dimensions Wet end interchangeable with Mark 3 Power end pullout without breaking sealed containment Uses standard NEMA motor Sealless Magnetic drive MK3 RV Impeller Provides consistent flow and pressure in containment shell No wear rings or close clearances needed to maintain hydraulic balance or recirculation flow Page 79
Features Limitations Solids 300 micron (0.012 ) Less than 3% by weight No ferrous particles 2 Moh maximum hardness Talc = 1 Moh Diamond = 10 Moh Viscosity 0.3 to 300 cp others by review Temperature (process temperature PLUS rise in containment shell) G series: Minus 100F to plus 250F H series: Minus 100F to plus 550F Magnetism decrease with temperature rise Page 80
Features Power Protection Monitor For overload protection Excessive wear or rubbing Bearing failure Decoupled magnets Motor overload For under-load protection Dry run Blocked suction Decoupled magnets Failed spacer element Air entrainment Minimum flow Loss of prime Page 81
Total Cost of Ownership MAINTENANCE COST Labor Parts Service OPERATION COST Auxiliaries Energy costs INITIAL COST Equipment Mark 3 Maximizes Reliability (MTBPM) and Save $$$ Page 82
FML SealSentry TM Flow Modified Large Bore (FML) Turns centrifugal flow caused by the seal into axial flow by the ribs along the chamber FML handles up to 60% solids Goulds design is limited to 10% Page 83
Oil Consumption Size Mark 3 (oz) 3196i (oz) Group 1 / STi 8.5 16 Group 2 / MTi 32 47 Group 2 l LTi N/A 47 Group 3 / XLTi 48 100 Intervals 3 Years 2 Years ANSI 3A Power End Superior Reliability Purchase / Disposal Cost Cool Running Bearings No Viscosity Breakdown Goulds uses 2 times the amount of lubrication for the same performance Goulds requires a shorter lubrication cycle Page 84
Myth # 1 Two Times More Wear Area = Longer Life, Reduced Repair Costs Goulds Claims The Truth Is More working area being worn does not reduce the wear rate it just damages more parts Adjusting open impellers towards the casing to compensate for wear increases the thrust loads from larger gap on backside causing seal chamber pressures to increase Cost to replace a rear cover is nearly 1/3 rd the casing price Rear covers are much easier to replace than a casing (and can be resurfaced) Balance holes in the Reverse Vane impeller ensure hydraulic loads are similar in magnitude to open impellers If open impeller is required, the Mark 3 has this option available Page 85
Myth # 2 Enclosed Impellers Cannot be Adjusted Goulds Claims The Truth Is Reverse Vane impellers are not fully enclosed Reverse Vane impellers are easily adjusted using micrometer adjustment Nose ring wear does not affect performance until it is almost gone (this is not a wear ring) With open impeller adjustment Goulds has to choose either performance or seal chamber pressure renewal. They can t get both. With the Reverse Vane impeller, one adjustment renews both! Page 86
Myth # 3 Back Pump Out Vanes Control Axial Thrust Goulds Claims The Truth Is Goulds back pump out vanes wear too, so they become less effective and controlling thrust loading and seal chamber pressure over time Pump out vane wear combined with moving the impeller away from the rear cover for performance renewal means that significant pressure increase occurs behind the Goulds open impeller which adds to the thrust loads and seal chamber pressure Page 87
Max Sphere Size Percent of Sizes with the Largest Passage Way Flowserve: 86% Goulds: 14% Page 88
Better Interchangeability Interchangeability Only 3 Mark 3 Power Ends cover all sizes. If customer has 6x4-10, then only shaft is different. Less Stock Required Only 3 Power Ends Goulds has 4 sizes Only 3 Seal Sizes Goulds has 4 sizes All Group 1 pumps use the same rear cover size Goulds has 2 cover sizes for Group 1 pumps Page 89
Shaft Comparisons Page 90
Competitive Product - ITT Goulds i-alert Features: Small and compact Weaknesses: Field activated following start up Temperature alert: 175 F preset (two consecutive readings) 195 F (91 C) max Measures overall vibration Initial learn mode sets baseline Green Light Normal, Red Light Alarm Built into the pump frame Vibration in horizontal mode only No Internal Memory Access Not User Configurable Temperature Limit factory set Vibration Limit 2X baseline Polling Rate 1 minute No Data Logging Capability Battery life less than 1 year in alarm mode No indication of past alert notification Page 91
IPS Beacon TM Patent Pending LEDs Mounting Hole On / Off or optional IPS Beacon TAM (Take Away Memory) IPS Beacon: Straight Forward Monitoring and Alert System for Vibration and Temperature Blinking green indicates normal condition Blinking red indicates either temperature and / or vibration is above the preset limit Alternate blinking red and green indicate that the equipment has returned to normal but that an alert condition had occurred within the last 14 days. Last Alert is time stamped and can be downloaded with optional Docking Station. Standard High Level Thresholds For ANSI and ISO Pumps Vibration: 9.4 mm/sec (.38 in/sec) RMS Temperature: 85C (185F) Sampling at 5 minute interval LED blinks at 5 second interval User Configurable w/ Optional Docking Station and Software Utility or TAM for Extended Data Logging Page 92
IPS Beacon - Specifications Three Axis Vibration Sensor measures vibration in either acceleration or velocity Onboard Temperature Sensor measures temperature readings from -40 F to 200 F (-40 C to 93 C) Material of Construction is a 316L Stainless Steel housing with borosilicate glass-protected LEDs providing vivid status indications. 14-Day Fault Indication provides extended visual notification of an alert condition over time Battery Life can be more than four years depending on the environment and operating parameters Certifications: CE, CSA (CL1, DIV 1, A,B,C,D,F&G,) ATEX and IECEx (CL 1, Zone 0) Page 93
Questions? Page 94