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FRBHJC User Manual 2004

1. 11 3 2 Name nomenclature 11 3 3 Design of major parts 11 3 4 Performance and operating limits 12 TABLE OF ENGINEERING DATA 13 MATERIALS OF CONSTRUCTION 17 4 INSTALLATION 18 4 1 Location 18 4 2 Part assemblies 18 4 3 Foundation 18 4 4 Baseplate installation 18 4 5 Initial alignment 19 4 6 Grouting 21 4 7 Piping 21 4 8 Final shaft alignment check 23 4 9 Electrical connections 23 4 10 Protection systems 23 5 COMMISSIONING STA RT UP OPERATION AND SHUTDOWN 24 5 1 Pre commissioning procedure 24 5 2 Pump lubricants 24 5 2 Pump lubricants 25 5 3 Direction of rotation 25 5 4 Guarding 25 5 5 Priming and
2. Pump Division Type FRBHJC VERTICAL CANTILEVER CENTRIFUGAL PUMPS USER INSTRUCTIONS INSTALLATION OPERATION MAINTENANCE PCN 71569179 11 04 These instructions must be read prior to installing operating using and maintaining this equipment FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 2 of 36 CONTENTS PAGE 1 INTRODUCTION AND SAFETY 4 1 1 General 4 1 2 CE marking and approvals 4 1 3 Disclaimer 4 1 4 Copyright 4 1 5 Duty conditions 4 1 6 Safety 5 1 7 Nameplate and warning labels 8 1 8 Specific machine performance 9 1 9 Noise level 9 2 TRANSPORT AND STO RAGE 10 2 1 Consignment receipt and unpacking 10 2 2 Handling 10 2 3 Lifting 10 2 4 Storage 10 2 5 Recycling and end of product life 11 3 PUMP DESCRIPTION 11 3 1 Configurations
3. Notes FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 42 of 42 FLOWSERVE REGIONAL SALES OFFICES USA and Canada Flowserve Corporation Pump Division 5215 North O Connor Blvd Suite 2300 Irving Texas 75039 USA Tel 1 972 443 6500 Toll free 800 728 PUMP 7867 Fax 1 972 443 6800 Europe Middle East amp Africa Flowserve Limited Pump Division Harley House 94 Hare Lane Claygate Esher Surrey KT10 0RB United Kingdom Tel 44 0 1372 463 700 Fax 44 0 1372 460 190 Latin America and Caribbean Flowserve Corporation Pump Division 6840 Wynnwood Lane Houston Texas 77008 USA Tel 1 713 803 4434 Fax 1 713 803 4497 Asia Pacific Flowserve Pte Ltd Pump Division 200 Pandan Loop 06 03 04 Pantech 21 Singapore 128388 Tel 65 775 3003 Fax 65 779 4607 Visit our web site at www flowserve com Your Flowserve factory contact Flowserve Pump Division 15 Worthington Drive PO Box 40 Brantford Ontario Canada N3T 5M5 Telephone 1 519 753 7381 Fax 1 519 753 0845 Your local Flowserve representative In Europe Flowserve Pumps Limited PO Box 17 Newark Notts NG24 3EN United Kingdom Telephone 24 hours 44 0 1636 494 600 Sales amp Admin Fax 44 0 1636 705 991 Repair amp Service Fax 44 0 1636 494 833 To find your local Flowserve represent ative please use the Sales Support Locator System found at www flowserve com
4. 6 10 6 Grease Fitting frame 3 a Install the appropriate grease fitting to the bearing frame at the line bearing b Charge grease fitting with grease 6 10 7 Bearing Frame Vent a Install street elbow in bearing frame and orientate elbow to towards drive end of shaft b Install Inpro vent valve 6 10 8 Stuffing Box area a Clean the shaft where the shaft sleeve 14 will be located b Prepare shaft and sleeve with Loctite Primer c Apply Loctite A to shaft d Install the shaft sleeve 14 onto the shaft 6 while turning the sleeve to spread the Loctite sealant over the inside surface of the sleeve e Assemble the throat bushing 63 into the lower housing 33A f Apply Loctite A to periphery of elastomeric bushing 39 at one end and slide into housing 33A using a twisting motion Wipe away excess compound If provided install studs and fit clamp plate to hold bushing in place g Slide the lower housing 33a over shaft and into spigot to support pipe 101 Clamp into position using C clamps h Using adjusting bolts on thrust bearing housing 33 adjust shaft forward so that the end of the sleeve protrudes slightly beyond the face of the lower housing 11 i Install impeller key 32 smear anti seize compound onto the shaft at the impeller location j Slide impeller 2 onto the shaft 6 k Apply Loctite A to shaft threads and install the impeller nut 24 Torque impeller nut as indicated in table below
5. Bearings worn Replace bearings Wearing ring surfaces worn Replace worn wear ring surfaces Impeller damaged or eroded Replace or CONSULT FLOWSERVE for improved material selection Leakage under sleeve due to joint failure Replace joint and check for damage Shaft sleeve worn or scored or running off centre Check and renew defective parts Mechanical seal improperly installed Check alignment of faces or damaged parts and assembly method used Incorrect type of mechanical seal for operating conditions CONSULT FLOWSERVE Shaft running off centre because of worn bearings or misalignment Check misalignment and correct if necessary If alignment satisfactory check bearings for exces sive wear Impeller out of balance resulting in vibration Abrasive solids in liquid pumped Internal misalignment of parts preventing seal ring and seat from mating properly Check and CONSULT FLOWSERVE Mechanical seal was run dry Check mechanical seal condition and source of dry running and repair Internal misalignment due to improper repairs causing impeller to rub Check method of assembly possible damage or state of cleanliness during assembly Remedy or CONSULT FLOWSERVE if necessary Excessive thrust caused by a mechanical failure inside the pump Check wear condition of impeller its clearances and liquid passages Excessive grease in ball bearings Check method of regreasing Lack of lubrication for beari
6. 1330 300 1070 240 890 200 950 700 470 350 720 530 1070 240 890 200 1330 300 100 4 1330 980 680 500 1000 740 1780 400 1420 320 1160 260 1330 980 680 500 1000 740 1420 320 1160 260 1780 400 125 5 1830 1340 940 690 1450 1070 2450 550 1960 440 1600 360 1830 1340 940 690 1450 1070 1960 440 1600 360 2450 550 150 6 2300 1700 1180 870 1760 1300 3110 700 2490 560 2050 460 2300 1700 1180 870 1780 1300 2490 560 2050 460 3110 700 200 8 3530 2600 1760 1300 2580 1900 4890 1100 3780 850 3110 700 3530 2600 1760 1300 2580 1900 3780 850 3110 700 4890 1100 250 10 5020 3700 2440 1800 3800 2800 6670 1500 5340 1200 4450 1000 5020 3700 2440 1800 3800 2800 5340 1200 4450 1000 6670 1500 300 12 6100 4500 2980 2200 4610 3400 8000 1800 6670 1500 5340 1200 6100 4500 2980 2200 4610 3400 6670 1500 5340 1200 8000 1800 350 14 6370 4700 3120 2300 4750 3500 8900 2000 7120 1600 5780 1300 6370 4700 3120 2300 4750 3500 7120 1600 5780 1300 8900 2000 400 16 7320 5400 3660 2700 5420 4000 10230 2300 8450 1900 6670 1500 7320 5400 3660 2700 5420 4000 8450 1900 6670
7. 1500 10230 2300 450 18 8200 6050 4200 3100 6100 4500 11570 2600 9650 2170 7560 1700 8200 6050 4200 3100 6100 4500 9610 2160 7560 1700 11570 2600 500 20 9080 6700 4750 3500 6780 5000 12900 2900 10720 2410 8450 1900 9080 6700 4750 3500 6780 5000 10760 2420 8450 1900 12900 2900 550 24 10850 8000 5830 4300 8130 6000 15480 3480 13120 2950 10230 2300 10850 8000 5830 4300 8130 6000 13080 2940 10230 2300 15660 3520 Notes 1 F External force tension or compression M External moment clockwise or counter clockwise 2 Forces and moments may be applied simultaneously in any direction 3 Values apply to all materials 4 Higher loads may be applicable if direction and magnitude of individual loads are known but these need written approval from Flowserve 5 Pumps must be on rigid foundations and baseplates must be fully grouted 6 Pump baseplate should not used as pipe anchor Expansion joints must be properly tied 7 The pump mounting bolt torques specified must be used to prevent relative movement between the pump casing and baseplate See section 6 6 Fastener torques The bolt material must have a minimum yield strength of 600 N mm2 87 000 lb in 2 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 23 of 42 4 7 2 Suction piping a Drop pipes may be used to extend the p
8. 2 restriction bushings 2 shaft sleeves 2 sets of gaskets and seals 2 casing wear plate 1 impeller 6 5 Tools required A typical range of tools that will be required to maintain these pumps is listed below Readily available in standard tool kits and dependent on pump size Open ended spanners wrenches to suit up to M 48 screws nuts Socket spanners wrenches up to M 48 screws Allen keys up to 10 mm A F Range of screwdrivers Soft mallet More specialized equipment Bearing pullers Bearing induction heater Dial test indicator C spanner wrench for removing shaft nut If difficulties in sourcing are encountered consult Flowserve FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 30 of 42 6 6 Fastener torques Torque Nm lbft Bolt size Pump feet fasteners All other fasteners M10 3 8 in M12 1 2 in M 16 in M 20 in M 24 in M 27 1 in M 30 1 in M 36 1 in M 42 1 in 23 17 54 40 170 125 340 250 590 435 770 570 1 100 810 1 840 1 350 2 000 1 475 23 17 54 40 84 62 165 120 285 210 375 275 540 400 900 660 1 410 1 040 6 7 Renewal clearances As wear takes place between the impeller and wear ring the overall efficiency of the pump set will decrease To maintain optimum efficiency it is recommended that rings are replaced and the impeller renovated when the radial clea
9. 65 150 10 3 150 9 7 140 6 2 90 13 8 200 8 3 120 95 200 10 3 150 9 3 135 6 2 90 13 4 195 8 3 120 120 250 10 3 150 9 0 130 6 2 90 12 6 185 8 3 120 150 300 12 1 175 8 3 120 175 350 CONSULT FACTORY FOR APPLICATIONS IN THIS RANGE CASTIRON NOT RECOMMENDED DUE TO THERMAL SHOCK RISKS 11 0 160 7 6 110 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 13 of 42 TABLE OF ENGINEERING DATA FRAMES 1 amp 2 LIQUID END ENGINEERING DATA 2 F R B H 1 2 1 3 F R B H 1 2 1 3 F R B H 1 0 1 4 F R B H 1 1 1 6 F R B H 1 1 1 3 F R B H 1 4 1 4 F R B H 1 4 1 6 F R B H 1 4 2 8 F R B H 1 5 2 3 F R B H 1 8 2 4 F R B H 1 8 2 8 F R B H 1 8 2 10 F R B H 1 8 2 PUMP DATA SUCTION DIA mm in 76 3 102 4 152 6 152 6 203 8 152 6 152 6 203 8 254 10 152 6 203 8 153 10 305 12 DISCHARGE DIA mm in 51 2 76 3 76 3 102 4 152 6 76 3 102 4 152 6 203 8 76 3 102 4 203 8 153 10 CASING THICKNESS mm in C I 11 2 44 11 2 44 11 2 44 11 2 44 11 2 44 11 2 44 11 2 44 17 5 69 17 5 69 16 63 16 63 20 8 82 20 8 82 CASING THICKNESS mm in S S 9 7 38 9 7 38
10. CONSULT FLOWSERVE Total head of system higher than differential head of pump Total head of system lower than pump design head Check system losses Remedy or CONSULT FLOWSERVE Specific gravity of liquid different from design Viscosity of liquid differs from that for which designed Check and CONSULT FLOWSERVE Operation at very low capacity Measure value and check minimum permitted Remedy or CONSULT FLOWSERVE Operation at high capacity Measure value and check maximum permitted Remedy or CONSULT FLOWSERVE B Mechanical troubles Misalignment due to pipe strain Check the flange connections and eliminate strains using elastic couplings or a method permitted Improperly designed foundation Check setting of baseplate tighten adjust grout base as required FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 36 of 42 FAULT SYMPTOM Pump overheats and seizes Bearings have short life Pump vibrates or is noisy Mechanical seal has short life Mechanical seal leaks excessively Pump requires excessive power Pump loses prime after starting Insufficient pressure developed Insufficient capacity delivered Pump does not deliver liquid PROBABLE CAUSES POSSIBLE REMEDIES Shaft bent Check shaft runouts are within acceptable values CONSULT FLOWSERVE Rotating part rubbing on stationary part internally Check and CONSULT FLOWSERVE if necessary
11. the units are aligned prior to shipment However baseplates can be sprung or distorted during shipment or installation and the alignment must be checked before the unit is put in service The coupling spacer must be removed to make this check For pumps and drivers which operate at different temperatures compensation must be made at the initial alignment stage when the units are at the same temperature to allow for thermal expansion during operation Consult the instruction manual supplied with the driver for the manufacturer s recommendations Shaft alignment is greatly simplified by the use of a dial indicator or with extension rods and a magnetic base Before taking readings ensure that the pump and driver mounting bolts are secure and that the thrust bearing housing is properly aligned in the bearing frame or cartridge See Section VII Maintenance Parallel Alignment FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 20 of 42 Mount the magnetic base on the pump half coupling hub and place the dial indicator button on the outside diameter of the driver half coupling hub Note that the length of extension rods should be kept at a minimum to reduce deflection Rotate the pump shaft and record the dial reading at the top bottom and each side Correct the parallel alignment by adding or removing shims under the driver and or moving the driver horizontally Repeat this procedure until the maximum total indicator readi
12. 6 10 9 Casing a Place the casing on the suction nozzle b Screw the wear plate studs into the wear plate Apply Loctite A to threads c Place sealing washers over the studs A small amount of grease may be used to hold them into position during assembly of wear plate d Lower the wear plate 181 studs first into the casing 1 align the studs with the casing holes e Fasten the wear plate 181 to the casing using the washers nuts and Loctite A on nuts Tighten in accordance with Table 6 6 f Remove C clamp from housing Smear the casing gasket 73 with a grease and position on lower cover 33A g Release thrust bearing housing hold down bolts h Lift the casing 1 and slide over the impeller and onto the lower housing 33 i Align discharge of casing 1 with slot in top plate 23 j Bolt casing 1 into position using Loctite 242 on threads Tighten bolts in accordance with Table 6 6 TABLE 6 10 8 MINIMUM IMPELLER NUT TIGHTENING TORQUE FRAME Ft lbs Nm 1 100 140 2 300 400 3 300 400 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 34 of 42 6 11 Setting Impeller Clearance Never attempt to change the clearance when the pump is running If the coupling has limited axial adjustment capability the pump and driver must be uncoupled prior to adjusting the clearance in order to permit free movement a Loosen the thrust bearing housing jam nuts and back off the three jacking
13. C MAX MISC FASTNERS PARTS STEEL Nickel Chrome Boron Coated except for units with mechanical seals Viton will be used for all applications operating above 120oC FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 18 of 42 4 INSTALLATION Equipment operated in hazardous locations must comply with the relevant explosion protection regulations See section 1 6 4 Products used in potentially explosive atmospheres 4 1 Location The pump should be located to allow room for access ventilation maintenance and inspection with ample headroom for lifting and should be as close as practicable to the supply of liquid to be pumped Allow sufficient room to facilitate the back pull out feature on V belt driven units Refer to the general arrangement drawing for the pump set 4 2 Part assemblies Motors may be supplied loose on FRBH pumps typically on frame sizes 400 and above It is the responsibility of the installer to ensure that the motor is assembled to the pump and lined up as detailed in section 4 5 2 4 3 Foundation The foundation may consist of any material that will afford permanent rigid support to the full area of the pump or driver supporting member It should be of sufficient size and mass to absorb expected strains and shocks that may be encountered in service Concrete foundations built on solid ground are desirable The purpose of foundation bolts is to anchor the pump unit securely to the foundation
14. applied Gland packing must not be used when pumping hazardous liquids DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 6 of 36 FLUORO ELASTOMERS When fitted When a pump has experienced temperatures over 250 C 482 F partial decomposition of fluoro elastomers eg 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 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 vapour could cause an explosion HOT and cold PARTS If hot or freezing components or auxiliary heating supplies can present a danger to operators and persons entering the immediate area action must be taken to avoid accidental contact If complete protection is not possible the machine access must be limited to maint
15. are any circumstances in which the system can allow the pump to run dry or start up empty a power monitor should be fitted to stop the pump or prevent it from being started This is particularly relevant if the pump is handling a flammable liquid If leakage of product from the pump or its associated sealing system can cause a hazard it is recommended that an appropriate leakage detection system is installed To prevent excessive surface temperatures at bearings it is recommended that temperature or vibration monitoring are carried out See sections 5 7 4 and 5 7 5 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 24 of 42 5 COMMISSIONING START UP OPERATION AND SHUTDOWN These operations must be carried out by fully qualified personnel 5 1 Pre commissioning procedure 5 1 1 Lubrication Determine the mode of lubrication of the pump set eg grease oil product lubrication etc For oil lubricated pumps fill the bearing housing with correct grade of oil to the correct level ie sight glass or constant level oiler bottle When fitted with a constant level oiler the bearing housing should be filled by unscrewing or hinging back the transparent bottle and filling the bottle with oil Where an adjustable body Trico oiler is fitted this should be set to the proper height The oil filled bottle should then be refitted so as to return it to the upright position Filling should be repeated until oil remains visible within the b
16. coupling surfaces Flush the pump internals of any rust preventative applied for long term storage Lift the baseplate assembly remove the shipping skids and clean the underside of the baseplate Position the baseplate over the foundation and lower the unit over the foundation bolts and onto the wedges shims or jacking nuts With the aid of a machinist s level adjust the wedges shims or jacking nuts to level the pump and driver mounting pads in each direction Check to ensure that the suction and discharge flanges are plumb level and at the correct elevation It is normal practice to set the mounting pads slightly low in order to permit lowering of units which may be required to suit future piping or minor changes Place washers over the foundation bolts and install nuts Tighten finger tight only Check the impeller axial clearance and that the rotor turns freely by hand Note Grout is not poured until an initial alignment of the pump and driver has been performed FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 19 of 42 4 5 Initial alignment 4 5 1 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 4 5 2 Alignment methods Ensure
17. desiccant material inside casing and completely seal all openings from the surrounding atmosphere The stuffing box should be packed with clean dry rags Use of this method requires that the casing be initially free of liquid The desiccant material should be checked at regular intervals to ensure that it has not absorbed excessive water vapour A warning instruction advising that the desiccant must be removed prior to installation should be wired to the pump A rust inhibitor should be added to the lubricating oil of oil lubricated units to give additional protection without destroying the lubricating properties of the oil For specific recommendations consult your lubrication dealer Grease lubricated units which can be identified by the grease fitting at each bearing location should be well lubricated prior to placing in storage Small amounts of additional grease should be added at regular intervals during storage Refer to Section III for additional information related to grease lubrication Storage of pumps in areas of high ambient vibration should be avoided to prevent bearing damage due to brinelling The risk of such damage can be reduced by frequent rotation of the shaft The pump half coupling and key should be removed from the shaft coated with rust preventative and wrapped to prevent metal to metal contact Exposed surfaces of the pump shaft should be protected with a rust preventative All dismantled parts should be wrapped an
18. 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 machines above a certain power level will exceed 85 dBA In such situations consideration must be given to the fitting of an acoustic enclosure to meet local regulations Pump noise level is dependent on a number of factors the type of motor fitted the operating capacity pipework design and acoustic characteristics of the building The levels specified in the table below are estimated and not guaranteed The dBA values are based on the noisiest ungeared electric motors that are likely to be encountered They are Sound Pressure levels at 1 m 3 3 ft from the directly driven pump for free field over a reflecting plane For Estimating Lwa sound power level re 1pW add 14Dba to the sound pressure value If a pump unit only has been purchased for fitting with your own driver then the pump only noise levels from the table should be combined with the level for the driver obtained from the supplier If the motor is driven by an inverter it may show an increase in noise level at some speeds Consult a Noise Specialist for the combined calculation For units driven by equipment other than electric motors or units contained within enclosures see the accompanying information sheets and manuals FRBH pump size Sound Pressure dBA 1 m 3 ft Sound Power dBA
19. number of equally spaced stop starts per hour shown in the table below Check actual capability of the driver and control starting system before commissioning Motor rating kW hp Maximum stop starts per hour Up to 15 20 15 Between 15 20 and 90 120 10 Above 90 120 6 Where duty and standby pumps are installed it is recommended that they are run alternately every week 5 8 Stopping and shutdown a Close the outlet valve but ensure that the pump runs in this condition for no more than a few seconds b Stop the pump c Switch off flushing and or cooling heating liquid supplies at a time appropriate to the process d For prolonged shut downs and especially when ambient temperatures are likely to drop below freezing point the pump and any cooling and flushing arrangements must be drained or otherwise protected 5 9 Hydraulic mechanical and electrical duty This product has been supplied to meet the performance specifications of your purchase order however it is understood that during the life of the product these may change The following notes may help the user decide how to evaluate the implications of any change If in doubt contact your nearest Flowserve office 5 9 1 Specific gravity SG Pump capacity and total head in metres feet do not change with SG however pressure displayed on a pressure gauge is directly proportional to SG Power absorbed is also directly proportional to SG It is therefore impo
20. nut from the shaft e The bearings may be removed from the shaft by using a puller or cutting torch If a torch is used caution is required to prevent damage to the shaft FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 31 of 42 f The thrust bearing housing may be removed from the shaft 6 8 6 Line Bearing a The line bearing is secured in place using a snap ring as well as an interference fit on the shaft Remove the snap ring b The bearing may be removed by using a bearing puller or can be cut from the shaft using a cutting torch Caution should be used with the cutting torch to prevent damaging the shaft and sleeve 6 8 7 a Remove the shaft sleeve from the shaft The sleeve has a locational fit and may be held in place with an anaerobic sealant b If required remove bearing frame 19 from the top plate 23 6 9 Examination of parts Used parts must be inspected before assembly to ensure the pump will subsequently run properly In particular fault diagnosis is essential to enhance pump and plant reliability 6 9 1 Casing wear plate stuffing box head and impeller a Inspect for excessive wear pitting corrosion erosion or damage and any sealing surface irregularities b Replace as necessary 6 9 2 Shaft and sleeve Replace if grooved pitted or worn 6 9 3 Gaskets and O rings a After dismantling discard and replace b Clean and inspect all gasket surfaces 6 9 4 Bearings and Stuffing Box Bushi
21. pump and driver are isolated electrically and the 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 If necessary align the motor to the pump not the pump to the motor Direct Driven Units The importance of accurate alignment of pump and driver shafts cannot be overemphasized IMPROPER ALIGNMENT IS THE PRIMARY CAUSE OF VIBRATION PROBLEMS AND REDUCED BEARING LIFE A flexible coupling is used to compensate for slight changes in alignment which occur during normal operation and is not used to correct for installation errors Install the pump and driver half couplings in accordance with the coupling manufacturer s instructions Note that the coupling hub faces are not always mounted flush with the ends of the shafts Place the driver on the baseplate such that the correct spacing is obtained between the two half couplings In the case of electric motors such as those with sleeve bearings it may be necessary to run the motor to establish the rotor magnetic center Consult the manufacturer s instruction manual for details The purpose of the alignment procedure is to ensure that the pump and driver shafts are in parallel and angular alignment under the normal operating conditions of load and temperature See Fig 2 When the pump coupling and driver are assembled at the factory
22. removed FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 35 of 42 7 FAULTS CAUSES AND REMEDIES FAULT SYMPTOM Pump overheats and seizes Bearings have short life Pump vibrates or is noisy Mechanical seal has short life Mechanical seal leaks excessively Pump requires excessive power Pump loses prime after starting Insufficient pressure developed Insufficient capacity delivered Pump does not deliver liquid PROBABLE CAUSES POSSIBLE REMEDIES A System troubles Pump not primed Pump or suction pipe not completely filled with liquid Check complete filling Vent and or prime Suction lift too high or level too low Insufficient margin between suction pressure and vapour pressure Check NPSHa gt NPSHr proper submergence losses at strainers fittings Excessive amount of air or gas in liquid Check and purge pipes and system Air or vapour pocket in suction line Check suction line design for vapour pockets Air leaks into suction line Check suction pipe is airtight Air leaks into pump through mechanical seal sleeve joints casing joint or pipe plugs Check and replace faulty parts CONSULT FLOWSERVE Foot valve too small Investigate replacing the foot valve Foot valve partially clogged Clean foot valve Inlet of suction pipe insufficiently submerged Check out system design Speed too low CONSULT FLOWSERVE Speed too high
23. screws at least 1 5 mm 0 06 in b Move the rotor towards the wear plate 181 by tightening the three hold down capscrews evenly and uniformly until the impeller 2 just touches the wear plate 181 This can be best established by rotating the shaft and stopping the forward motion at the first sign of rubbing If the shaft cannot be rotated back off the bearing housing with the jacking screws until a just detectable rub is obtained c Set a dial indicator on the end of the shaft or the flange of the bearing housing 33 Set dial to 0 d Determine the required impeller axial running clearance from Engineering Tables of Section 3 4 e Loosen the thrust bearing housing hold down capscrews slightly and tighten the jack screws to achieve the clearance reading on the dial indicator f Alternately and gradually tighten the hold down capscrews and jack screws while maintaining the reading on the dial indicator The gap between the housing and the bearing frame should be even within 0 08mm 0 003 in g While preventing the jack screws from rotating tighten h the jam nuts to lock them in position i Manually rotate the shaft to ensure that there is no rubbing or binding j On belt driven units adjust the pump or driver sheave to maintain belt alignment Section 4 5 k Check the alignment on direct driven units refer to Section 4 5 and reassemble the coupling components l Replace any safety guards that may have been
24. such that the foundation and pump assembly become a single structural unit High strength steel foundation bolts SAE Gr 5 or equal of the specified diameter should be located according to the elevation drawing provided Each bolt should be surrounded by a pipe sleeve two or three times the diameter of the bolt The sleeves should be securely anchored and designed to allow the bolts to be moved to conform with the holes in the baseplate The bolts should be sufficiently long to allow for wedges or shims or levelling nuts under the baseplate and a washer heavy hex nut and hex jam nut for retention Since baseplate levelling is performed after the foundation has cured it is best to use extra long bolts that can be shortened after the installation is complete 4 4 Baseplate installation Position the baseplate and pump next to the foundation and clean the foundation surface thoroughly Remove the rag packing from the pipe sleeves and place wedges or ships as close to the foundation bolts as possible These may be omitted if a jacking nut on the foundation anchor bolts is preferred for levelling Initial levelling should be within 0 75 mm 030 inches Remove the flange covers and check inside the pump nozzles for cleanliness Kerosene is recommended as the best solvent for removing factory applied rust preventative Ensure that all traces of rust preventative are removed from the discharge and suction flange faces the exposed shafting and all
25. surface of the baseplate is completely submerged Do not fill isolated areas around the shims or levelling nuts Once the grout has set sufficiently remove the wooden forms and finish off the sides and top as desired At the same time roughen the grout surface inside the baseplate Cover with wet burlap and allow the grout to cure for at least 40 hours After grouting has cured shims and levelling nuts should be removed or backed off Tighten down baseplate to the new grout to put bolts in tension and ensure rigidity of structure Install jam nuts and cut the bolts to the desired length Finish grouting isolated areas Fill the baseplate including pump and driver support pedestals with concrete Trowel and slope the surface to give suitable drainage 4 7 Piping 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 4 7 1 Suction and discharge pipework In order to minimize friction losses and hydraulic noise in the pipework it is good practice to choose pipework that is one or two sizes larger than the pump suction and discharge Typically main pipework velocities should not exceed 2 m s 6 ft sec suction and 3 m s 9 ft sec on the discharge Take into account the available NPSH which must be higher than the required NPSH of the pump Never use the pump as a support for piping Maxi
26. to under or over grease the bearings as this will lead to over heating and premature failure It is recommended that the bearings be filled with grease using a suitable spatula In addition the housings should be no more than half filled 6 3 Spare parts 6 3 1 Ordering of spares Flowserve keep records of all pumps that have been supplied When ordering spares the following information should be quoted 1 Pump serial number 2 Pump size 3 Part name taken from section 8 4 Part number taken from section 8 5 Number of parts required The pump size and serial number are shown on the pump nameplate To ensure continued satisfactory operation replacement parts to the original design specification should be obtained from Flowserve Any change to the original design specification modification or use of a non standard part will invalidate the pump s safety certification 6 3 2 Storage of spares Spares should be stored in a clean dry area away from vibration Inspection and re treatment of metallic surfaces if necessary with preservative is recommended at 6 monthly intervals 6 4 Recommended spares and consumable items For start up purposes 1 restriction bushing 2 shaft sleeves 1 set of gaskets and seals For 2 years operation 1 set of bearings line and thrust 2 restriction bushings 2 shaft sleeves 2 sets of gaskets and seals 1 casing wear plate For 4 years operation 1 set of bearings line and thrust
27. 12 356 14 406 16 152 6 203 8 457 18 CASING C I mm in 17 5 69 19 0 75 20 8 82 20 8 82 19 0 75 20 8 82 17 3 68 THICKNESS S S mm in 14 2 56 15 7 62 17 5 69 17 5 69 16 0 63 17 5 69 14 2 56 CASING TYPE SV DV SV DV DUAL VOLUTE GAUGE CONNECTION 1 2 NPT DRAIN CONNECTION 1 NPT 1 1 4 NPT 1 NPT 1 5 NO OF VANES 4 6 5 4 5 IMPELLER EYE AREA cm2 in 2 292 45 2 755 117 839 130 1090 169 352 54 4 564 87 4 1510 234 MAX SPHERE DIA mm in 48 3 1 9 96 5 3 8 40 6 1 6 40 6 1 6 50 8 2 0 61 2 4 61 2 4 WK2 kg x m2 lb x ft2 83 19 8 93 22 0 1 57 37 2 1 39 33 0 1 64 38 8 1 88 44 5 3 91 92 9 PUMP WT kg lb IMPELLER AXIAL mm CLEARANCE in 38 76 015 030 MAXIMUM TEMPERATURE 121oC 250oF STUFFING BOX DATA O D SLEEVE mm in 95 25 3 750 STUFFING BOX BORE mm in 127 00 5 000 DEPTH OF BOX mm in 122 2 4 81 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 16 of 42 TABLE OF ENGINEERING DATA FRAMES 3 amp 4 FRAME DETAILS ENGINEERING DATA 6 F R B H 1 8 3 12 F R B H 1 8 3 14 F R B H 1 8 3 16 F R B H 1 8 3 6 F R B H 2 2 3 8 F R B H 2 2 3 18 F R B H 2 2 3 SHAFT AND BEARING DATA
28. 22 Bearing Lock Nut 37 Thrust Bearing Cover 89B O ring 6 Shaft 22A Bearing Lock Washer 40 Deflector 101 Column Pipe 11 Stuffing Box Head 23 Top Plate 46 Drive Key 161 Discharge Pipe 14 Shaft Sleeve 24 Impeller nut 47 Seal Inboard 181 Wearplate 16 Line Bearing 30 O ring Impeller Nut 49 Seal Outboard 209A Stud Wearplate 17 Bushing Cover 32 Impeller Key 53 Motorstand 215A Nut Wearplate 18 Thrust bearing set 33 Housing Thrust bearing 73 Gasket Casing 8 5 General arrangement drawing The typical general arrangement drawing and any specific drawings required by the contract will be sent to the Purchaser separately unless the contract specifically calls for these to be included into the User Instructions If required copies of other drawings sent separately to the Purchaser should be obtained from the Purchaser and retained with these User Instructions 9 CERTIFICATION Certificates determined from the contract requirements will be provided with this manual Examples are certificates for CE marking and ATEX marking If required copies of other certificates sent separately to the Purchaser should be obtained from Purchaser for retention with the User Instructions See section 1 9 Noise level for details of typical noise certification 10 OTHER RELEVANT DOCUMENTATION AND MANUALS 10 1 Supplementary User Instruction manuals Supplementary instruction determined from the con
29. 9 7 38 9 7 38 9 7 38 9 7 38 9 7 38 14 2 56 16 63 12 7 50 12 7 50 16 63 17 5 69 CASING TYPE SV SINGLE VOLUTE DV SV DV GAUGE CONNECTION 1 4 NPT 1 2 NPT DRAIN CONNECTION 3 8 NPT 1 2 NPT 3 4 NPT 1 NPT NO OF VANES 4 IMP EYE AREA cm2 in 2 34 5 2 61 9 5 93 14 4 137 21 3 214 33 2 127 19 7 182 28 2 247 38 3 361 56 183 28 3 200 31 0 359 55 6 555 86 0 MAX SPHERE DIA mm in 12 7 5 17 8 7 25 4 1 0 30 5 1 2 43 2 1 7 25 4 1 0 35 6 1 4 38 1 1 5 55 9 2 2 19 1 75 27 9 1 1 55 9 2 2 68 6 2 7 WK2 kg x m2 lb x ft2 07 1 7 08 1 9 07 1 6 08 1 9 12 2 8 19 4 6 27 6 5 34 8 2 48 11 5 51 12 0 53 12 5 88 20 8 1 19 28 2 PUMP WEIGHT kg lb IMPELLER AXIAL CLEARANCE mm in 38 76 015 030 38 76 015 030 MAXIMUM TEMPERATURE 121oC 250oF 121oC 250oF MAX HYDRO C I 12 1 bar 175 psi 15 5 bar 225 psi PRESSURE S S 20 7 bar 300 psi 20 7 bar 300 psi STUFFING BOX DATA O D SLEEVE mm in 50 80 2 000 76 20 3 000 STUFF BOX BORE mm in 69 85 2 750 101 60 4 000 DEPTH OF BOX mm in 77 5 3 05 99 1 3 90 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 14 of 42 TABLE OF ENGINEERING DATA FRAMES 1 amp 2 FRAME DETAILS
30. A gt Care must be taken during assembly to avoid contamination of the parts with dirt or other foreign matter 6 10 1 Preparation a Inspect all new parts Remove all nicks burrs etc that may have been caused by handling b Lubricate internal bores of bearing frame 19 with same grease used to lubricate bearings c Install the thrust bearing housing 33 into the applicable bore of the bearing frame 19 to ensure a good sliding fit then remove d Clean shaft free of grease at the spacer sleeve 78 location Spray the area with Loctite Primer T The primer acts as a catalyst to ensure optimum bond strength and rapid cure of the Loctite compound 6 10 2 Line Bearings a Apply Loctite 680 to the shaft and install the sleeve 79 at the line bearing against the shaft shoulder FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 32 of 42 b Lightly lubricate the shaft 6 at the bearing position c Use an induction heater or oil bath to first heat up the line bearing 16 to 100 C 2100F Press the bearing on the shaft with the aid of a sleeve designed to push the inner race only Note that the inner race must seat on the shaft sleeve shoulder d After the bearing has cooled protect the bearing by wrapping with a clean lint free cloth e Slide the retaining ring 706 over the shaft and place in groove f The bearings are sealed for life and do not need greasing 6 10 3 Thrust Bearings a Slide the thrust b
31. DIA AT IMPELLER mm in 69 85 2 750 DIA UNDER SLEEVE mm in 82 55 3 250 DIA BETWEEN mm BEARINGS in 104 65 4 12 DIA AT COUPLING mm in 63 50 2 500 LINE BEARING 6321 2RS1 C3 THRUST BEARING 7318 BECBY BEARING SPAN mm in 952 5 37 5 B10 BEARING LIFE MINIMUM 3 YEARS BEARING SEALS THRUST BEARING LIP SEAL NATIONAL 417191 LINE BEARING LIP SEAL NATIONAL 417511 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 17 of 42 MATERIALS OF CONSTRUCTION LIQUID END BASIC CONSTRUCTION ALL IRON AIF ALL 316 SS SS IRON CASING SS FITTED SSF 317 SS 317L SS WORTHITE W CASING LOWER HOUSING AND WEAR PLATE ASTM A48 CL35 ASTM A743 CF8M ASTM A48 CL35 ASTM A743 CG8M ASTM A743 CG3M ASTM A743 CN7MS IMPELLER ASTM A48 CL30 ASTM A743 CF8M ASTM A743 CF8M ASTM A743 CG8M ASTM A743 CG3M ASTM A743 CN7MS IMPELLER NUT ASTM A743 CG3M ASTM A743 CG3M ASTM A743 CG3M ASTM A743 CG3M ASTM A743 CG3M ASTM A743 CN7M SHAFT SLEEVE ASTM A743 CG3M ASTM A743 CG3M ASTM A743 CG3M ASTM A743 CG3M ASTM A743 CG8M ASTM A743 CN7M SHAFT AISI 1045 AISI 316 AISI 1045 AISI 317L AISI 317L AISI A20 PIPE PLUGS LIQUID END C I AISI 316 C I A 20 A 20 A 20 IMPELLER KEY AISI 1045 AISI 316 AISI 1045 A 20 A 20 A 20 WEAR PLATE STUDS amp NUTS AISI 316 A 20 GASKETS SYNTHETIC FIBRE O RINGS LIQUID END BUNA N 120o
32. ENGINEERING DATA 2 F R B H 1 2 1 3 F R B H 1 2 1 3 F R B H 1 0 1 4 F R B H 1 1 1 6 F R B H 1 1 1 3 F R B H 1 4 1 4 F R B H 1 4 1 6 F R B H 1 4 2 8 F R B H 1 5 2 3 F R B H 1 8 2 4 F R B H 1 8 2 8 F R B H 1 8 2 10 F R B H 1 8 2 SHAFT AND BEARING DATA DIA AT IMPELLER mm in 28 58 1 125 34 93 1 375 50 80 2 000 DIA UNDER SLEEVE mm in 41 27 1 625 66 68 2 625 DIA BETWEEN mm BEARINGS in 104 65 4 12 DIA AT COUPLING mm in 63 50 2 500 LINE BEARING 6321 2RS1 C3 THRUST BEARING 7318 BECBY BEARING SPAN mm in 691 27 2 B10 BEARING LIFE MINIMUM 3 YEARS BEARING SEALS THRUST BEARING LIP SEAL 1 NATIONAL 417191 LINE BEARING LIP SEAL 1 C R 49929 NATIONAL 417511 1 LIP SEAL MAY BE REPLACED BY APPROPRIATE LABRYNTH SEALS FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 15 of 42 TABLE OF ENGINEERING DATA FRAME 3 LIQUID END ENGINEERING DATA 6 F R B H 1 8 3 12 F R B H 1 8 3 14 F R B H 1 8 3 16 F R B H 1 8 3 6 F R B H 2 2 3 8 F R B H 2 2 3 18 F R B H 2 2 3 PUMP DATA SUCTION DIAMETER mm in 254 10 356 14 356 14 406 16 254 10 305 12 457 18 DISCHARGE DIA mm in 152 6 305
33. Pump speed rpm 2 FRBH 121 75 89 1780 3 FRBH 121 75 89 1780 3 FRBH 101 75 89 1780 3 FRBH 141 77 91 1780 4 FRBH 111 77 91 1780 4 FRBH 141 78 92 1780 6 FRBH 111 80 93 1780 6 FRBH 142 81 95 1780 8 FRBH 182 83 98 1180 8 FRBH 152 85 99 1780 10 FRBH 182 85 99 1180 6FRBH 183 85 100 1780 8FRBH 183 86 101 1780 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 10 of 36 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 one month 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 fork lift vehicles or slings dependent on their size and construction The pump should be lifted with suitably sized and located slings Do not u
34. acement of either component is required loosen wear plate nuts and remove wear plate 181 c Remove impeller nut 24 application of heat may be required to break bond of resinous sealant on threads heat evenly d Remove impeller 2 For ease of removal the impeller hub is slotted to accept a standard bearing puller e Remove impeller key 32 and sleeve stop 82 6 8 3 Stuffing Box Head a Remove stuffing box head 33A from the support pipe 101 b Inspect lower bushing 39 if replacement is required carefully press bearing out c Remove the support pipe 101 d Inspect shaft sleeve 6 for excessive wear Remove shaft sleeve only if replacement is necessary The sleeve is a hook type that is normally held in place with an anaerobic sealant 6 8 4 Bearing Frame a If the motor stool was not removed with the motor it should be unfastened from the bearing frame now b Unfasten and remove the line bearing cover from the bearing frame c Loosen and remove jacking stud nuts and bolts from the thrust bearing housing 33 d Remove the shaft assembly from the bearing frame 19 set on wooden V blocks 6 8 5 Thrust bearings a Loosen cap screws from thrust bearing cover 37 remove cover b Slide thrust bearing housing 33 towards the inboard line bearing to expose bearings c To remove the bearings first bend the locking tab of the bearing lock washer 22A from lock nut 22 d Using a hook type wrench unscrew the lock
35. and casing external surface temperatures 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 make routine vibration monitoring checks In dirty or dusty environments regular checks must be made and dirt removed from areas around close clearances bearing housings and motors 1 6 4 4 Preventing the build up of explosive mixtures ENSURE THE PUMP IS PROPERLY FILLED AND VENTED AND DOES NOT RUN DRY Ensure the pump and relevant suction and discharge pipeline system is totally filled with liquid at all times during the pump operation so that an explosive atmosphere is prevented 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 cannot avoid this condition the fitting of an appropriate dry run protection device is recommended eg liquid detection or a power monitor To avoid potential hazards from fugitive emissions of vapour or gas to atmosphere the surrounding area must be well ventilated 1 6 4 5 Preventing sparks To prevent a potential hazard from mechanical contact the coupling guard must be non sparking and anti static for Category 2 To avoid the potential hazard from random induced current generating a spark the earth contact on the baseplate must be u
36. as possible If any change in NPSHA is proposed ensure these margins are not significantly eroded Refer to the pump performance curve to determine exact requirements particularly if flow has changed If in doubt please consult your nearest Flowserve office for advice and details of the minimum allowable margin for your application 5 9 5 Pumped flow Flow must not fall outside the minimum and maximum continuous safe flow shown on the pump performance curve and or data sheet 6 MAINTENANCE 6 1 General It is the plant operator s responsibility to ensure that all maintenance inspection and assembly work is carried out by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail See also section 1 6 2 Any work on the machine must be performed when it is at a standstill It is imperative that the procedure for shutting down the machine is followed as described in section 5 8 On completion of work all guards and safety devices must be re installed and made operative again Before restarting the machine the relevant instructions listed in section 5 Commissioning start up operation and shut down must be observed Oil and grease leaks may make the ground slippery Machine maintenance must always begin and finish by cleaning the ground and the exterior of the machine If platforms stairs and guard rails are required for maintenance they must be placed for e
37. asy access to areas where maintenance and inspection are to be carried out The positioning of these accessories must not limit access or hinder the lifting of the part to be serviced When air or compressed inert gas is used in the maintenance process the operator and anyone in the vicinity must be careful and have the appropriate protection Do not spray air or compressed inert gas on skin Do not direct an air or gas jet towards other people Never use air or compressed inert gas to clean clothes Before working on the pump take measures to prevent an uncontrolled start Put a warning board on the starting device with the words Machine under repair do not start With electric drive equipment lock the main switch open and withdraw any fuses Put a warning board on the fuse box or main switch with the words Machine under repair do not connect Never clean equipment with inflammable solvents or carbon tetrachloride Protect yourself against toxic fumes when using cleaning agents 6 2 Maintenance schedule It is recommended that a maintenance plan and schedule is adopted in line with these User Instructions to include the following a Any auxiliary systems installed must be monitored if necessary to ensure they function correctly FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 28 of 42 b Check for any leaks from gaskets and seals The correct functioning of the shaft seal must be checked regularly c Check
38. auxiliary supplies 25 5 6 Starting the pump 25 5 7 Running the pump 26 5 8 Stopping and shutdown 26 5 9 Hydraulic mechanical and electrical duty 26 6 MAINTENANCE 27 6 1 General 27 6 2 Maintenance schedule 27 6 3 Spare parts 29 6 4 Recommended spares and consumable items29 6 5 Tools required 29 6 6 Fastener torques 30 6 7 Renewal clearances 30 6 8 Disassembly 30 6 9 Examination of parts 31 6 10 Assembly 31 6 11 Setting Impeller Clearance 34 7 FAULTS CAUSES AND REMEDIES 35 8 PARTS LIST AND DRAWINGS 38 8 1 FRBHJC Sectional drawing 38 8 5 General arrangement drawing 39 9 CERTIFICATION 39 10 OTHER RELEVANT DOCUMENTATION AND MANUALS 39 10 1 Supplementary User Instruction ma
39. bearing lubricant level and if the hours run show a lubricant change is required d Check that the duty condition is in the safe operating range for the pump e Check vibration noise level and surface temperature at the bearings to confirm satisfactory operation f Check dirt and dust is removed from areas around close clearances bearing housings and motors g Check coupling alignment and re align if necessary Our specialist service personnel can help with preventative maintenance records and provide condition monitoring for temperature and vibration to identify the onset of potential problems If any problems are found the following sequence of actions should take place a Refer to section 7 Faults causes and remedies for fault diagnosis b Ensure equipment complies with the recommendations in this manual c Contact Flowserve if the problem persists 6 2 1 Routine inspection daily weekly The following checks should be made and the appropriate action taken to remedy any deviations a Check operating behaviour Ensure noise vibration and bearing temperatures are normal b Check that there are no abnormal fluid or lubricant leaks static and dynamic seals and that any sealant systems if fitted are full and operating normally c Check that shaft seal leaks are within acceptable limits d Check the level and condition of oil lubricant On grease lubricated pumps check running hours since last recharge of grease or co
40. centreline A button screwed into one of the shaft ends is normally fitted between the motor and pump shaft ends to fix the axial position If the motor does not run in its magnetic centre the resultant additional axial force may overload the pump thrust bearing Complete piping as below and see sections 4 7 Final shaft alignment check up to and including section 5 Commissioning startup operation and shutdown before connecting driver and checking actual rotation V Belt Drive Units Check that both sheaves are free of grease rust nicks or burrs Install the correct size sheave on the pump shaft and locate the sheave axially to minimize overhang Re check the impeller axial clearance and ensure that the pump is properly secured to the baseplate Install the driver on the adjustable base provided and install the driver sheave in line with the pump sheave Ensure that the sheaves are tight on the shafts With a dial indicator check the run out on the periphery and face of each sheave to ensure that each is running true Tighten the adjustable base and check that the driver rotation in the correct direction and that vibration levels are not unacceptable Checking V Belt Sheave Alignment FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 21 of 42 Before starting the driver refer to the manufacturer s instruction manual The correct rotation of the pump shaft is marked on the pump casing or frame Check that all bel
41. chedule 6 2 27 Piping 4 6 21 Priming and auxiliary supplies 5 5 25 Reassembly see 6 10 Assembly 31 Replacement parts see 6 3 and 6 4 29 Safety protection systems see 1 6 and 4 9 5 23 Sound level see 1 9 Noise level 9 Specific machine performance 1 8 9 Starting the pump 5 6 25 Stopping and shutdown 5 8 26 Storage 2 4 10 Supplementary manuals or information sources 38 Tools required 6 5 29 Torques for fasteners 6 6 30 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 4 of 36 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 utilising sophisticated quality techniques and safety requirements We are committed to continuous quality improvement and being at your service for any further i
42. d tagged according to pump serial number and a record kept of their location Pumps covered with plastic should not be stored in a cool environment because resulting condensation can cause rusting FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 11 of 36 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 PUMP DESCRIPTION 3 1 Configurations Flowserve FRBH pumps are single stage end suction centrifugal pumps specifically designed for the pulp and paper industry and consequently are ideally suited to many process fluids A volute type casing with integrally cast feet and top centerline discharge nozzle is standard Th e semi open impeller with rear pump out vanes is capable of passing pulpy material and solids of a limited size A rigid steel sump cover plate
43. de the shaft assembly through Bearing Cartridge 19 from the drive end and align to the adjusting bolt holes d Assemble adjusting bolts and hardware 6 10 5 Lower Column 6 10 5 1 Integral line bearing cover In some designs the line bearing cover is integral with the column support pipe 101 a Place the support pipe 101 in a horizontal position on a V block arrangement and install lip seal 47 with the primary sealing lip away from the bearings b Lubricate the shaft sleeve for the line bearing seal c Lift the support pipe and carefully install over the shaft and to the top plate bearing frame assembly The sealing lip could be damaged during the assembly if adequate precaution not taken d Fasten the support pipe to the top plate bearing frame assembly Use Loctite A thread locking compound on all capscrew threads Tighten in accordance with Table 6 6 6 10 5 2 Loose line bearing cover a Install the lipseal 47 or labyrinth seal in the line bearing cover 37 Place the lipseal with the primary sealing lip away from the bearings For labyrinth seals the shoulder is outside and away from the bearings b Lubricate the shaft sleeve for the line bearing seal c Install the line bearing cover to the bearing frame 19 and fasten in place with appropriate fasteners d Lift the support pipe and carefully install over the shaft and to the line bearing cover FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 33 of 42
44. earing housing 33 onto the shaft 6 between the line bearing 16 and thrust bearing 18 Location b Lightly lubricate the shaft 6 at the bearing position c Use and induction heater or not oil bath to heat the bearings to 100 C 2100F Install the thrust bearings 18 as noted below Note that the angular contact bearings are mounted back to back commonly called the O arrangement The inner race must seat on the shaft shoulder d Slide the bearing lockwasher 22A on the shaft and fit the bearing locknut 22 Tighten the locknut snugly and allow to cool Check the tightness and bend one lockwasher tab over to lock the nut e Pack the thrust bearings 18 with grease f Slide the thrust bearing housing 33 over the bearings g Install the grease fitting into the thrust bearing cover 37 h Carefully install the lip seal 49 or labyrinth seal into the thrust bearing cover 37 by pressing squarely into the bore i Slide the thrust bearing cover over the shaft Care must be taken to ensure that the lip seal is not damaged on the shaft keyway j Secure to the thrust bearing housing using the capscrews and lockwashers tighten in accordance with Table in section 6 6 6 10 4 Bearing Frame a Place the top plate 23 in a vertical position and block in place with angle plates b Bolt the bearing frame 19 to the top plate 23 Use Loctite A on the capscrew threads tighten in accordance to Table 6 6 c Sli
45. emperature is recorded at the commissioning stage and after the bearing temperature has stabilized Record the bearing temperature t and the ambient temperature ta Estimate the likely maximum ambient temperature tb Set the alarm at t tb ta 5 C t tb ta 10 F and the trip at 100 C 212 F for oil lubrication and 105 C 220 F for grease lubrication It is important particularly with grease lubrication to keep a check on bearing temperatures After start up the temperature rise should be gradual reaching a maximum after approximately 1 5 to 2 hours This temperature rise should then remain constant or marginally reduce with time Refer to section 6 2 3 1 for further information 5 7 5 Normal vibration levels alarm and trip For guidance pumps generally fall under a classification for rigid support machines within the International rotating machinery standards and the recommended maximum levels below are based on those standards Alarm and trip values for installed pumps should be based on the actual measurements N taken on the pump in the fully commissioned as new condition Measuring vibration at regular intervals will then show any deterioration in pump or system operating conditions Vibration velocity unfiltered mm s in s r m s FRBHJC Normal N 7 1 0 28 Alarm N x 1 25 9 0 0 35 Shutdown trip N x 2 0 14 2 0 56 5 7 6 Stop start frequency Pump sets are normally suitable for the
46. enance 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 or below 5 C 20 F in a restricted zone or exceeds local regulations action as above shall be taken 1 6 4 Products used in potentially explosive atmospheres 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 1 6 4 1 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 and any additional equipment with the necessary CE Certificate Declaration of Conformity establishing it is suitable for the area i
47. ends on the temperature class and must not exceed the values in the table that follows The temperature rise at the seals and bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated Temperature class to EN 13463 1 Maximum surface temperature permitted Temperature limit of liquid handled depending on material and construction 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 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 when the pump is required to be used in differently classified potentially explosive atmospheres In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in its actual installed location If an explosive atmosphere exists during the installation do not attempt to check the direction of rotation by starting the pump unfilled Even a short run time may give a high temperature resulting from contact between rotating and stationary components Where there is any risk of the pump being run against a closed valve generating high liquid
48. ll 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 purchaser 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 you the user seek our written agreement before start up FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 5 of 36 1 6 Safety 1 6 1 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 would affect personal safety This symbol indicates safety instructions where non compliance would affect personal safety This symbol indicates safety instructions where non compliance would affect protection of a safe life environment This symbol i
49. mplete grease change e Check any auxiliary supplies eg heating cooling if fitted are functioning correctly Refer to the manuals of any associated equipment for routine checks needed 6 2 2 Periodic inspection six monthly a Check foundation bolts for security of attachment and corrosion b Check pump running records for hourly usage to determine if bearing lubricant requires changing c The coupling should be checked for correct alignment and worn driving elements Refer to the manuals of any associated equipment for periodic checks needed 6 2 3 Re lubrication Lubricant and bearing temperature analysis can be useful in optimizing lubricant change intervals In general however the following is recommended 6 2 3 1 Grease lubrication See section 5 2 2 for grease recommendations Regrease via grease nipples every 2 000 hours or sooner depending on the severity of the application It is important not to under or over grease the bearings as this will lead to over heating and premature failure a Grease lubricated bearing housings have grease nipples fitted in the bearing covers b Move the axial seal ring back so the gap between the pump shaft and bearing cover can be seen c Connect grease gun to the nipple d Press grease into the bearing housing until the first signs of it appear in the gap between the housing and shaft then stop greasing e V rings should be seated at the proper distance from the sealing surface
50. mum forces and moments allowed on the pump flanges vary with the pump size and type To minimize these forces and moments that may if excessive 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 The table in 4 7 2 summarizes the maximum forces and moments allowed on FRBH pump casings Refer to Flowserve for other configurations Ensure piping and fittings are flushed before use Ensure piping for hazardous liquids is arranged to allow pump flushing before removal of the pump FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 22 of 42 4 7 2 Maximum forces and moments allowed on FRBH pump flanges Maximum forces F in N lbf and moments M in Nm lbf ft Suction Discharge Flange Size DN in Mx My Mz Fx Fy Fz Mx My Mz Fx Fy Fz 50 2 460 340 230 170 350 260 890 200 710 160 5808 130 460 340 230 170 350 260 710 160 580 130 890 200 65 2 1 2 710 520 350 260 540 400 1110 250 890 200 760 170 710 520 350 260 540 400 890 200 760 170 1110 250 80 3 950 700 470 350 720 530
51. n which it is to be installed The output from a variable frequency drive VFD can cause additional heating affects in the motor and so for pumps sets with a VFD the ATEX Certification for the motor must state that it is covers the situation where electrical supply is from the VFD This particular requirement still applies even if the VFD is in a safe area 1 6 4 2 Marking An example of ATEX equipment marking is shown below The actual classification of the pump will be engraved on the nameplate II 2 GD c IIC 135 C T4 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 c Constructional safety in accordance with En13463 5 Gas Group Equipment Category 2 only IIA Propane typical IIB Ethylene typical IIC Hydrogen typical Maximum surface temperature Temperature Class See section 1 6 4 3 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 7 of 36 1 6 4 3 Avoiding excessive surface temperatures ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate These are based on a maximum ambient of 40 C 104 F refer 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 dep
52. ndicates safety instructions where non compliance would affect the safe operation or protection of the pump or pump unit 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 1 6 2 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 1 6 3 Safety action This is a summary of conditions and actions to prevent injury to personnel and damage to the environment and to equipment For products used in potentially explosive atmospheres section 1 6 4 also applies 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 fla
53. nformation 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 and 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
54. ng T I R is within 0 076 mm 0 003 inch Angular Alignment With the magnetic base mounted on the pump half coupling hub move the dial indicator button to indicate on the face of the driver half coupling hub as close to the outside diameter as possible Turn both shafts 360 and record the dial readings at 90 intervals Adjust the shims under the motor as required and repeat the procedure until the angular alignment is within 0 0005 mm T I R per mm 0 0005 inch per inch of maximum hub diameter Repeat the checks on parallel and angular alignment ensuring the mounting bolts are secure until the unit is properly aligned Note that correction in one direction may affect the alignment in another direction Re check the gap between the coupling hubs If any difficulty is encountered in achieving the recommended alignment tolerances the runout of the pump and driver shafts and each coupling hub diameter and face should be checked Occasionally due to practical and unavoidable manufacturing tolerance build up associate with the pump coupling and driver it may be necessary to match up the two coupling hubs in the most advantageous relative angular position in order to achieve an acceptable alignment Do not install the coupling spacer or sleeve until grouting is complete and cured and the alignment is re checked When the electric motor has sleeve bearings it is necessary to ensure that the motor is aligned to run on its magnetic
55. ng a It is recommended that bearings are not re used after any removal from the shaft b The plain liquid lubricated bearings may be re used if both the stuffing box bush and bearing sleeve show no sign of wear grooving or corrosion attack It is recommended that both the bush and sleeve are replaced at the same time 6 9 5 Bearing isolators labyrinths or lip seals if fitted a The lubricant bearings and bearing housing seals are to be inspected for contamination and damage b If bearing damage is not due to normal wear and the lubricant contains adverse contaminants the cause should be corrected before the pump is returned to service c Labyrinth seals and bearing isolators should be inspected for damage but are normally non wearing parts and can be re used d Inspect all bearing lip seals 47 amp 49 and replace move if worn damaged or in doubt 6 9 6 Bearing frame and housing a Clean and flush bearing housing internal surfaces 6 10 Assembly To assemble the pump consult the sectional drawings see section 8 Parts list and drawings Ensure threads gasket and O ring mating faces are clean Apply thread sealant to non face sealing pipe thread fittings The following consumable material are required for pump assembly high strength thread locking compound equivalent to Loctite 680 primer T medium strength thread locking compound equivalent to Loctite A anti seize compound Loctite Corporation Newington Conn US
56. nge ENSURE CORRECT LUBRICATION See section 5 Commissioning startup operation and shutdown START THE PUMP WITH OUTLET VALVE PART OPENED Unless otherwise instructed at a specific point in the user instructions This is recommended to minimize the risk of overloading and damaging the pump motor at full or zero flow Pumps may be started with the valve further open only on installations where this situation cannot occur The pump outlet control valve may need to be adjusted to comply with the duty following the run up process See section 5 Commissioning start up operation and shutdown NEVER RUN THE PUMP DRY INLET VALVES TO BE FULLY OPEN WHEN PUMP IS RUNNING Running the pump at zero flow or below the recommended minimum flow continuously will cause damage to the seal DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES Operating at a flow rate higher than normal or at a flow rate with no back pressure on the pump may overload the motor and cause cavitation Low flow rates may cause a reduction in pump bearing life overheating of the pump instability and cavitation vibration NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER HAZARDOUS LIQUIDS When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by appropriate siting of the pump limiting personnel access and by operator training If the liquid is flammable and or explosive strict safety procedures must be
57. ngs Check hours run since last change of lubricant the schedule and its basis Improper installation of bearings damage during assembly incorrect assembly wrong type of bearing etc Check method of assembly possible damage or state of cleanliness during assembly and type of bearing used Remedy or CONSULT FLOWSERVE if necessary Damaged bearings due to contamination Check contamination source and replace damaged bearings FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 37 of 42 FAULT SYMPTOM Pump overheats and seizes Bearings have short life Pump vibrates or is noisy Mechanical seal has short life Mechanical seal leaks excessively Pump requires excessive power Pump loses prime after starting Insufficient pressure developed Insufficient capacity delivered Pump does not deliver liquid PROBABLE CAUSES POSSIBLE REMEDIES C MOTOR ELECTRICAL PROBLEMS Wrong direction of rotation Reverse 2 phases at motor terminal box Motor running on 2 phases only Check supply and fuses Motor running too slow Check motor terminal box connections and voltage FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 38 of 42 8 PARTS LIST AND DRAWINGS 8 1 FRBHJC Sectional drawing ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION 1 Casing 19 Bearing Frame 35 Cover Line Bearing 78 Sleeve Bearing 2 Impeller
58. ngs are fitted as standard and grease lubricated The inboard bearing located just above the top plate is pregreased and is sealed for life Greasing if necessary will only be required for the lip seal that seals the bearing housing The outboard bearing cover has a grease fitting accessible through the motorstand 3 3 5 Stuffing box housing The stuffing box or lower housing has a spigot rabbet fit between the pump casing and bearing housing for optimum concentricity The design enables a number of sealing options to be fitted for horizontal configuration FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 12 of 36 3 3 6 Driver The driver is normally an electric motor driving via couplings belts gearboxes drive shafts etc 3 3 7 Accessories Accessories may be fitted when specified by the customer 3 4 Performance and operating limits This product has been selected to meet the specifications of your purchase order see section 1 5 The following data is included as additional information to help with your installation It is typical and factors such as temperature materials and seal type may influence this data If required a definitive statement for your particular application can be obtained from Flowserve 3 4 1 Operating limits Pumped liquid temperature limits up to 177 C 350 F Maximum ambient temperature up to 50 C 122 F Maximum soft solids in suspension up to 7 by volume Maximum pump speed Refer
59. nuals 39 10 2 Change notes 39 10 3 Additional sources of information 39 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 3 of 36 INDEX PAGE Alignment of shafting see 4 5 4 7 and 4 3 19 21 18 CE marking and approvals 1 2 4 Clearances see 6 7 Renewal clearances 30 Commissioning and operation see 5 24 Configurations 3 1 11 Direction of rotation 5 3 25 Dismantling see 6 8 Disassembly 30 Duty conditions 1 5 4 Electrical connections 4 8 23 Examination of parts 6 9 31 Faults causes and remedies 34 General assembly drawings see 8 37 Grouting 4 4 21 Guarding 5 4 25 Handling 2 2 10 Hydraulic mechanical and electrical duty 5 9 26 Lifting 2 3 10 Location 4 1 18 Lubrication schedule see 5 2 Pump lubricants 17 Maintenance s
60. of technical documents and safety instructions Where applicable this document incorporates information relevant to these Directives To establish approvals and if the product itself is CE marked check the serial number plate 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 Corporation 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 organisations Genuine parts and accessories have been designed tested and incorporated into the products to help ensure their 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 authorised 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 A
61. ottle Approximate oil volumes are shown in section 3 4 2 Pump and impeller data Grease lubricated pumps and electric motors are supplied pre greased Other drivers and gearboxes if appropriate should be lubricated in accordance with their manuals In the case of product lubricated bearings the source of product supply should be checked against the order There may be requirements for an external clean supply particular supply pressure or the commencement of lubrication supply before pump start up FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 25 of 42 5 2 Pump lubricants 5 2 1 Recommended grease lubricants Grease nipples Grease NLGI 2 NLGI 3 Temp range C F 20 to 100 4 to 212 20 to 100 4 to 212 Designation according to DIN K2K 20 K2K 30 BP Energrease LS2 Energrease LS3 DEA Glissando 20 Glissando 30 Elf Elfmulti 2 Elfmulti 3 Esso Beacon 2 Beacon 3 Mobil Mobilux 2 Mobilux 3 Q8 Rembrandt 2 Rembrandt 3 Shell Alvania Fett G2 Alvania Fett R2 Alvania R3 Texaco Multilak 20 Multilak EP2 Multilak 30 Multilak EP3 Wintershall BASF Group Wiolub LFK 2 SKF LGMT 2 LGMT 3 Silkolene G55 T G56 T NLGI 2 is an alternative grease and is not to be mixed with other grades Factory packed bearings for the temperature range with grease nipples 5 2 2 Recommended fill quantities Refer to section 3 4 2 Pump and impeller data 5 2 3 Lubrica
62. pment 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 4 9 4 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 4 9 5 A device to provide emergency stopping must be fitted 4 9 6 If not supplied pre wired to the pump unit the controller starter electrical details will also be supplied within the controller starter 4 9 7 For electrical details on pump sets with controllers see the separate wiring diagram 4 9 8 See section 5 3 Direction of rotation before connecting the motor to the electrical supply 4 10 Protection systems The following protection systems are recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous liquid If in doubt consult Flowserve If there is any possibility of the system allowing the pump to run against a closed valve or below minimum continuous safe flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsafe level If there
63. rance detailed in section 3 4 2 has doubled to 1 0 to 1 5 mm 0 040 to 0 060 in depending on pump size 6 8 Disassembly Refer to section 1 6 Safety before dismantling the pump Before dismantling the pump for overhaul ensure genuine Flowserve replacement parts are available Refer to sectional drawings for part numbers and identification 6 8 1 Pump unit a Isolate motor and lock off electrical supply in accordance with local regulations b Isolate discharge valves c Remove coupling guards and disconnect the coupling halves d On units with larger drivers it is recommended to remove the motor If the bearing frame will be dismantled it is suggested that the motor be left connected to the motor Unfasten the motorstand from the top plate and remove e Unscrew and remove discharge pipe flange bolts remove spool sections to allow pump to be removed from well f Unscrew and remove top plate mounting bolts g Install eyebolts in top plate h Using overhead crane or hoist remove pump from well i Place the pump assembly in a horizontal position preferably on a V block fixture Adequate support must be provided to support columns and liquid end to eliminate bending stresses imposed on the shaft and column support pipes 6 8 2 a With casing 1 adequately supported by a hoist unscrew and remove bolts holding casing 1 Remove casing 1 away from support pipe 101 b Inspect wear plate 181 and casing 1 if repl
64. 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 1 7 Nameplate and warning labels 1 7 1 Nameplate For details of nameplate see the Declaration of Conformity 1 7 2 Warning labels ROTATION WARNING P N 2113932 001 GROUT WARNING P N 2113934 001 WARNING BEFORE STARTING THE PUMP ON SERVICE CHECK TO ENSURE CORRECT ROTATION OF MOTOR FAILURE TO DO THIS COULD RESULT IN SERIOUS DAMAGE TO THE EQUIPMENT WARNING BEFORE GROUTING REALIGN THIS UNIT RECHECK ALIGNMENT BEFORE STARTING FAILURE TO DO THIS COULD RESULT IN SERIOUS DAMAGE TO THE EQUIPMENT REFER TO INSTALLATION MANUAL AND OR COUPLING INSTRUCTIONS FOR METHOD OF CHECKING ALIGNMENT FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 9 of 36 1 8 Specific machine performance For performance parameters see section 1 5 Duty conditions When the contract requirement specifies these to be incorporated into User Instructions these are included here Where performance data has been supplied separately to the purchaser these should be obtained and retained with these User Instructions if required 1 9 Noise level When pump noise level exceeds 85 dBA attention must be given to prevailing Health and Safety Legislation to limit the exposure of plant operating personnel to the noise The usual approach is to control exposure time to the noise or to
65. rtant to check that any change in SG will not overload the pump driver or over pressurize the pump FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 27 of 42 5 9 2 Viscosity For a given flow rate the total head reduces with increased viscosity and increases with reduced viscosity Also for a given flow rate the power absorbed increases with increased viscosity and reduces with reduced viscosity It is important that checks are made with your nearest Flowserve office if changes in viscosity are planned 5 9 3 Pump speed Changing pump speed effects flow total head power absorbed NPSHR noise and vibration Flow varies in direct proportion to pump speed head varies as speed ratio squared and power varies as speed ratio cubed The new duty however will also be dependent on the system curve If increasing the speed it is important therefore to ensure the maximum pump working pressure is not exceeded the driver is not overloaded NPSHA gt NPSHR and that noise and vibration are within local requirements and regulations 5 9 4 Net positive suction head NPSHA NPSH available NPSHA is a measure of the head available in the pumped liquid above its vapour pressure at the pump suction branch NPSH required NPSHR is a measure of the head required in the pumped liquid above its vapour pressure to prevent the pump from cavitating It is important that NPSHA gt NPSHR The margin between NPSHA gt NPSHR should be as large
66. se the shaft for lifting and take special care to prevent the pump from rotating in the slings due to unbalanced weight distribution 2 3 Lifting A crane must be used for all pump sets in excess of 25 kg 55 lb Fully trained personnel must carry out lifting in accordance with local regulations The driver and pump weights are recorded on their respective nameplates or massplates 2 4 Storage 2 2 1 Short Term Storage When it is necessary to store a pump for a short time before it can be installed place it in a dry cool location Protect it thoroughly from moisture and condensation Protective flange covers should not be removed until the pump is being installed Wrap the exposed portions of the shaft and coupling to protect against sand grit or other foreign matter Oil lubricated units should be lubricated refer to Section III to protect the bearings Grease lubricated units are lubricated at the factory during assembly Turn the rotor over by hand at least once a week to maintain a protective film on the bearing components 2 4 2 LONG TERM STORAGE More than precautions are required if long term storage in excess of 90 days from factory shipment is unavoidable The internal surfaces of the pump should be sprayed with a rust preventative such as a water soluble oil or other suitable alternative Particular attention should be given to the impeller wear plate and stuffing box An optional method of protection is to suspend bags of
67. sed Avoid electrostatic charge do not rub non metallic surfaces with a dry cloth ensure cloth is damp The coupling must be selected to comply with 94 9 EC and correct alignment must be maintained 1 6 4 6 Preventing leakage 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 FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 8 of 36 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 ancillary 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 1 6 4 7 Maintenance to avoid the 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
68. supports the pump and drive system The three point thrust bearing housing support permits precision bearing alignment and impeller clearance setting The pump liquid end is fitted with a non flush restriction bushing that also acts as a bearing for start up conditions All pumps are carefully inspected and prepared for shipment All exterior machined surfaces are coated with a rust preventative compound and openings are provided with covers or plugs The axial impeller running clearance is preset at the factory but should be checked prior to final alignment in case of tampering 3 2 Name nomenclature The pump size will be engraved on the nameplate The following example explains how the pump name identifies the construction features and options 8FRBH 182 Nominal discharge branch size Configuration see below Nominal maximum impeller diameter Frame size JC is added for vertical cantilever 3 3 Design of major parts 3 3 1 Pump casing The pump casing is a volute type casing with integrally cast feet for horizontal configuration and centerline discharge nozzle It is a one piece pressure retaining casting with gasket connections to the stuffing box head and the suction and discharge flanges 3 3 2 Impeller The impeller is semi open design keyed to the shaft and secured with a contoured impeller nut 3 3 3 Shaft The large diameter stiff shaft mounted on bearings has a keyed drive end 3 3 4 Pump bearings and lubrication Ball beari
69. the shaft are securely fixed 5 5 Priming and auxiliary supplies Ensure all electrical hydraulic pneumatic sealant and lubrication systems as applicable are connected and operational Ensure the inlet pipe and pump casing are completely full of liquid before starting continuous duty operation 5 6 Starting the pump a Ensure flushing and or cooling heating liquid supplies are turned ON before starting the pump b CLOSE the outlet valve c OPEN all inlet valves d Prime the pump e Ensure all vent connections are closed before starting f Start motor and check outlet pressure g If the pressure is satisfactory slowly OPEN outlet control valve h Do not run the pump with the outlet valve closed for a period longer than 30 seconds FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 26 of 42 i If NO pressure or LOW pressure STOP the pump Refer to section 7 Faults causes and remedies for fault diagnosis 5 7 Running the pump 5 7 1 Venting the pump Vent the pump to enable all trapped air to escape taking due care with hot or hazardous liquids Under normal operating conditions after the pump has been fully primed and vented it should be unnecessary to re vent the pump 5 7 4 Bearings If the pumps are working in a potentially explosive atmosphere temperature or vibration monitoring at the bearings is recommended If bearing temperatures are to be monitored it is essential that a benchmark t
70. tion schedule 5 2 3 1 Grease lubricated bearings When grease nipples are fitted one charge between grease changes is advisable for most operating conditions ie 2 000 hours interval Normal intervals between grease changes are 4 000 hours or at least every 6 months The characteristics of the installation and severity of service will determine the frequency of lubrication Lubricant and bearing temperature analysis can be useful in optimising lubricant change intervals The bearing temperature may be allowed to rise to 55 C 131 F above ambient but should not exceed 95 C 204 F For most operating conditions a quality grease having a lithium soap base and NLGI consistency of No 2 or No 3 is recommended The drop point should exceed 175 C 350 F Never mix greases containing different bases thickeners or additives 5 3 Direction of rotation Ensure the pump is given the same rotation as the pump direction arrow cast on the pump casing To avoid dry running the pump must either be filled with liquid or have the flexible coupling disconnected before driver is switched on If maintenance work has been carried out to the site s electricity supply the direction of rotation should be re checked as above in case the supply phasing has been altered 5 4 Guarding Guarding is supplied fitted to the pump set If this has been removed or disturbed ensure that all the protective guards around the pump coupling and exposed parts of
71. to avoid overheating f The maximum allowable operating temperatures for anti friction bearings will vary from unit to unit depending on ambient and fluid temperature The rise above ambient should not normally exceed 55 C 131 F or a combined maximum of 95 C 204 F g A continuously rising temperature or an abrupt temperature rise indicates a problem If these symptoms occur stop the pump immediately and investigate the cause TIME TEMPERATURE Grease change every 4 000 hours or sooner depending on the severity of the application FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 29 of 42 a Remove the bearing housing from the rotor assembly b Brush the bearing housing with hot kerosene 100 to 115 C 212 to 240 F or other non toxic solvent c Clean and flush out the housing with a light mineral oil d Do not use waste oil to clean the housing To clean the bearings a Wipe off as much grease as possible with a clean lint free cloth b Brush bearings with hot kerosene 80 to 90 C 175 to 195 F while gently spinning the outer bearing ring c Spin each ball to ensure that it is clean To remove badly oxidized grease which refuses to come off a Support the rotor in a vertical position and immerse the bearing in hot kerosene or a mixture of alcohol and light mineral solvent b Gently spin the bearing outer ring c Dry and reflush the bearing with clean light oil d It is important not
72. to the nameplate 3 4 2 Speed torque curves To bring a centrifugal pump up to rated speed the driver must be capable of providing more torque at each speed than required by the pump The margin between the available and required torque affects the time it takes the unit to reach full speed If the torque required by the pump exceeds the torque capability of the drive at any run up speed the unit will not accelerate to full speed Normally this is not a problem with standard induction or synchronous motors provided the proper voltage is supplied at the motor For pumps started at shut valve conditions 100 percent full speed torque can be calculated by using the formula Torque Nm 9545 Shutoff Power kW r min Torque lbfx ft 5250 Shutoff Power hp r min Torque required by the pump at any other speed during start up can be determined from the curve above Note that the driver manufacturer usually bases 100 percent torque on the design power of the driver and consequently the speed torque curves should be plotted in torque units e g Nm instead of percentage torque to avoid confusion 3 4 3 MAXIMUM WORKING PRESSURES bar psi CONSTRUCTION CAST IRON AND C I S S FITTED STAINLESS STEEL 316 317L WORTHITE ETC TEMPERATURE OC OF UP TO 12 DISCHARGE 14 TO 16 DISCHARGE 18 TO 20 DISCHARGE UP TO 16 DISCHARGE 18 TO 20 DISCHARGE 30 to 38 20 to100 10 3 150 10 3 150 6 2 90 13 8 200 8 3 120
73. tract requirements for inclusion into User Instructions such as for a driver instrumentation controller sub driver seals sealant system mounting component etc are included under this section If further copies of these are required they should be obtained from the purchaser for retention with these User Instructions Where any pre printed set of User Instructions are used and satisfactory quality can be maintained only by avoiding copying these they are included at the end of these User Instructions such as within a standard clear polymer software protection envelope 10 2 Change notes If any changes agreed with Flowserve Pump Division are made to the product after its supply a record of the details should be maintained with these User Instructions 10 3 Additional sources of information Reference 1 NPSH for Rotordynamic Pumps a reference guide Europump Guide No 1 Europump amp World Pumps Elsevier Science United Kingdom 1999 Reference 2 Pumping Manual 9th edition T C Dickenson Elsevier Advanced Technology United Kingdom 1995 Reference 3 Pump Handbook 2nd edition Igor J Karassik et al McGraw Hill Inc New York 1993 Reference 4 ANSI HI 1 1 1 5 Centrifugal Pumps Nomenclature Definitions Application and Operation Reference 5 ANSI B31 3 Process Piping FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 40 of 42 Notes FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11 04 Page 41 of 42
74. ts making up one drive set have matched code numbers Loosen the adjustable base and install the belts in their proper grooves Adjust the center distance between the sheaves to obtain proper belt tension Check the alignment of the pump and driver sheaves with a taught string or straight edge For proper alignment and the sheave faces must be parallel to each other and in line Adjustments are made by slackening the belts moving and retightening the drive or driver sheave and repeating the above procedure When the sheaves are aligned that the shafts rotate freely by hand and install safety guard 4 6 Grouting The purpose of grouting is to provide rigid support to the pump and driver by increasing the structural rigidity of the baseplate and making it an integral mass with the foundation Clean the roughed foundation surface and build a wooden form around the baseplate see Fig 1 For initial grouting forms should be placed to isolate shims and levelling nuts The foundation surface should be thoroughly saturated with water before grouting A typical mixture for grouting in a pump base is composed of one part pure Portland cement and two parts of clean building sand with sufficient water to provide the proper consistency The grout should flow freely but not be so wet as to cause the sand and cement to separate Thoroughly puddle the grout while pouring to eliminate air pockets and low spots Pour sufficient grouting to ensure that the bottom
75. ump setting yet maintain cantilever design All designs are reviewed for shaft deflection and critical speeds b Inlet strainers when used should have a net free area of at least three times the inlet pipe area 4 7 3 Discharge piping A non return valve should be located in the discharge pipework to protect the pump from excessive back pressure and hence reverse rotation when the unit is stopped Pipework reducers should have a maximum total angle of divergence of 15 degrees Fitting an isolation valve will allow easier maintenance 4 7 5 Final checks Check the tightness of all bolts in the suction and discharge pipework Check also the tightness of all foundation bolts 4 8 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 Recheck the coupling alignment as previously described to ensure no pipe strain If pipe strain exists correct piping 4 9 Electrical connections 4 9 1 Electrical connections must be made by a qualified Electrician in accordance with relevant local national and international regulations 4 9 2 It is important to be aware of the EUROPEAN DIRECTIVE on potentially explosive areas where compliance with IEC60079 14 is an additional requirement for making electrical connections 4 9 3 It is important to be aware of the EUROPEAN DIRECTIVE on electromagnetic compatibility when wiring up and installing equi

FRBHJC User Manual 2004

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