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UNIREX Pump User's Manual

1. A Page 62 of 68 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE 8 7 Mark 3 In Line pump Group 1 e _ NN TIR CES Ael Y NN Av item Description 4120 Gland 65703 Screw bearing carrier set 1100 Casng 4130 Packing optional 6570 12 Screw clamp 1220 Covr 4134 Seal cage packing optional 6570 15 Screw pump stand 2100 Shaft 4200 Mechanical seal 65721 Stud casing 2200 Impeller 2400 Sleeve optional 2540 Deflector inboard optional 4590 3 Gasket Gland 6580 2 Nut gand 3011 Ballbearing inboard 46102 O ring bearing carrier 6580 3
2. V PROBABLE CAUSES POSSIBLEREMEDIES ut Recalculate NPSH available It must be greater than the NPSH maje si is TE enc Mo e maj mobbe required by pump at desired flow If not redesign suction piping present holding number of elbows and number of planes to a minimum to D Pe est is sie ieee tH 2 avoid adverse flow rotation as it approaches the impeller na Reduce system head by increasing pipe size and or reducing DUM System head greater than anticipated number of fittings Increase impeller diameter note Increasing 1 III impeller diameter may require use of a larger motor 1 Check suction line gaskets and threads for tightness maje k Entrained air Air leak from 2 f vortex formation is observed in suction tank install vortex atmosphere on suction side breaker Mi S Check for minimum submergence 6 6 o LA tt yd Entrained gas from process Process generated gases may require larger pumps LA TE EE RES Speed too low Check motor speed against design speed sale Directi f rotati After confirming wrong rotation reverse any two of three leads on i a aia a three phase motor The pump should be disassembled and JA ZE EM ee 4Jispectedbeforeitisrestarted 1 O Replace with proper diameter impeller NOTE Increasing eiii doas aliia impeller diameter may require use of a larger motor o
3. m T t races in a stationary bearing intervals of one to three months e Thrust overload on bearing identified i by flaking ball path on one side of the Follow correct mounting procedures for bearings outer race or in the case of maximum capacity bearings may appear as a spalling of the races in the vicinity of the loading slot Please note maximum capacity bearings are not recommended in Mark 3 pumps These thrust failures are caused by improper mounting of the bearing or E ha jexessivethrstloads Bd e E ea Bu Ve sa Handle parts carefully and follow recommended mounting hoer racs and aharrower cocked ball procedures Check all parts for proper fit and alignment path on the outer race Misalignment is caused by poor mounting practices or defective drive shaft For example bearing not square with the centerline or possibly a bent shaft due to NA QU RA al improper handling s Bearing damaged by electric arcing 1 Where current shunting through the bearing cannot be identified as electro etching of both ees E in the form of a slip ring assembly should be i incorporated iuis ENEJ d la EUN d 2 Check all wiring insulation and rotor windings to be sure that bya GIA electrical charge they are sound and all connections are properly made emanating from belt drives electrical 3 Where pumps are belt driven consider the elimination of static leakage or short circuiting c
4. 5240 Item Description 3200 Bearing housing 4610 2 O ring bearing carrier 1100 Casing 3240 Bearing carrier 6521 Plug bearing housing vent 1220 Cover 3712 Bearing locknut 6541 1 Lockwasher bearing 1340 Adapter bearing housing 3855 Constant level oiler not shown 6569 1 Plug bearing housing drain 2100 Shaft 3856 Sight gage bearing housing 6570 12 Screw clamp 2200 Impeller 4120 Gland 6570 2 screw cover adapter 2400 Sleeve optional 4130 Packing optional 6570 3 Screw bearing carrier set 2530 1 Retaining ring bearing 4134 Seal cage packing optional 6570 4 Screw foot 2530 2 Retaining ring clamp type 4200 Mechanical seal 6570 5 Screw bearing housing 2540 Deflector inboard optional 4310 1 Oil seal inboard 6572 1 Stud casing 2541 Oil flinger optional 4310 2 Oil seal outboard 6572 2 Stud gland 3011 Ball bearing inboard 4590 1 Gasket cover 6580 1 Nut casing 3013 Ball bearing outboard 4590 2 Gasket impeller 6580 2 Nut gland 8126 1 Shim 4590 3 Gasket Gland 6700 Key shaft coupling 3134 Support foot 4610 1 O ring adapter Page 59 of 68 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE 8 2 Standard Mark 3 pump Group 2 and Group 3 6700 43510 215240 5712 6541 501 5 253
5. 2300 1350 1500 1300 310 310 1400 1350 3250 1200 1460 690 2K 6x4 10 and 10H N 6 005 6 672 1 763 1 492 1 492 6 227 6 005 14 456 1 627 2 034 936 2700 1350 1500 1300 1100 1100 1400 1350 3250 1200 1500 690 12010 6005 6672 1 763 909 909 6227 6005 14456 719 719 719 2K Slots and LF13 2 700 1 350 1 500 1 300 670 670 1400 1 350 3 250 530 530 530 2K 3x2 13 8 540 5 471 5 471 1 763 475 475 6 227 6 005 14 456 1 627 1 722 936 1920 1230 1230 1300 350 350 1400 1350 3250 1200 1270 690 2K 3x2US 13 8 540 5471 5 471 1 763 475 475 6 227 6 005 14 456 1 627 1 722 936 po 1920 1230 1230 1300 350 350 1400 1350 3250 1200 1270 690 12010 6005 6672 1 763 542 542 6227 6005 14456 1627 2034 936 2K 4x3 13 and 13HH 2 700 1 350 1 500 1 300 400 400 1 400 1 350 3 250 1 200 1 500 690 2K 4x3US 13 12 010 6 005 6 672 1 763 542 542 6 227 6 005 14 456 1 627 2 034 936 2700 1350 1500 1300 400 400 1400 1350 3250 1200 1500 690 2K 4x8R 13 p 6 005 6 672 1 763 542 542 6 227 6 005 14 456 1627 2 034 936 2700 1350
6. The Mark 3 Unitized self priming centrifugal pumps have a slightly different requirement regarding priming The initial priming liquid must be added to the pump casing until the liquid has reached the bottom of the suction nozzle Once the initial prime is in place the pump will automatically replenish itself and additional priming liquids are not normally needed If liquid is lost additional priming liquid may be needed 5 7 Starting the pump a Open the suction valve to full open position It is very important to leave the suction valve open while the pump is operating Any throttling or adjusting of flow must be done through the discharge valve Partially closing the suction valve can create serious NPSH and pump performance problems b Never operate pump with both the suction and discharge valves closed This could cause an explosion Ensure the pump is primed See section 5 6 d All cooling heating and flush lines must be started and regulated e Start the driver typically the electric motor f Slowly open the discharge valve until the desired flow is reached keeping in mind the minimum continuous flow listed in section 3 4 g It is important that the discharge valve be opened within a short interval after starting the driver Failure to do this could cause a dangerous build up of heat and possibly an explosion 5 8 Running or operation 5 8 1 Minimum continuous flow Minimum continuous stable flow i
7. 1K 3x2 6 8985 4670 4 670 3 105 298 298 8 985 6 005 27756 1397 1397 692 2020 1050 1050 2290 220 220 2020 1350 6240 1030 1030 510 1K 1 5x1 8 and LF 8 8985 5382 5 382 2 481 258 258 8 985 6 005 E 488 488 488 2020 1210 1210 1830 190 190 2020 1350 6240 360 360 360 SES 5US 8 8985 5382 5 382 2 481 258 258 8 985 6 005 kve 488 488 488 TONY 2020 1210 1210 1830 190 190 2020 1350 6240 360 360 360 1K 3x1 5 8 8985 5516 7 295 3 105 664 664 8 985 6 005 Es 597 597 597 l 2020 1240 1640 2290 490 490 2020 1350 6240 440 440 440 2K 3x2 8 12010 6005 DE 5 058 814 814 8 763 6 005 HO 895 895 895 2700 1350 2490 3730 600 600 1970 1350 6240 660 660 660 2K 4x3 8 12010 6005 8 184 5 058 475 475 8 985 6 005 Eis 1980 1 980 936 2700 1350 1840 3730 350 350 2020 1350 6240 1460 1460 690 10408 4270 4270 4936 298 298 8985 6005 27756 895 895 895 2K agat NG QU 2340 960 960 3 640 220 220 2 020 1 350 6240 660 660 660 2K 2x1 5US 10A 10 408 4270 4 270 4 936 298 298 8 985 6 005 n 895 895
8. Impeller clearance too large Reset impeller clearance ie le Plugged impeller suction line or 1 Reduce length of fiber when possible casing which may be due to a product 2 Reduce solids in the process fluid when possible le pe pe MM t uds or large solids 3 Consider larger pump Wet end parts casing cover impeller el worn corroded or missing mepiace PAMO PANS Repeat priming operation recheck instructions If pump has run ee DOUPIODSID DORT dry disassemble and inspect the pump before operation bbi 1 Check and reset impeller clearance E DP b dr m Musso 2 Check outboard bearing assembly for axial end play lele Damaged pump shaft impeller Replacedamagedparts o Hedesign suction piping holding the number of elbows and planes s Abnormal fluid rala due to to a minimum to avoid adverse fluid rotation as it approaches the complex suction piping impeller PERS TH Beari famines 1 Work with clean tools in clean surroundings caring contamination appearing ON 5 Remove all outside dirt from housing before exposing bearings the raceways as scoring pitting 3 Handle with clean dry hands scratching or rusting caused by 4 Treat a used bearing as carefully as a new one adverse environment and entrance of 5 Use clean solvent and flushing oil iue contaminants from 6 Protect disassembled bearing from dirt and moisture ane pte 7 Keep bearings wrapped in paper
9. Outboard Bearing Carrier Bearing Coupling End View 1 8 NPT Grease Fitting and Relief Pipe Plug side View Bearing Housing Coupling End View Figure 5 10 Horizontal lubrication amounts Until grease 3 3 Until grease comes out of plug Until grease 3 kong Group 2 inboard comes out of plug 17 cm 1 0 in Until grease 3 3 Group 2 outboard comes out of plug 28 cm 1 7 in Group 2 duplex 68 cm 4 1 in 34 cm 2 1 in Until grease 3 E Group 3 inboard comes out of plug 30 cm 1 8 in Until grease 3 3 Group 3 outboard comes out of plug 54 cm 3 3 in Group 3 duplex 115cm 7 0in 60 cm 3 7 in Group2inboard 164 cm 1 0 in 17 cm 1 0 in Group 2 outboard 47 4 cm 2 9 in 28 cm 1 7 in 3 If new bearings are not lubricated they should be packed prior to installation and the housing lubricated as described above ZN CAUTION Do not fill the housing with oil when greased bearings are used The oil will leach the grease out of the bearings and the life of the bearings may be drastically reduced 5 2 2 1 Grease for life Double shielded or double sealed bearings These bearings are packed with grease by the bearing manufacturer and should not be relubricated The replacement interval for these bearings is greatly affected by their operating temperature and speed Shielded bearings typically operate co
10. 3 4 4 Minimum continuous flow The minimum continuous flow MCF is based on a percentage of the best efficiency point BEP Figure 3 7 identifies the MCF for all Mark 3 pump models with the exception of the Lo Flo pump line there is no MCF associated with this product line 3 4 5 Minimum suction pipe submergence The minimum submergence is shown in figure 3 8 and 3 9 for Unitized self priming pumps flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE Figure 3 2 Alloy cross reference chart Flowserve Designation Durco legacy ACI Equivalent wrought ASTM Material material code codes designation designation specifications Group No E3020 Ductile iron DCI None None A395 Gr 60 40 18 1 0 E3033 High chrome iron CR28 None None A532 class 3 Cr E4027 High chrome iron CR29 None None None Cr E4028 High chrome iron CR35 None None None Cr C3009 Carbon steel DS None Carbon steel A216 Gr WCB 1 1 C3062 Durco CF8 D2 CF8 304 A744 Gr CF8 2 1 C3069 Durco CF3 DaL CF3 304L A744 Gr CF3 2 1 C3063 Durco CF8M D4 CF8M 316 A744 Gr CF8M 2 2 C3067 Durco CF3M D4L CF3M 316L A744 Gr CF3M 2 2 C3107 Durcomet 100 CD4M CD4MCuN Ferralium A995 Gr CD4AMCUN 28 C4028 Durimet 20 D20 CN7M Alloy 20 A744 Gr CN7M 847 C4029 Durcomet 5 DV None No
11. 3 851 8500 3180 2000 1500 1480 1480 1500 3000 3500 1250 2840 2840 3K 10x8 16 and 16H 15 568 14 145 8 896 2 034 1532 1532 6 672 13 344 15 568 1 695 3 851 3 851 8500 3180 2000 1500 1130 1130 1500 3000 3500 1250 2840 2840 3K 1038 17 15 568 14 145 8 896 2 034 1532 1 532 6 672 13 344 15 568 1 695 3 851 3 851 8500 3180 2000 1500 1130 1130 1500 3000 3500 1250 2840 2840 Page 26 of 68 flowserve com M FLOWSERVE s MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 4 16 Maximum combined loading Pump size Forces N Ibf Moments Nm Ibf ft Forces N Ibf Moments Nm Ibf ft Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd Mzd 1K1 5x1 LF4 8985 3336 3 336 2 481 231 231 8 985 6 005 E 556 556 556 2020 750 750 1830 170 170 2020 1350 6240 410 410 410 1K 1 5x1 6 8985 3336 3 336 2 481 231 231 8 985 6 005 ps 556 556 556 2020 750 750 1830 170 170 2020 1350 6240 410 410 410 1K 3x1 5 6 8985 5516 9 385 3 105 664 664 8 985 6 005 Eds 746 746 692 2020 1240 2110 2290 490 490 2020 1350 6240 550 550 510
12. 6240 1460 1460 690 2K 6x4 10 and 10H 12010 6005 IEEE 5 058 1492 1492 8 985 6 005 HO 4 204 4 204 936 2700 1350 6240 3730 1100 1100 2020 1350 6240 3100 3100 690 12010 6005 13611 5058 909 909 8985 6005 27756 719 719 719 2K SET due LF13 2700 1350 3 060 3 730 670 670 2 020 1 350 6240 530 530 530 2K 3x2 13 8540 5471 5 471 5 058 475 475 8 985 6 005 Eus 1980 1 980 936 1920 1230 1230 3730 350 350 2020 1350 6240 1460 1460 690 2K 3x2US 13 8540 5471 5 471 5 058 475 475 8 985 6 005 Es 1980 1 980 936 1920 1230 1230 3730 350 350 2020 1350 6240 1460 1460 690 12010 6005 10631 5058 542 542 8985 6005 27756 2346 2346 936 2K aN NO 2700 1350 2 390 3 730 400 400 2 020 1 350 6 240 1730 1 730 690 2K 4x3US 13 12010 6005 10 631 5 058 542 542 8 985 6 005 Es 2 346 2 346 936 2700 1350 2390 3730 400 400 2020 1350 6240 1730 1730 690 2K 4x8R 13 12010 6005 10 631 5 058 542 542 8 985 6 005 P 2 346 2 346 936 2700 1350 2390 3730 400 400 2020 1350 6240 1730 1730 690 2K 6x4 13A 12010 6005 E 5 05
13. 72 6 66 6 6 3 4 7 76 70 73 656 66 63 64 4 5 7 76 71 73 65 66 6 64 5 5 7 5 76 77 72 75 66 67 6 6 7 5 10 76 77 72 75 66 6 64 65 11 15 80 8 76 78 70 7 6 6 15 20 80 81 76 78 70 71 68 6 18 5 25 L ser sef 2 78 zt l zw 9 Z 22 30 8t et 7 79 71 71 eg 71 30 40 83 83 79 a z z IRI 73 37 50 2839 83 vwa a d z 3 7a zB 45 60 86 86 s8 a8 76 76 74 76 55 75 86 86 82 8 76 76 74 76 75 100 82 1 gz 588 T 85 XC 7z 2 7 90 120 87 88 83 85 77 78 75 78 110 150 89 90 85 87 79 a8 77 80 150 200 89 90 85 87 79 80 77 go 200 270 o o o o 8 s8 s s8 300 400 87 90 85 86 Q The noise level of machines in this range will most likely be of values which require noise exposure control but typical values are inappropriate Note for 1 180 and 960 r min reduce 1 450 r min values by 2 dBA For 880 and 720 r min reduce 1 450 r min values by 3 dBA Page 8 of 68 flowserve com M FLOWSERVE ss 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 n
14. 73 100 1 00 1 00 1 00 1 00 0 50 0 83 0 93 1 00 1 00 0 83 089 344 650 0 63 074 060 062 O60 066 073 082 082 039 370 700 0 74 0 59 0 60 058 0 66 073 0 79 079 033 Page 24 of 68 flowserve com M FLOWSERVE s Figure 4 12 Baseplate correction factors MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 4 13 Coordinate system Base type Grouted Bolted Stilt mounted Type A 10 07 0 65 Type B Polybase 10 ma 0 95 Type C ma 190 1 0 Type D 10 08 0 75 Type E PIP 10 0 95 n a Polyshield baseplate 1 0 n a n a foundation Figure 4 14 Acceptance criteria equations Set Equations Figure Remarks 10 25 10 fe co VS co LAS o L Mz aco xs adj ys adj zs adj M s adj Mys adj Mzs adj Adjusted Maximum 1 4 15 individual ha o 35 s10 Lfd cto Mad eio LM co Mz lt 10 loading Fxa adj Fyd adj Fzd adj Mxd adj Myd adj Mza adj F M E LIL Se oL 6058 WS 8 lu AA Ne Fxs adj Fys adj Fzs ag Mxs ag Mys ag Mzs adj Adjusted stress bolt F M 4 16 stress pump _ Fxg Ta ms cm et Leg T _ xa oo eels NN Mz lt 2 0 slippage Fxd ag Fyd adj Fzd_aadj Mxa adj Myd adj Mza adj A ur M s Me
15. Balance Seenote 1 Bearing housing Diameter ID tolerance n s 0 013 0 0005 at bearings Power end assembly Shaft runout 0 05 0 002 0 03 0 001 Shaft sleeve runout 0 05 0 002 0 05 0 002 0 05 0 002 Radial deflection static n s 0 076 0 003 0 05 0 002 Shaft endplay n s 0 05 0 002 0 05 0 002 Seal chamber Face sguareness to shaft 0 08 0 003 0 03 0 001 0 08 0 003 Register concentricity 0 13 0 005 0 13 0 005 Complete pump Shaft movement caused by pipe strain n s 0 05 0 002 0 05 0 002 Alignment n s See note 2 Vibration at bearing housing See note 3 See note 3 n s not specified 1 The maximum values of acceptable unbalance are 1 500 r min 40 g mm kg 1 800 r min 0 021 oz in Ib of mass 2 900 rpm 20 g mm kg 3 600 rpm 0 011 oz in lb of mass Flowserve performs a single plane spin balance on most impellers The following impellers are exceptions 10X8 14 10X8 16 and 10X8 16H On these Flowserve performs a two plane dynamic balance as reguired by the ASME B73 1M standard All balancing whether single or two plane is performed to the ISO 1940 Grade 6 3 tolerance criteria 2 The ASME B73 1M standard does not specify a recommended level of alignment Flowserve recommends that the pump and motor shafts be aligned to within 0 05 mm 0 002 in parallel FIM full indicator movement and 0 0005 mm mm 0 0005 in in angular FIM Closer alignment will extend
16. FLOWSERVE us J N CAUTION Never compress the snap ring unless it is positioned around the shaft and between the bearings In this configuration it is contained therefore if it should slip off the compression tool it is unlikely to cause serious injury d The shaft bearings and bearing carrier assembly figure 6 14 can now be installed into the bearing housing 3200 The bearing carrier 3240 should be lubricated with oil on the O rings and threads before installing the assembly into the bearing housing Thread the bearing carrier into the bearing housing by turning it clockwise to engage the threads Thread the carrier onto the housing until the carrier flange is approximately 3 mm gin from the housing Install the set ame 6570 3 loosely e Reinstall any tags plugs site gages and oiler Mark 3 and Mark 3A design Install the following items onto the bearing housing oil level tag figure 6 18 and combination Trico oiler site gage 3855 vent breather 6521 and drain plug 6569 1 ANSI 3A design Install the following items onto the bearing housing oil level tag figure 6 18 and site gage 3855 plug 6521 and magnetic drain plug 6569 4 f On Group 2 and 3 pumps assemble the bearing housing adapter 1340 to the bearing housing 3200 Be sure to install a new O ring 4610 1 Mark 3 In Line design The adapter O ring 4610 1 should not be installed if there is a drain tap in the adapter 1340 This t
17. Fzs Fzp Mzc Mzs Mzp Fxs x SRs t Fxp x SRp Me YE Ma hpc lee nde 0707 Er lt FTMax S S Fy F p Melt Mel z MAX e OTOR PSE Page 29 of 68 flowserve com av FLOWSERVE ss Figure 4 22 Allowable stand loads Fr max In N Ibf Fu max In N Ibf GP1 8 020 108 531 Man ou ud 800 2440 8 129 120 115 GP2 V 10 pumps 1 827 27 004 6 792 140 461 GP2 V 13 pumps 1 535 31 579 4 6 5 Pump and shaft alignment check After connecting the piping rotate the pump drive shaft clockwise viewed from motor end by hand several complete revolutions to be sure there is no binding and that all parts are free Recheck shaft alignment see section 4 5 If piping caused unit to be out of alignment correct piping to relieve strain on the pump 4 6 6 Auxiliary piping 4 6 6 1 Mechanical seal When the pump is intended to be equipped with a mechanical seal it is Flowserve standard practice to install the mechanical seal in the pump prior to shipment Specific order requirements may specify that the seal be shipped separately or none be supplied It is the pump installer s responsibility to determine if a seal was installed If a seal was supplied but not installed the seal and installation instructions will be shipped with the pump Failure to ensure that a seal is installed may result in serious leakage of the pumped fluid Seal and seal support system must be installed and operational as specified
18. M FLOWSERVE USER INSTRUCTIONS Installation Durco Mark 3 sealed metallic pumps Operation Mark 3 Standard In Line Lo Flo Recessed Impeller Maintenance Unitized Self Priming and Sealmatic pumps PCN 71569102 08 06 E incorporating P 10 502 E These instructions must be read prior to installing operating using and maintaining this equipment Experience In Motion M FLOWSERVE us CONTENTS Page SNE 2 1 INTRODUCTION AND SAFETY 3 ult Be ETA RERUM 3 1 2 CE marking and approvals 3 t3 DISC i r iole EN 3 MA CODY PIG IM emt 3 to DULY coridilorisicscurseetipivatqn ele pi e ei patada 3 1 6 OB 4 1 7 Name plate and safety labels 7 1 8 NOISE Ie VOLus one na cnn es a deb ek es uc adea 8 2 TRANSPORT AND STORAGE 9 2 1 Consignment receipt and unpacking 9 2 2 Aandi ana dated ee oe ben doutes de 9 2 S UMUN Ji ere ae ai es 9 2 4 SOLAS e oo a ena nje 10 2 5 Recycling and end of product life 11 2 DESCRIPTION KR 11 OUI CODIQUE Oris I aqu ee a Dolce catis du 11 3 2 Nomenclature eeseeeeeeneeeneeee 11 3 3 Design of major parts 12 3 4 Performance and operation limits 12 4 INSTALEATIOD ino teet NN 18 deje BO UNO e ali ei 18 4 2 Part assemblies a aii ate tette cus tea 18 4 3 FOUNJAV OM sad eo det
19. Recessed impellers PT PT LoFlopumps PT PT Opnimples PT P are to use the standard pump ratings given For example 2K 3x2V 13 and 2K 3x2US 13 pumps utilize the standard 2K 3x2 13 ratings P T Only limited by Pressure Temperature ratings Open impeller pumps including the Lo Flo and Recessed Impeller products are limited in suction pressure only by the Pressure Temperature ratings 4 Sealmatic pump suction pressure is limited by the repeller Qm Page 17 of 68 Figure 3 7 Minimum continuous flow MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 3 9 Minimum submergence Suction Pipe Velocity m s 0 33 Minimum Submergence ft 66 98 2 3 Minimum Submergence m 13 1 ks 131 98 166 33 5 flowserve com Suction Pipe Velocity f s M FLOWSERVE ss 4 INSTALLATION Zirconium 702 or high chrome iron components If any of the components of the pump have been made of zirconium or high chrome iron the following precautionary measures should be followed e Use hand wrenches rather than impact wrenches e This equipment should not be subjected to sudden changes in temperature or pressure e Avoid striking this equipment with any sharp blows Zirconium 705 and high chrome iron components Avoid any repair or fabrication welds on Zirconium 705 and high chrome iron components 4 1 Location The pump should be located to allow room for
20. T6 85 C 185 F Consult Flowserve T5 100 C 212 F Consult Flowserve T4 135 C 275 F 110 C 230 F T3 200 C 392 F 175 C 347 F T2 300 C 572 F 270 C 518 F T1 450 C 842 F 350 C 662 F The responsibility for compliance with the specified maximum liquid temperature is with the plant operator Temperature classification Tx is used when the liquid temperature varies and the pump could be installed in different hazardous atmospheres In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in the particular hazardous atmosphere Do not attempt to check the direction of rotation with the coupling element pins fitted due to the risk of severe contact between rotating and stationary components Where there is any risk of the pump being run against a closed valve generating high liquid and casing external surface temperature it is recommended that users fit an external surface temperature protection device Avoid mechanical hydraulic or electrical overload by using motor overload trips temperature monitor or a power monitor and perform routine vibration monitoring In dirty or dusty environments regular checks must be made and dirt removed from areas around close clearances bearing housings and motors Additional requirements for self priming casing pumps Where the system operation does not ensure control of prim
21. consumable items Mechanical process fluid seals bearing housing lip seals bearings shafting impeller and gaskets 6 4 Tools required A typical range of tools that will be required to maintain these pumps is listed below Figure 6 1 6 5 Fastener torques Figure 6 2 Recommended bolt torques m Group 1 Group 2 Group 3 Item Description non lubricated non lubricated non lubricated 6570 12 Bearing retainer cap screws standard bearings n a n a ye in 16 Nm 12 lpfft 6570 12 Bearing retainer cap screws duplex bearings he in 6 Nm 4 lbfeft sin 6 Nm 4 Ibfeft sin 16 Nm 12 Ibfeft 6570 5 Bearing housing adapter cap screws and nuts n a Yo in 54 Nm 40 lbfeft in 122 Nm 90 lbfeft 6580 2 Mechanical seal gland studs nuts with gasket in 16 Nm 12 Ibfeft in 16 Nm 12 Ibfeft vein 41 Nm 30 Ibfeft 6580 2 Mechanical seal gland studs nuts with O ring in 27 Nm 20 Ibfeft in 27 Nm 20 Ibf ft 2 in 54 Nm 40 Ibfeft Yo in 41 Nm 30 Ibf ft 34 in 136 Nm 100 Ibf ft 1 e 6580 1 Casing studs nuts 2 in 41 Nm 30 Ibf ft in 81 Nm 60 Ibfeft 7 in 217 Nm 160 Ibf ft 6570 2 Cap screw cover adapter token bolts in 27 Nm 20 lbfeft in 27 Nm 20 lbfeft in 54 Nm 40 lbfeft 6570 3 Bearing carr
22. interfere with the piloting and centering of the seal components and alter the hydraulic loading of the seal faces resulting in reduction of seal life and performance The seal chamber register concentricity should be less than 0 13 mm 0 005 in The diagram below shows how to measure this concentricity Page 49 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Concentricity 6 8 4 7 Installed pump Complete pump installed Shaft movement caused by pipe strain Pipe strain is any force put on the pump casing by the piping Pipe strain should be measured as shown below Install the indicators as shown before attaching the piping to the pump The suction and discharge flanges should now be bolted to the piping separately while continuously observing the indicators Indicator movement should not exceed 0 05 mm 0 002 in Pipe strain movement Alignment Misalignment of the pump and motor shafts can cause the following problems e Failure of the mechanical seal e Failure of the motor and or pump bearings e Failure of the coupling e Excessive vibration noise The schematics below show the technique for a typical rim and face alignment using a dial indicator It is important that this alignment be done after the flanges are loaded and at typical operating temperatures If proper alignment cannot be maintained a C flange motor adapter and or stilt spring mounting should be considered N Parallel Align
23. 159 152 200 200 159 200 100 7 275 275 285 140 230 220 290 290 230 290 i 29 172 197 190 190 197 97 159 152 200 200 159 200 20 250 285 275 275 285 140 230 220 290 290 230 i 0 250 285 275 275 285 140 230 220 290 290 183 38 17 2 19 7 19 0 19 0 19 7 9 7 15 9 15 2 20 0 20 0 15 9 20 0 12 6 100 250 285 275 275 285 140 230 220 290 290 230 290 183 93 16 2 17 9 15 9 16 2 17 9 9 7 13 8 13 8 17 9 17 9 13 8 17 9 12 6 200 235 260 230 235 260 140 200 200 260 260 200 260 183 14 8 15 9 9 7 13 1 12 4 15 9 15 9 12 4 i 300 215 230 205 215 230 140 190 180 230 230 180 230 183 171 14 4 15 0 13 7 14 3 15 0 9 7 13 0 12 1 15 0 15 0 11 9 15 0 12 6 340 209 218 199 207 218 140 188 176 218 218 172 218 183 204 13 8 13 8 13 1 13 4 13 8 9 7 12 8 11 7 13 8 13 8 11 0 13 8 260 11 7 11 7 117 ara i7 9 7 11 7 11 0 11 7 11 7 10 3 11 7 500 170 170 170 170 170 140 170 160 170 170 150 170 J 316 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 600 PAESE 140 PARARA 140 140 140 140
24. 550 510 1K 3x2 6 4 670 4 670 4 670 1220 298 298 3 558 6 005 13 344 678 1356 692 1050 1050 1050 900 220 220 800 1350 3000 500 1000 510 4670 5382 5382 976 258 258 3558 6005 13344 488 488 488 1K 1 5x1 8 and LF8 1 050 1 210 1 210 720 190 190 800 1 350 3 000 360 360 360 1K 1 5x1 5US 8 4 670 5 382 5 382 976 258 258 3 558 6 005 13 344 488 488 488 1050 1210 1210 720 190 190 800 1350 3000 360 360 360 1K 3x1 5 8 4 670 5516 5 560 1 220 664 664 3 558 6 005 13 344 597 597 597 1050 1240 1250 900 490 490 800 1350 3000 440 440 440 2K 3x2 8 12 010 6 005 6 672 1 763 814 814 6 227 6 005 14 456 895 895 895 2700 1350 1500 1300 600 600 1400 1350 3250 660 660 660 2K 4x3 8 12 010 6 005 6 672 1 763 475 475 6 227 6 005 14 456 1 627 1 980 936 2700 1350 1500 1300 350 350 1400 1350 3250 1200 1460 690 10 408 4270 4270 1 722 298 298 6227 6005 14456 895 895 895 2K zal Omana LF10 2 340 960 960 1 270 220 220 1400 1 350 3 250 660 660 660 2K 2x1 5US 10A 10 408 4 270 4 270 1 722 298 298 6
25. 6570 3 in incremental steps up to the final torque value to lock the bearing carrier in place EP E 4 a M4 V J UME s wo Rosae di i i reins h E 7 i Te B J Figure 6 6 Example If a pump was to be placed in a service with an operating temperature of 100 C 212 F the impeller setting would be 0 53 mm 0 021 in off the rear cover plate Since it is necessary to add 0 05 mm 0 002 in for the movement caused by tightening the set screws an adjustment of 0 58 mm 0 023 in is needed First turn the bearing carrier counter clockwise until the impeller comes into light rubbing contact with the rear cover To determine the number of indicator patterns that you will need to rotate the carrier divide 0 10 into the desired setting 0 58 0 10 5 8 0 023 0 004 5 8 Rotate the bearing carrier clockwise 6 indicator patterns which Will give a clearance of 0 60 mm 0 024 in Flowserve suggests that a felt tip pen be used to mark an initial reference point on the bearing housing and the bearing carrier as shown in figure 6 6 Then make a second mark on the bearing carrier 6 indicator patterns counter clockwise from the initial reference point Rotate the bearing carrier clockwise until the second mark on the bearing carrier lines up with the initial reference point mark on the bearing housing Lastly uniformly tighten the set screws 6570 3 in incremental steps up to the f
26. F Figure 5 3b Recommended lubricants Quality mineral oil with rust and oxidation inhibitors Mobil DTE heavy medium or equivalent Royal Purple or Conoco SYNCON or equivalent Some synthetic lubricants require Viton O rings EXXON POLYREX EM or compatible horizontal Polyurea with mineral oil EXXON Unirex N3 or compatible In Line Lithium Complex with mineral oil oil Mineral Synthetic Maximum oil ISO viscosity Minimum temperature grade viscosity index Up to 71 C 160 F 46 95 71 80 C 160 175 F 68 95 80 94 C 175 200 F 100 95 Page 34 of 68 Figure 5 5 Maximum external housing temperatures Lubrication Temperature Oil bath 82 C 180 F Oil mist 82 C 180 F Grease 94 C 200 F Under 71 C 71 80 C 80 94 C Lubricant 160 F 160 175 F 175 200 F Grease 6 months 3 months 1 5 months Mineral oil 6 months 3 months 1 5 months Synthetic oil 18 months 18 months 18 months Assuming good maintenance and operation practices and no contamination May be increased to 36 months with ANSI 3A M power end Bearing temperatures up to 16 C 30 F higher than housing flowserve com M FLOWSERVE us 5 2 2 Grease 5 2 2 1 Regreasable Single shielded regreasable bearings When the grease lubrication option is specified single shielded bearings grease
27. General instructions for assembling these baseplates are given below For dimensional information please refer to the appropriate Flowserve Sales print 4 3 4 1 Stilt mounted baseplate assembly instructions Refer to figure 4 3 a Raise or block up baseplate pump above the floor to allow for the assembly of the stilts b Predetermine or measure the approximate desired height for the baseplate above the floor c Set the bottom nuts 2 above the stilt bolt head 1 to the desired height d Assemble lock washer 3 down over the stilt bolt e Assemble the stilt bolt up through hole in the bottom plate and hold in place f Assemble the lock washer 3 and nut 2 on the stilt bolt Tighten the nut down on the lock washer g After all four stilts have been assembled position the baseplate in place over the floor cups 4 under each stilt location and lower the baseplate to the floor h Level and make final height adjustments to the suction and discharge pipe by first loosening the top nuts and turning the bottom nuts to raise or lower the baseplate Page 19 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 i Tighten the top and bottom nuts at the lock washer 3 first then tighten the other nuts j It should be noted that the connecting pipelines must be individually supported and that the stilt mounted baseplate is not intended to support total static pipe load Figure 4 3 BE Om
28. in oil until it is visually half way up in the sight glass 3856 Fill the constant level oiler bottle if used and return it to its position The correct oil level is obtained with the constant level oiler in its lowest position which results in the oil level being at the top of the oil inlet pipe nipple or half way up in the sight glass window Oil must be visible in the bottle at all times Note that on ANSI 3A power ends there is no constant level oiler As stated above proper oil level is the center of the bull s eye sight glass 3856 See figure 5 1 Figure 5 1 flowserve com M FLOWSERVE us In many pumping applications lubricating oil becomes contaminated before it loses its lubricating qualities or breaks down For this reason it is recommended that the first oil change take place after approximately 160 hours of operation at which time the used oil should be examined carefully for contaminants During the initial operating period monitor the bearing housing operating temperature Record the external bearing housing temperature See figure 5 5 for maximum acceptable temperatures The normal oil change interval is based on temperature and is shown in figure 5 6 Figure 5 3a Recommended oil lubricants MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 5 2 Amount of oil required The maximum temperature that the bearing can be exposed to is 105 C 220 F e Cil Spl
29. used to push on the motor mounting studs to achieve parallel alignment The motor mounting fasteners must be snug but not tight during alignment It may be necessary to check the motor alignment with motor fasteners tight Corrections may be made until the desired alignment is achieved The motor fasteners adjusters and jam nuts should be tight 4 8 3 In Line pumps The final field alignment follows the same procedure as the initial alignment as described in section 4 5 2 Maximum pump reliability is obtained by having near perfect alignment Flowserve recommends no more than 0 05 mm 0 002 in parallel and 0 0005 mm mm 0 0005 in in angular misalignment 4 9 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 flowserve com M FLOWSERVE us 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 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 t
30. with the lip facing the bearing housing all the way to the ceramic seat Position the O ring 4610 10 over the tail of the lip seal See section 8 3 flowserve com SR FLOWSERVE Rn i Reinstall the repeller cover repeller rear cover and impeller as instructed in section 6 9 3 j The Checkmatic gland must now be moved forward toward the impeller pushing the forward lip ahead of it It is important that the forward lip be firmly loaded against the seat when the gland is seated Care must be taken to maintain even pressure on both sides of the gland keeping the lip seal ceramic seal faces perpendicular to the shaft k Tighten the gland nuts evenly Finally the rear lip must be slipped forward and tight against the seat Care should be taken so as not to damage the seal face 6 9 2 5 Reassembly Sealmatic with dry running seal Component seals will generally require that the wet end is assembled as described in 6 9 3 so that the impeller may be set prior to seal installation Review the seal assembly instructions and drawings provided by the seal manufacturer Section 6 9 2 2 contains the general assembly sequences for component seals 6 9 2 6 Reassembly Sealmatic with FXP seal a Remove any sharpness of edge at wet end of shaft with 400 emery cloth b Clean all exposed surfaces of the wet end of the shaft c Install a shaft guide tool from the Flowserve tool kit See figure 6 1 d Insert the O rings into
31. 1 US gpm as shown below Outlet Outlet Inlet Inlet Figure 4 26 4 6 6 6 Piping connection heating cooling fluid for jacketed cover casing The piping connections for jacketed covers and casings are shown below The flow rate of the cooling water less than 32 C 90 F should be at least 0 13 l s 2 US gpm Inlet for Steam or Self Venting Outlet for Liquid Suggested Inlet tor Liquid Drain or Self Draining Plug Plumbing to Outlet for Steam Obtain Drain Condensate When Using Liquid Figure 4 27 Discharge Outlet 3 4 NPT Inlet Vent 8 Outlet tz S 3 4 NPT Inlet Vent Outlet Figure 4 28 Page 31 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Notes 1 When circulating steam use top hole for inlet Both bottom holes must be plumbed together for outlet to ensure draining both sides of jacket 2 When circulating liquid use both bottom holes as inlets Use top hole as outlet 4 6 6 7 Piping connection Oil mist lubrication system The piping connections for an oil mist lubrication system are shown below DIL MIST READY HOUSING WET SUMP Locate Vent Fitting Above Horizontal At Assy Locate Pipe Plug Below Horizontal At Assy 1 4 NPT Opp Side Figure 4 29 OIL MIST READY HOUSING DRY SUMP Locate Vent Fitting Above Horizontal Al Assy Locate Pipe Plug 1NPT 1 4 NPT Opp Side Below Horizontal amp At Assy Figure 4 30 4 7 Electrical connectio
32. 140 343 8 6 8 6 8 6 8 6 8 6 8 6 8 6 8 6 8 6 650 125 125 125 125 125 125 125 125 125 371 7 6 7 6 7 6 7 6 7 6 7 6 7 6 7 6 Lam 9 n bomi Lo imi me debi hal m Figure 3 4A Group 2 13 in In Lines and Group 3 pumps with Class 300 flanges Temp Material Group No x 11 21 22 28 32 34 35 37 38 317 Ti F bar psi 73 244 24 1 24 1 17 4 24 1 24 1 24 1 24 1 24 1 24 1 100 850 350 350 252 350 350 350 350 350 350 29 24 1 24 1 24 1 24 1 17 4 24 1 24 1 24 1 24 1 24 1 24 1 20 350 350 350 350 252 350 350 350 350 350 350 18 24 1 24 1 24 1 24 1 17 4 24 1 24 1 24 1 24 1 24 1 24 1 0 350 350 350 350 252 350 350 350 350 350 350 38 24 1 24 1 24 1 24 1 17 4 24 1 24 1 24 1 24 1 24 1 24 1 100 350 850 350 350 252 350 350 350 350 350 350 93 22 0 20 1 20 8 23 2 17 4 21 3 22 9 24 1 24 1 20 9 21 4 200 319 292 301 336 252 309 332 350 350 303 310 149 21 4 18 1 18 8 21 4 17 4 19 9 21 4 23 5 23 5 18 7 18 7 300 310 263 272 310 252 289 310 341 341 271 271 204 20 7 16 6 17 3 19 8 17 4 19 3 19 9 22 7 22 7 16 9 15 9 400 300 241 250 287 252 280 288 329 329 245 231 260 19 6 15 3 16 1 18 5 17 4 19 1 19 3 21
33. 1500 1300 400 400 1400 1350 3250 1200 1500 690 2K 6x4 13A dl 6 005 6 672 1 763 1 763 1 492 6 227 6 005 14 456 1 627 2 034 936 2700 1350 1500 1300 1300 1100 1400 1350 3250 1200 1500 690 2K 6x4US 13A 20d 6 005 6 672 1 763 1 763 1 492 6 227 6 005 14 456 1 627 2 034 936 2700 1350 1500 1300 1300 1100 1400 1350 3250 1200 1500 690 2K 6x4R 13 PUE 6 005 6 672 1 763 1 763 1 492 6 227 6 005 14 456 1 627 2 034 936 2700 1350 1500 1300 1300 1100 1400 1350 3250 1200 1500 690 3K 8x6 14A 15 568 14 145 8 896 2 034 1 587 1 587 6 672 13 344 15 568 1 695 3 851 3 851 8500 3180 2000 1500 1170 1170 1500 3000 3500 1250 2840 2840 3K 108 14 15 568 eot 8 896 2 034 2 712 2915 6672 13 344 5d 1695 3 851 3 851 8500 3180 2000 1500 2000 2150 1500 3000 3500 1250 2840 2840 3k 64 16 15 568 12 721 8 006 1 831 1 431 1 431 6 005 12 010 14 011 1 526 3 465 3 465 8500 2860 1800 1350 1055 1055 1350 2700 3150 1125 2555 2555 3K 8x6 16A 15 568 14 145 8 896 2 034 2 007 2 007 6 672 13 344 15 568 1 695 3 851
34. 558 8 896 13 344 2 034 1 356 3 390 1 050 1 250 1500 1 200 2 500 800 2000 3 000 1 500 1 000 2 500 Group 15 568 H 6 672 2 034 1 763 4 746 6 227 11 120 14 456 2 034 2 915 4 746 3 500 1 500 1500 1300 3 500 1400 2500 3 250 1 500 2 150 3 500 Group 3 15 568 z 8 896 2 034 5 560 5 424 6 672 17 792 15 568 2 034 6 780 5 424 3 500 2 000 1500 4 100 4 000 1 500 4 000 3500 1 500 5 000 4 000 4 6 4 2 Mark 3 In Line pumps ASME B73 2M 4 6 4 2a Pump mounting Review Pump mounting section 4 3 The pump may be mounted such that it is free to move with the piping The pump may be supported by the piping so that it is free to move in all directions The pump may also be supported underneath the casing or by the optional pump stand which is not bolted to the foundation In these cases the pump is free to move with the piping in all directions except for vertically downward The above mounting methods are recommended as they reduce the piping loads applied to the pump In these cases nozzle loads are limited only by the casing limitations The pump may also be rigidly mounted with the optional pump stand bolted to the foundation In this case pump movement is restricted and piping loads are applied to both the pump and stand In this case nozzle loads are limited by both the casing and pump stand
35. 895 2340 960 960 3640 220 220 2020 1350 6240 660 660 660 2K 2x2R 10 10 408 4270 4 270 4 936 298 298 8 985 6 005 27 756 895 895 895 2340 960 960 3640 220 220 2020 1350 6240 660 660 660 2K 3x1 5 10A 12010 6005 8 496 5 058 570 570 8 629 6 005 Es 502 502 502 2700 1350 1910 3730 420 420 1940 1350 6240 370 370 370 2K 3x2 10A 12010 6005 6 583 5 058 420 420 8 985 6 005 K 759 759 759 2700 1350 1480 3730 310 310 2020 1350 6240 560 560 560 2K 3x2US 10 12010 6005 6 583 5 058 420 420 8 985 6 005 p 759 759 759 2700 1350 1480 3730 310 310 2020 1350 6240 560 560 560 2K 3x3R 10 12010 6005 6 583 5 058 420 420 8 985 6 005 E 759 759 759 2700 1350 1480 3730 310 310 2020 1350 6240 560 560 560 2K 4x8 10 and 10H 10230 6005 7 295 5 058 420 420 8 985 6 005 Ko 1 980 1 980 936 2300 1350 1640 3730 310 310 2020 1350 6240 1460 1460 690 2K 4x3US 10H 10230 6005 7 295 5 058 420 420 8 985 6 005 noms 1980 1 980 936 2300 1350 1640 3730 310 310 2020 1350
36. Ib to the impeller end of the shaft While applying this force the movement of an indicator is observed as shown in the following diagram The movement should be checked at a point as near as possible to the location of the seal faces A movement of more than 0 05 mm 0 002 in is not acceptable flowserve com M FLOWSERVE us Deflection Shaft endplay The maximum amount of axial shaft movement or endplay on a Durco pump should be 0 03 mm 0 001 in and is measured as shown below Observe indicator movement while tapping the shaft from each end in turn with a soft mallet Shaft endplay can cause several problems It can cause fretting or wear at the point of contact between the shaft and the secondary sealing element It can also cause seal overloading or underloading and possibly chipping of the seal faces It can also cause the faces to separate if significant axial vibration occurs Endplay 6 8 4 6 Seal chamber Assembled power end and rear cover Face squareness to shaft Also referred to as Seal chamber face run out This run out occurs when the seal chamber face is not perpendicular to the shaft axis This will cause the gland to cock which causes the stationary seat to be cocked which causes the seal to wobble This run out should be less than 0 08 mm 0 003 in and should be measured as shown below Face squareness Register concentricity An eccentric seal chamber bore or gland register can
37. MTBPM For a detailed discussion of this subject see the A ignment section of this manual 3 The ASME B73 1M paragraph 5 1 4 Group 1 Group 2 Group 3 OB Bs 30 000 29 990 50 000 49 987 70 000 69 985 beating 1 1811 1 1807 1 9685 1 9680 2 7569 2 7553 shaft bi a 30 013 30 003 50 013 50 003 70 015 70 002 mm in 1 1818 1 1812 1 9690 1 9686 2 7565 2 7560 E 0 023T 0 003T 0 026T 0 003T 0 030T 0 002T __ 0 000870 0001 0 00101 0 0001 T 0 0012T 0 0001 IB 35 000 34 989 50 000 49 987 70 000 69 985 Beso d B 1 3780 1 3775 1 9685 1 9680 2 7559 2 7553 Shaft TT 35 01435 004 50 013 50 003 70 015 70 002 mm in 1 3785 1 3781 1 9690 1 9686 2 565 2 7560 0 025T0 004T O 026T 0 003T 0 030T 0 002T 0 0010T 0 00017 0 0010T 0 00017 0 0012T 0 0001T Page 48 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 6 21 Group 1 Group 2 Group 3 DE Boar 71 999 71 986 110 000 109 985 150 000 149 979 E 28346 28341 4 33074 3301 5 9055 59047 camier Came 71999772017 110 007 110 022 150 002 150 080 Iram 28346 28353 4 33104 3316 5905659067 E 0 031L0 000L 0 037L0 007L 0 051L0 002L 0 0012L0 0000L 0 001500 0003L 0 0020L 0 0001L lp Bear 71 999 71 986 110 000 109 985 150 000 149 979 RE 28346 28341 4 33074 3301 5 9055 59047 ous ces 71 999 72 017 110 007 1 10 022 150
38. Nut pedestalcasing 3013 Ballbearing outboard 6521 Plug bearinghousingvent 6580 4 Nut jackscrewjamnut 3160 Motor pedestal 6541 1 Lockwasher bearing _ 6700 Key shafUcouping 3170 Pump stand 3200 Bearing housing 65691 Pug To y 3240 Bearingcarrier e5e93 Plug sightgage 3712 Bearing locknut 65702 Screw cover adapter Not shown Page 63 of 68 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE 8 8 Mark 3 In Line pump Group 2 540 390919199199 bearing carrier set 2100 Shat 4200 Mechanical seal 6570 5 Screw bearing housing 2200 Impeller 43104 Oil seal inboard 6570 12 Screw clamp 2400 Sleeve optional 4310 2 Oil seal outboard 6570 15 Screw pump stand 2530 1 Retaining ring bearing 4590 1 Gasket cover 6572 2 Stud gland 2530 2 R
39. STILT BOLT NUTS 3 LOCK WASHER 4 FLOOR CUP 4 3 4 2 Stilt spring mounted baseplate assembly instructions Refer to figure 4 4 a Raise or block up baseplate pump above the floor to allow for the assembly of the stilts b Setthe bottom nuts 4 above the stilt bolt head 1 This allows for 51 mm 2 in upward movement for the final height adjustment of the suction discharge flange C Assemble the lock washer 6 flat washer 5 and bottom spring cup assembly 2 down over the stilt bolt 1 d Assemble the stilt bolt bottom spring up through hole in the bottom plate and hold in place e Assemble top spring cup assembly 3 down over stilt bolt f Assemble flat washer 5 lock washer 6 and nuts 4 on the stilt bolt g Tighten down top nuts compressing the top spring approximately 13 mm 0 5 in Additional compression may be required to stabilize the baseplate h After all four stilts have been assembled position the baseplate in place over the floor cups 7 under each stilt location and lower the baseplate down to the floor i Level and make final height adjustments to the suction and discharge pipe by first loosening the top nuts and turning the bottom nuts to raise or lower the baseplate j Recompress the top spring to the compression established in step g and lock the nuts flowserve com M FLOWSERVE ss k It should be noted that the connecting pipelines must be ind
40. a 3 dBA tolerance and cannot be guaranteed MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Similarly the motor noise assumed in the pump and motor noise is that typically expected from standard and high efficiency motors when on load directly driving the pump Note that a motor driven by an inverter may show an increased noise at some speeds If a pump unit only has been purchased for fitting with your own driver then the pump only noise levels in the table should be combined with the level for the driver obtained from the supplier Consult Flowserve or a noise specialist if assistance is required in combining the values It is recommended that where exposure approaches the prescribed limit then site noise measurements should be made The values are in sound pressure level L at 1 m 3 3 ft from the machine for free field conditions over a reflecting plane For estimating sound power level Lwa re 1pW then add 14 dBA to the sound pressure value Motor size JL M TT or i REZINI ajo vi ovo TI and speed 3 550 r min 2 900 r min 1 750 r min 1 450 r min kW hp Pump Pump and Pump Pump and Pump Pump and Pump Pump and only motor only motor only motor only motor lt 0 55 lt 0 75 72 72 6 6 62 6 62 64 0 75 1 72 72 6 66 62 64 6 6 1 1 1 5 74 74 66 67 6 a e 6 1 5 2 74 74 6 71 6 6 e 63 2 2 3 75 76 68
41. 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 Refer to the general arrangement drawing for the pump set 4 2 Part assemblies The supply of motors and baseplates are optional As a result it is the responsibility of the installer to ensure that the motor is assembled to the pump and aligned as detailed in section 4 5 and 4 8 4 3 Foundation 4 3 1 Protection of openings and threads When the pump is shipped all threads and all openings are covered This protection covering should not be removed until installation If for any reason the pump is removed from service this protection should be reinstalled 4 3 2 In Line pump mounting The Mark 3 In Line can be supported in several ways e he pump may be supported by the piping in which case it is recommended that the suction and discharge pipes be supported adjacent to the pump nozzles e he pump may be supported under the casing foot or on the optional pump stand The pump stand will allow the pump to free stand without the aid of piping The pump stand may be bolted and grouted into place In this case the piping loads must be within the limits of the casing and of the pump stand as found in section 4 6 Page 18 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 The most advantageous method is the one that permits the pump to move with the piping Th
42. by the seal manufacturer The stuffing box seal chamber gland may have ports that have been temporarily plugged at the factory to keep out foreign matter It is the installer s responsibility to determine if these plugs should be removed and external piping connected Refer to the seal drawings and or the local Flowserve representative for the proper connections 4 6 6 2 Packing When the pump is intended to be equipped with shaft packing it is not Flowserve standard practice to install the packing in the stuffing box prior to shipment The packing is shipped with the pump It is the pump installer s responsibility to install the packing in the stuffing box LA cmon Failure to ensure that the packing is installed may result in serious leakage of the pumped fluid Page 30 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Fy 0 941 Fr s 120 115 Fu 0 0086 Fr 0 941 Fr s 27 004 1 8 453 Fr s 140 461 1 8 453 Fr 31 579 4 6 6 3 Piping connection seal packing support system If the pump has a seal support system itis mandatory that this system be fully installed and operational before the pump is started If packing is used 4 6 6 3a Packing lubrication Water when compatible with the pumpage should be introduced into tap V figure 4 23 at pressure 69 to 103 kPa 10 to 15 Ibf in above the stuffing box pressure The gland should be adjusted to give a flow rate of 20 to 30 d
43. clockwise from the initial reference point Rotate the bearing carrier counter clockwise until the second mark on the bearing carrier lines up with the initial reference point mark on the bearing housing Lastly uniformly tighten the set screws 6570 3 in incremental steps up to the final torque value to lock the bearing carrier in place The impeller is now set for an impeller setting of 0 7 mm 0 028 in off the casing flowserve com FLOWSERVE us The above procedure is fairly straightforward when e doing the final setting of the impeller However it canbe f quite laborious when doing the preliminary setting in order to establish the location of the mechanical seal For this reason the following practice is recommended Before the pump is taken out of service adjust the impeller until it touches the casing and then rotate the g bearing carrier until the desired impeller clearance is obtained Identify this location on the bearing carrier and then rotate the bearing carrier until the impeller h contacts the rear cover Record the distance from the desired impeller clearance setting to when the impeller contacts the rear cover The pump is now removed I from the casing and taken to the shop for maintenance When it is time to set the seal the impeller is simply set off the rear cover by the same distance recorded earlier N N The above technique is only applicable if all of the original pump components are rei
44. commitment to continuous quality control utilizing sophisticated quality techniques and safety requirements Flowserve is committed to continuous quality improvement and being at your service for any further information about the product in its installation and operation or about its support products repair and diagnostic services These instructions are intended to facilitate familiarization with the product and its permitted use Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks The instructions may not take into account local regulations ensure such regulations are observed by all including those installing the product Always coordinate repair activity with operations personnel and follow all plant safety requirements and applicable safety and health laws regulations These instructions must be read prior to installing operating using and maintaining the equipment in any region worldwide The equipment must not be put into service until all the conditions relating to safety noted in the instructions have been met 1 2 CE marking and approvals It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and where applicable Low Voltage Equipment Electromagnetic Compatibility EMC Pressure Equipment Directive PED and Equi
45. is initially filled with grease by Flowserve Lubrication fittings are provided to allow the customer to periodically replenish the grease as recommended by the bearing and or grease manufacturer 3 These bearings are shielded on both sides They come pre greased by the bearing manufacturer The user does not need to regrease these bearings The shields do not actually contact the bearing race so no heat is generated 4 These bearings are sealed on both sides They come pre greased by the bearing manufacturer The user does not need to regrease these bearings The seals physically contact and rub against the bearing race which generates heat These bearings are not recommended at speeds above 1750 r min 5 The codes shown are SKF codes Inboard and outboard bearings have the C3 greater than normal clearance These clearances are recommended by SKF to maximize bearing life 6 Regreasable single shielded bearings are not available in the duplex configuration however open oil bath type bearings can be used for the regreasable configuration These bearings must be pre greased during assembly Lubrication fittings are provided to allow the user to periodically replenish the grease as recommended by the bearing and or grease manufacturer Not available All bearing configurations are supplied only with steel cages NO S Page 51 of 68 SKF the 5300 and 3300 bearing series are identical and therefore can be used interchangeably
46. limitations 4 6 4 2b Casing limitations To simplify or eliminate additional calculations the In Line casing may be treated as a spool of schedule 40 pipe with a diameter equal to the discharge length equal to the face to face dimension SD and material equal to that of the casing In cases where pump movement is limited the constraint may be placed at the center of the spool Stress in the pump flanges and bolting should not be ignored This method Page 28 of 68 allows for the use of automated piping programs to determine the acceptability of loads The casing limitations can also be determined by ANSI HI 9 6 2 All information necessary to complete the evaluation is given below For complete details please review the standard a Determine the appropriate casing Nozzle load material group from figure 3 2 Find the Casing material correction factor in figure 4 11 based upon the Nozzle load material group and operating temperature Interpolation may be used to determine the correction factor for a specific temperature Multiply the allowable loads found in figure 4 20 by the material correction factor Record the adjusted loads Calculate the applied piping loads at the center of the casing flanges according to the coordinate system found in figure 4 19 The 12 forces and moments possible are Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd and Mzd For example Fxd designates force in the x direction on the d
47. o lt lt 75 120 5 z o co 2 5 40 1 2 0 0 0 4 0 8 1 2 1 6 2 2 4 Specific Gravity Figure 3 5b Suction pressure limits 3 500 r min 27 5 400 29 4 360 a S 22 5 320 amp o i a gq 20 280 8 18 c 17 4 240 S o 15 o O 200 12 5 co 160 8 10 14 S 13 lt 12 120 7 5 E 2 11 Z E E x 5 x S 10 2 5 40 5 6 7 8 9 0 0 0 4 1 6 2 2 4 Specific Gravity Page 16 of 68 flowserve com M FLOWSERVE us Figure 3 6 Suction pressure reference numbers Pump size 1750 3 500 ltktsxt6 7 wo 1ksx156 C ww 15 IK 32 6 10 12 IK2x158V6 Pm 1 O 1K 1 5x1 5US 8 1K2x1SV8 0 PT 16 O IKS3t58 4 4 IK 3x2V 7 PT 11 2K3x28 10 7 2K 4x3 8 10 13 JE ET 8 8 2K 2x1 5US 10A 2Ksx 510A 10 17 2K 3x2V 10 In Line 11 9 2KA310 6 2 2K4xs10H O 8 m 2kex410 8 8 J 2k6x410H 10 w 2Ksx1513 d 9 5 2K 3x2 13 5 1 2K4xs 19318 1 m 2K4xs 1942 1 m 2K 4x3 13 11max 1 2 O 2K4x3 3HH 10 m 2K64 13A4 O 1 m 2K 6x4 13A 1025 1 SKX8614A 2 nm 3K108 144 PT m 64 16 PP nm sKsxe 16A PT m SK108 16816H P m 3K10x8 17 83 m O
48. on one of the square lugs as shown in figure 6 13 flowserve com FLOWSERVE ss Mark 3 design On Group 1 and 2 pumps the bearing carrier is turned by using a strap wrench with the strap located around the outside diameter of the carrier face On Group 3 pumps the bearing carrier is turned by using a spanner wrench to engage the cogs on the outside diameter of the bearing carrier Figure 6 13 Because the O rings 4610 2 will cause some resistance in removing the bearing carrier assembly from the housing hold the bearing carrier flange firmly and with slight rotation pull it out of the bearing housing The bearing carrier assembly with the shaft and bearings should come free This unit will appear as shown in figure 6 14 Further disassembly is not required unless the bearings are to be replaced i Figure 6 14 Remove the snap ring 2530 see figure 6 15 on Group 1 and 2 pumps or the bearing retainer 2530 1 on Group Ze A Figure 6 15 Group 1 and 2 pumps equipped with duplex angular contact bearings use a bearing retainer 2530 1 instead of the snap ring Remove the carrier from the bearing The bearing locknut 3712 and lockwasher 6541 1 may now be removed from the shaft 2100 Discard the lockwasher An arbor or hydraulic press may be used to remove the bearings 3011 and 3013 from the shaft Itis extremely important to apply even Page 46 of 68 MARK 3 USER INSTRUCTIONS ENGL
49. or clean cloth while not in use 8 Clean inside of housing before replacing bearings 9 Check oil seals and replace as required 10 Check all plugs and tapped openings to make sure that they are tight Page 57 of 68 flowserve com M FLOWSERVE ss Pump not reaching design flow rate U Pump not reaching design head TDH V No discharge or flow with pump running U Pump operates for short period then loses prime MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 U Excessive noise from wet end U Excessive noise from power end Py ee IM ee pT tL LS I y PROBABLE CAUSES POSSIBLE REMEDIES e sb E MA ally When mounting the bearing on the drive shaft use a proper size caused by incorrectly applied forces ng and apply the pressure against the inner ring only Be sure in assembling the bearing or by shock when mounting a bearing to apply the mounting pressure slowly loading such as hitting the bearing or andeveniy ERE ERR jQriveshafttwth ahammer J ooo e False brinelling of bearing identified 1 Correct the source of vibration again by either axial or circumferential 2 Where bearings are oil lubricated and employed in units that indentations usually caused by may be out of service for extended periods the drive shaft should vibration of the balls between the be turned over periodically to relubricate all bearing surfaces at 1 E
50. or the bearing housing adapter Group 2 and 3 by using the capscrews 6570 2 h Attach the gland seat to the rear cover plate 1220 using studs 6572 2 and nuts 6580 2 Single external seal installation Carry out steps a to c above d Locate the rotary seal unit onto the shaft sleeve according to the set dimension provided by the seal manufacturer Tighten set screws on the seal to lock the rotating unit to the shaft sleeve e Attach the gland 4120 and stationary seat onto rear cover plate 1220 using studs 6572 2 and nuts 6580 2 f Install the rear cover plate 1220 to the bearing housing Group 1 or the bearing housing adapter Group 2 and 3 by using the capscrews 6570 2 Double seal installation Carry out steps a to c above d Place the gland 4120 and stationary seat onto the shaft until it lightly touches the bearing housing Group 1 or adapter Group 2 and 3 Install a gland gasket 4590 3 into the gland See figure 6 28 e Locate the rotary seal unit onto the shaft sleeve according to the set dimension provided by the seal manufacturer Tighten set screws on the seal to lock the rotating unit to the shaft sleeve Install a stationary seat into the rear cover plate 1220 f Install the rear cover plate 1220 to the bearing housing Group 1 or the bearing housing adapter Group 2 and 3 by using the capscrews 6570 2 g Attach the gland seat to the rear cover plate 1220 using studs
51. overfill the groove in which it is located When installing the seal into its corresponding housing in addition to compressing the O ring a certain amount of material may shear off This sheared material should be removed An arbor press should be used to install the seal Install the inboard seal in the bore of the bearing housing Group 1 or adapter Group 2 and Group 3 with the single expulsion port positioned at the 6 o clock position Install the outboard seal in the bore of the bearing carrier There are no orientation issues since this is a multiport design seal Magnetic seals Follow the installation instructions provided by the manufacturer 6 9 1 3 Bearing carrier power end assembly a Install new O rings 4610 2 onto the bearing carrier Be sure to use the correct size O rings The Mark 3 and Mark 3A bearing carriers use different O rings b Slide the bearing carrier 3240 over the outboard bearing 3013 c Install the outboard bearing retaining device Double row bearings on Group 1 and 2 pumps Slide the snap ring 2530 in place with its flat side against the outboard bearing and snap it into its groove in the bearing carrier Duplex angular contact bearings on Group 1 and 2 pumps all bearings on Group 3 pumps Slide the bearing retainer 2530 1 against the outboard bearing and install and tighten the socket head capscrews 6570 12 See figure 6 2 for correct torque values flowserve com M
52. port size in e 4 Nominal discharge port size in e Modifier for specialty pumps Blank or no letter standard pump M Sealmatic R recessed impeller US unitized self priming V vertical In Line LF Lo Flo e Nominal maximum impeller diameter 13 13 in e Pump design variation A This pump has been redesigned from an earlier version The impeller and casing are no longer interchangeable with the earlier version H This pump is designed for a higher flow capacity than another pump with the same basic designation Examples 4X3 10 and 4X3 10H 6X4 10 and 6X4 10H 10X8 16 and 10X8 16H HH This pump is designed for a higher head than another pump with the same basic designation Example 4X3 13 and 4X3 13HH e Actual impeller size 12 5 12 Yin diameter 8 13 8 in 10 75 10 34 in Previous annotation 124 12 g or 12 t in diameter 83 8 in e Impeller style RV reverse vane impeller OP Open impeller flowserve com M FLOWSERVE ss 3 3 Design of major parts 3 3 1 Pump casing Removal of the casing is not required when performing maintenance of the rotating element The pump is designed with a gasket perpendicular to the shaft allowing the rotating element to be easily removed back pull out 3 3 2 Impeller Depending on the product the impeller is either reverse vane or open 3 3 3 Shaft sleeve Solid and sleeved shafts are available supported on bear
53. the grooves on the inside diameter of the seal rotor e Slide the drive collar onto the shaft until it contacts the bearing housing pins facing away from bearing housing f Lubricate the O rings and shaft with non abrasive liquid hand soap and slide the seal rotor onto the shaft until it contacts the rotor drive collar The notches on the back side of the rotor should face toward the bearing housing g Place repeller cover face down on workbench and set the Teflon disk against the gland surface i e end of stuffing box Attach gland to repeller cover and screw on gland nuts finger tight h Reinstall the repeller cover repeller rear cover and impeller as instructed in section 6 9 3 i Tighten gland nuts fully Slide the seal rotor forward until it contacts the Teflon disk Slide the drive collar forward until its pins are fully engaged in the slots on the back side of the seal rotor j Preload the seal by applying even pressure on the back of the drive collar in order to push it and the seal rotor into the Teflon disk The rotor and drive collar should be moved approximately 3mm 7s in into the Teflon disk Tighten the drive Page 55 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 collar setscrews while maintaining pressure on the back of the drive collar k Once the pump is flooded check the seal to ensure itis not leaking If the seal leaks repeat step j above applying only enough pressure to the drive co
54. the set screws 6570 3 will cause the impeller to move 0 05 mm 0 002 in away from the casing because of the internal looseness in the bearing carrier threads This must be considered when setting the impeller clearance Rotate the bearing carrier counter clockwise the required amount to get the desired clearance to the casing Lastly uniformly tighten the set screws 6570 3 in incremental steps up to the final torque value to lock the bearing carrier in place See section 5 3 for impeller clearance settings Example If a pump was to be placed in a service with an operating temperature of 150 C 302 F the impeller setting would be 0 69 mm 0 027 in off the casing Since it is necessary to subtract 0 05 mm 0 002 in for the movement caused by tightening the set screws an adjustment of 0 64 mm 0 025 in is needed First turn the bearing carrier clockwise until the impeller comes into light rubbing contact with the casing To determine the number of indicator patterns that you will need to rotate the carrier divide 0 10 into the desired setting 0 64 0 10 6 4 025 0 004 6 3 Rotate the bearing carrier counter clockwise 6 5 indicator patterns which will give a clearance of 0 65 mm 0 026 in Flowserve suggests that a felt tip pen be used to mark an initial reference point on the bearing housing and the bearing carrier as shown in figure 6 6 Then make a second mark on the bearing carrier 6 5 indicator patterns
55. ys adj xs adj ys adj zs adj Adjusted y axis 3 bo M M j M y xd je y 4 zd 4 17 movement Fu adj M a adj M a aj M d aj 1 0 lt A lt 1 0 B cc Em qu Ma Se v WM n xs adj zs adj xs adj ys adj zs adj Adjusted Z axis 4 F I F M M 4 M Xd XE QR NA E LOU Md y zd 4 18 movement Fa _adj Fu _ adj P3 _ adj M _ adj M yd adj zd adj pe a CC SA I EE Combined 9 JA B lt 1 0 axis movement Note All of the above equations are found by dividing the applied piping loads by the adjusted figure values Page 25 of 68 flowserve com M FLOWSERVE s Figure 4 15 Maximum individual loading MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Suction flange Discharge flange Pump size Forces N Ibf Moments Nm Ibf ft Forces N Ibf Moments Nm Ibf ft Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd Mzd 1K1 5x1 LF4 4 670 3 336 3 336 976 231 231 3 558 6 005 13 344 556 556 556 1050 750 750 720 170 170 800 1350 3000 410 410 410 1K 1 5x1 6 4 670 3 336 3 336 976 231 231 3 558 6 005 13 344 556 556 556 1050 750 750 720 170 170 800 1350 3000 410 410 410 IK 3x1 5 6 4 670 5516 5 560 1 220 664 664 3 558 6 005 13 344 678 746 692 1050 1240 1250 900 490 490 800 1350 3000 500
56. 0 1 6521 3855 5011 4310 1 1 540 2540 2400 4120 41 54 4590 2 41 50 URGO 2200 STANDARD REVERSE VANE IMPELLER 6572 2653721 3126 151 54 116570 411 6569114610 2 6570 5 6580 26580 1 4120116570 2 4590 1 4610 213856 1220 4134 41 50 Group 2 Optional duplex bearing arrangement Group 3 Standard bearing clamp arrangement JU 5240 Item Description 3200 Bearing housing 4610 2 O ring bearing carrier 1100 Casing 3240 Bearing carrier 6521 Plug bearing housing vent 1220 Cover 3712 Bearing locknut 6541 1 Lockwasher bearing 1340 Adapter bearing housing 3855 Constant level oiler not shown 6569 1 Plug bearing housing drain 2100 Shaft 3856 Sight gage bearing housing 6570 12 Screw clamp 2200 Impeller 4120 Gland 6570 2 Screw cover adapter 2400 Sleeve optional 4130 Packing optional 6570 3 Screw bearing carrier set 2530 1 Retaining ring bearing 4134 Seal cage packing optional 6570 4 Screw foot 2530 2 Retaining ring clamp type 4200 Mechanical seal 6570 5 Screw bearing housing 2540 Deflector inboard optional 4310 1 Oil seal inboard 6572 1 Stud casing 2541 Oil flinger optional 4310 2 Oil seal outboard 6572 2 Stud gland 3011 Ball bearing inboard 45
57. 0 to 176 301 to 350 0 69 0 027 177 to 204 351 to 400 0 76 0 030 205to 232 401 to 450 0 84 0 033 gt 232 450 0 91 0 036 1 For 3x1 5 13 and 3x2 13 at 3500 rpm add 0 08 mm 0 003 in 2 Rotation of bearing carrier from center of one lug to center of next results in axial shaft movement of 0 1 mm 0 004 in 3 Reverse vane impeller set to cover open impeller to casing 5 4 Direction of rotation 5 4 1 Rotation check It is absolutely essential that the rotation of the motor be checked before connecting the shaft coupling Incorrect rotation of the pump for even a short time can dislodge and damage the impeller casing shaft and shaft seal All Mark 3 pumps turn clockwise as viewed from the motor end Page 36 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 A direction arrow is cast on the front of the casing as shown in figure 5 13 Make sure the motor rotates in the same direction Figure 5 13 5 4 2 Coupling installation A caution The coupling figure 5 14 should be installed as advised by the coupling manufacturer Pumps are shipped without the spacer installed If the spacer has been installed to facilitate alignment then it must be removed prior to checking rotation Remove all protective material from the coupling and shaft before installing the coupling lt Figure 5 14 5 5 Guarding Power must never be applied to the driver when the coupl
58. 00 400 252 350 350 400 400 350 400 38 276 27 6 27 6 27 6 17 4 24 1 24 1 27 6 27 6 24 1 27 6 100 400 400 400 400 252 350 350 400 400 350 400 93 252 23 0 23 7 26 5 17 4 21 3 22 9 27 6 27 6 20 9 24 5 200 865 333 344 384 252 309 332 400 400 303 355 149 244 20 7 21 5 24 5 17 4 19 9 214 26 8 26 8 18 7 21 3 300 854 300 311 855 252 289 310 389 389 271 309 204 237 19 0 19 7 22 6 17 4 19 3 19 9 25 9 25 9 16 9 18 2 400 843 275 286 328 252 280 288 376 376 245 264 260 224 17 5 18 4 21 1 17 4 19 1 19 3 24 5 24 5 15 7 15 1 500 324 253 267 307 252 277 280 355 355 228 219 316 205 16 7 17 2 20 4 17 4 19 1 19 2 222 22 2 14 5 12 0 600 297 242 250 296 252 277 278 323 323 210 173 343 19 9 16 5 17 0 E 7 19 1 19 0 21 7 21 7 E 10 4 650 289 239 247 277 276 815 815 051 371 199 16 3 16 5 _ _ 19 1 18 9 21 0 21 0 _ 8 8 700 289 236 239 277 274 304 304 128 Page 15 of 68 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE Figure 3 5a Suction pressure limits 1 750 r min 27 5 400 25 360 G z S 22 5 320 9 o o 5 20 74 280 o o a 17 5 O S 240 5 S 15 O 200 9 12 5 o o Q S 160 S o 10
59. 007 150 025 mi 9 28346 28353 43310 4 3316 5905859065 E 0 031L0 000L 0 037L0 007L 0 046L 0 007L 0 0012L 0 0000L 0 0015L 0 0003L 0 00181 0 0008L 6 8 4 5 Power end Assembled bearing housing carrier bearings and shaft Shaft shaft sleeve run out Shaft run out is the amount the shaft is out of true when rotated in the pump It is measured by attaching a dial indicator to a stationary part of the pump so that its contact point indicates the radial movement of the shaft surface as the shaft is rotated slowly If a shaft sleeve is used then shaft sleeve run out must be checked It is analogous to shaft run out Measurement of shaft run out shaft sleeve run out will disclose any out of roundness of the shaft any eccentricity between the shaft and the sleeve any permanent bend in the shaft and or any eccentricity in the way the shaft or bearings are mounted in the bearing housing Shaft run out can shorten the life of the bearings and the mechanical seal The following diagram shows how to measure shaft shaft sleeve run out Note that both ends need to be checked The run out should be 0 025 mm 0 001 in FIM or less Runout Radial deflection static Radial movement of the shaft can be caused by a loose fit between the shaft and the bearing and or the bearing and the housing This movement is measured by attempting to displace the shaft vertically by applying an upward force of approximately 4 5 kg 10
60. 1 0 31 0 20 9 27 5 200 422 410 375 388 432 252 309 379 450 450 303 399 149 27 4 27 5 23 3 24 1 27 5 17 4 19 9 244 30 2 30 2 18 7 24 0 300 397 398 338 350 399 252 289 354 438 438 271 348 200 255 26 6 21 3 22 2 25 4 17 4 19 3 22 7 29 2 29 2 16 9 20 5 400 369 386 309 322 369 252 280 330 423 423 245 297 260 240 25 2 19 7 20 7 23 8 17 4 19 1 22 1 27 5 27 5 15 7 17 0 500 348 365 285 300 845 252 277 320 399 399 228 246 316 22 5 23 1 18 7 19 4 23 0 17 4 19 1 21 9 25 0 25 0 14 5 13 4 600 327 334 272 281 333 252 277 318 363 363 210 195 343 218 22 4 18 5 19 2 nam 19 1 21 8 24 4 24 4 B 11 7 650 316 325 269 2780 277 816 854 354 170 871 22 4 18 3 18 5 _ 19 1 21 6 23 6 23 6 _ 9 9 00 325 266 269 277 813 942 942 144 Figure 3 4C All other Class 300 flanges Temp Material Group No C 11 21 22 28 32 34 35 37 38 317 Ti F oo dr rr m o mea 73 27 6 27 6 27 6 174 24 1 24 1 27 6 27 6 24 1 27 6 100 400 400 400 252 350 850 400 400 350 400 29 276 27 6 27 6 27 6 17 4 24 1 24 1 27 6 27 6 24 1 27 6 20 400 400 400 400 252 350 350 400 400 350 400 18 276 27 6 27 6 27 6 17 4 24 1 24 1 27 6 27 6 24 1 27 6 0 400 400 4
61. 1569102 08 06 Remove the coupling guard See section 5 5 Remove the spacer from the coupling Close coupled pumps required that the motor be removed from the pump assembly The motor must be fully supported and the jackscrews 6575 loose before removal Remove casing fasteners 6580 1 On Group 1 In Line pumps the studs 6572 1 must be removed Remove the fasteners holding the bearing housing foot to the baseplate Not applicable on In Line pumps Move the power end rear cover and seal chamber assembly away from the casing On In Line pumps the simplest method of power end removal is to first remove the motor and motor adapter with a crane However this is often not practical and the power end must be removed by hand This operation is illustrated in figures 6 7 6 8 and 6 9 Discard the E asket 4590 1 The power end and rear cover assembly is heavy It is important to follow plant safety guidelines when lifting it Transport the assembly to the maintenance shop Figure 6 7 Figure 6 8 Figure 6 9 flowserve com FLOWSERVE us 6 7 2 Pump disassembly k Remove the coupling hub from the pump shaft 2100 Close coupled pumps require the motor adapter 3160 be removed Using the shaft key 6700 mount the impeller wrench from the Flowserve Mark 3 tool kit figure 6 1 to the end of the shaft With the wrench handle pointing to the left when viewed from the impeller end grasp the impeller
62. 2 1 1 42 0 75 067 0 53 360 8976 960 510 720 510 2 824 28 147 2 824 1120 1722 1120 pT 0 67 0 75 0 53 685 6328 685 900 1270 900 1 601 17 685 1 601 692 976 692 d 1 88 0 7 0 83 0 53 360 8976 360 510 720 510 1423 17 685 1 423 692 976 692 158 0 75 0 83 0 65 320 8976 320 510 720 510 i 2 402 28 147 2 402 1120 1722 1120 1 67 0 79 0 88 0 65 540 6328 540 900 1270 900 xau 0 635 0 292 0 343 0 197 2 823 28 147 2 823 1803 2 549 1803 2 08 0 96 1 13 0 65 638 6 328 638 1330 1880 1330 mE 0 61 0 292 0 318 0 248 1 134 17 685 1 134 692 976 692 oi 200 0 96 1 04 0 81 255 8976 255 510 720 510 Sn 0 61 0 292 0 318 0 248 2 002 28 147 2 002 1 120 1722 1 120 2 00 0 96 1 04 081 450 6328 450 900 1270 900 mm 0 711 0 33 0 381 0 248 2 535 28 147 2 535 1803 2 549 1803 2 833 1 08 1 25 0 81 570 6328 570 1330 1880 1330 EET 0 762 0 356 0 406 0 248 2 891 83 195 2 891 2 210 3 119 2 210 250 117 133 081 650 18704 650 1630 2300 1630 Figure 4 21 Pump stand load translation formulae Forces Moments Fxc Fxs Fxp Mxc Mxs Mxp Fzs x SRs Fzp x SRp Fvc Fys Fyp Myc Mys Mvo Fzc
63. 2 should be installed immediately after the bearing is placed on the shaft and tightened to ensure the bearing remains in contact with the shaft shoulder The locknut should then be retightened repeatedly during the time the bearing is cooling Once cool the locknut should be removed Figure 6 26 Pump Press force Locknut torque N Ibf Nm Ibf ft Group 1 5780 1 300 27 4 0 20 5 0 Group 2 11 100 2 500 54 7 0 40 5 0 Group 3 20 000 4 500 95 7 0 70 5 0 e Install lockwasher 6541 1 and locknut 3712 The locknut should be torqued to the value shown in figure 6 26 One tang on the lockwasher must be bent into a corresponding groove on the locknut Page 52 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 6 9 1 2 Bearing housing seals Lip seals If lip seals were used see figure 6 16 install new lip seals in the bearing carrier 3240 and the housing 3200 Group 1 or the adapter 1340 Group 2 and 3 The lip seals 4310 1 and 4310 2 are double lip style the cavity between these two lips should be to filled with grease When installing this part the large metal face on the lip seal must face away from the bearings Labyrinth seals The following are general installation instructions regarding the VBXX Inpro seal Follow the instructions provided with the seal by the manufacturer The elastomer O ring located on the OD of the seal has been sized to
64. 2200 firmly with both hands wear heavy gloves By turning the impeller in the clockwise direction move the wrench handle to the 11 o clock position and then spin the impeller quickly in a counter clockwise direction so that the wrench makes a sudden impact with a hard surface on the bench After several sharp raps the impeller should be free Unscrew the impeller and remove from the shaft Discard the impeller gasket 4590 2 Do not apply heat to the impeller If liquid is entrapped in the hub an explosion could occur If a cartridge type mechanical seal 4200 is used figure 6 10 the spacing clips or tabs should be installed prior to loosening the set screws which attaches the seal to the shaft or removing it from the cover This will ensure that the proper seal compression is maintained ZE a Figure 6 10 Remove the seal or packing gland nuts 6580 2 if so equipped Remove the cover All pumps except Sealmatic Remove the two cap screws 6570 2 which attach the rear cover 1220 to the adapter Carefully remove this part Sealmatic pump only Remove the cap screws that hold the rear cover 1220 to the repeller cover 1220 1 For Group 3 pumps remove the capscrews 6570 2 that hold the rear cover 1220 to the adapter 1340 Remove the cover The repeller is now exposed 2200 1 and should be free to slip from the shaft In the event it is stuck the repeller can be pried off by the use of 2 screwdrivers wedg
65. 227 6 005 14 456 895 895 895 2340 960 960 1270 220 220 1400 1350 3250 660 660 660 2K 2x2R 10 10 408 4 270 4 270 1722 298 298 6 227 6 005 14 456 895 895 895 2340 960 960 1270 220 220 1400 1350 3250 660 660 660 2K 3x1 5 10A 12 010 6 005 6 672 1 763 570 570 6 227 6 005 14 456 502 502 502 2700 1350 1500 1300 420 420 1400 1350 3250 370 370 370 2K 3x2 10A 12 010 6 005 6 583 1 763 420 420 6 227 6 005 14 456 759 759 759 2700 1350 1480 1300 310 310 1400 1350 3250 560 560 560 2K 3x2US 10 12 010 6 005 6 583 1 763 420 420 6 227 6 005 14 456 759 759 759 2700 1350 1480 1300 310 310 1400 1350 3250 560 560 560 2K 3x3R 10 12 010 6 005 6 583 1 763 420 420 6 227 6 005 14 456 759 759 759 2700 1350 1480 1300 310 310 1400 1350 3250 560 560 560 10230 6005 6672 1 763 420 420 6227 6005 14456 1627 1980 936 2K 4x3 10 and 10H 2 300 1 350 1 500 1 300 310 310 1400 1 350 3 250 1 200 1 460 690 2K 4x3US 10H 10 230 6 005 6 672 1 763 420 420 6 227 6 005 14 456 1 627 1 980 936
66. 3A design Remove the site gage 3856 figure 5 1 and oil level tag figure 6 18 from the bearing housing save these parts for reuse Figure 6 17 flowserve com SR FLOWSERVE nr OIL LEVEL MUST BE MAINTAINED AT CENTER OF SIGHT GLASS Figure 6 18 6 8 Examination of parts 6 8 1 Cleaning inspection All parts should now be thoroughly cleaned and inspected New bearings O rings gaskets and lip seals should be used Any parts that show wear or corrosion should be replaced with new genuine Flowserve il It is important that only non flammable non contaminated cleaning fluids are used These fluids must comply with plant safety and environmental guidelines 6 8 2 Critical measurements and tolerances To maximize reliability of pumps it is important that certain parameters and dimensions are measured and maintained within specified tolerances It is important that all parts be checked Any parts that do not conform to the specifications should be replaced with new Flowserve parts 6 8 3 Parameters that should be checked by users Flowserve recommends that the user check the measurements and tolerances in figure 6 19 whenever pump maintenance is performed Each of these measurements is described in more detail on the following pages 6 8 4 Additional parameters checked by Flowserve The parameters listed below are somewhat more difficult to measure and or may require specialized equipment For this reason the
67. 4 21 4 15 7 13 2 500 284 222 233 268 252 277 280 310 310 228 191 316 17 9 14 6 15 1 17 9 17 4 19 1 19 2 19 5 19 5 14 5 10 5 600 260 211 219 259 252 277 278 282 282 210 152 343 17 4 14 4 14 9 19 1 19 0 19 0 19 0 9 1 650 253 209 216 277 276 275 275 132 371 17 4 14 2 14 4 19 1 18 9 18 3 18 3 7 7 700 253 207 209 i i 277 274 266 266 E 112 Page 14 of 68 flowserve com M FLOWSERVE s MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 3 4B Group 2 13 in Lo Flo pumps with Class 300 flanges Temp atria Group NOW 10 11 21 22 28 32 34 35 37 38 317 Ti py a A U E ee eem 73 _ 31 0 31 0 310 174 24 1 27 6 31 0 31 0 24 1 31 0 100 450 450 450 252 350 400 450 450 350 450 29 31 0 31 0 31 0 31 0 31 0 17 4 24 1 27 6 31 0 31 0 24 1 31 0 20 450 450 450 450 450 252 350 400 450 450 350 450 18 31 0 31 0 31 0 31 0 31 0 17 4 24 1 27 6 31 0 31 0 24 1 31 0 0 450 450 450 450 450 252 350 400 450 450 350 450 38 31 0 31 0 31 0 31 0 31 0 17 4 24 1 27 6 31 0 31 0 24 1 31 0 100 450 450 450 450 450 252 350 400 450 450 350 450 93 29 1 28 3 25 9 26 7 29 8 17 4 21 3 26 1 3
68. 6572 2 and nuts 6580 2 h Install the impeller 2200 as instructed in section 6 6 Remember that the impeller clearance is already set It cannot be changed at this point without resetting the seal 6 9 2 3 Packing Split gland installation a Install the rear cover plate 1220 to the bearing housing Group 1 or the bearing housing adapter Group 2 and 3 by using the capscrews 6570 2 b Install and set the impeller 2200 clearance as outlined in section 6 6 c Install the packing rings 4130 and seal cage halves 4134 into the stuffing box as shown in figures 4 23 and 4 24 Always stagger the end gaps 90 degrees to ensure a better seal To speed Page 54 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 installation of each ring have an assistant turn the pump shaft in one direction This movement of the shaft will tend to draw the rings into the stuffing box d A split gland 4120 is an assembly of two matched gland halves that are bolted together Unbolt the gland halves and install the gland halves around the shaft Bolt the halves together to form a gland assembly e Now install the gland assembly 4120 using studs 6572 2 and nuts 6580 2 f Lightly snug up the gland Final adjustments must be made after the pump has begun operation One piece gland installation a Install the gland 4120 over shaft until it lightly touches the bearing housing Group 1 or adapter Group 2 and 3 b Insta
69. 8 6 753 1492 8 985 6 005 K 2 915 2 915 936 2700 1350 6240 3730 4980 1100 2020 1350 6240 2150 2150 690 2K 6x4US 13A 12010 6005 20d 5 058 6 753 1492 8 985 6 005 Eus 2 915 2 915 936 2700 1350 6240 3730 4980 1100 2020 1350 6240 2150 2150 690 2K 6x4R 13 12010 6005 IE d 5 058 6 753 1492 8 985 6 005 Eds 2 915 2 915 936 2700 1350 6240 3730 4980 1100 2020 1350 6240 2150 2150 690 3K 8x6 14A 28 289 14 145 22 596 12 163 1 587 1 587 28 289 14 145 59870 9194 5 221 3 851 6360 3180 5080 8970 1170 1170 6360 3180 13460 6780 3850 2840 3K 10x8 14 28 289 14 145 59 870 12 163 3 322 2 915 28 289 14 145 59 870 12 163 9 790 3 851 6360 3180 13460 8970 2450 2150 6360 3180 13460 8970 7220 2840 3k 6x4 16 28289 14145 20 327 12 163 1 431 1 431 25 465 12 720 53 888 8272 4 699 3 465 6360 3180 4570 8970 1055 1055 5725 2860 12115 6100 3465 2555 3K 8x6 16A 28 289 14 145 29713 12 163 2 007 2 007 28 289 14 145 59870 8895 5 044 3 851 6360 3180 6680 8970 1480 1480 6360 3180 13460 6560 3720 2
70. 840 3K 10x8 16 amp 16HH 28 289 14 145 22 818 12 163 1 532 1 532 28 289 14 145 59 870 12 163 12 285 3 851 6360 3180 5130 8970 1130 1130 6360 3180 13460 8970 9060 2840 3K 10x8 17 28 289 14 145 22 818 12 163 1 532 1 532 28 289 14 145 59 870 12 163 12 285 3 851 6360 3180 5130 8970 1130 1130 6360 3180 13460 8970 9060 2 840 Page 27 of 68 flowserve com M FLOWSERVE s MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 4 17 Maximum Y axis loading for shaft deflection Pump size Forces N lbf Moments Nm Ibf ft Forces N lbf Moments Nm Ibf ft Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd Mzd Group 1 z 8896 _ Ra 1 627 2 En 6 672 678 2 034 1 695 2000 800 1200 1250 1500 500 1500 1250 Group H 15 568 1 762 8 1 762 8 4 068 11 120 1627 2 034 4 068 3500 1300 1300 3000 2500 1200 1500 3000 Group 3 J E B 2 034 2712 5424 13 344 _ 1 695 6 780 5 424 5 000 1500 2000 4 000 3 000 1 250 5000 4000 Pumpsize Forces N Ibf Moments Nm Ibf ft Forces N Ibf Moments Nm Ibf ft Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd Mzd Group 1 4 670 u 5 560 2 034 1 627 3 390 3
71. 90 1 Gasket cover 6580 1 Nut casing 3013 Ball bearing outboard 4590 2 Gasket impeller 6580 2 Nut gland 3126 1 Shim 4590 3 Gasket gland 6700 Key shaft coupling 3134 Support foot 4610 1 O ring adapter Page 60 of 68 flowserve com M FLOWSERVE us 8 3 Mark 3 Sealmatic pump Group 2 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 8 4 Mark 3 Lo Flo Group 2 Page 61 of 68 4590 9 1220 1 tem Description 297 Sel 208 lipea 1100 Casing 1220 Covr 1220 1 Cover repeller 2200 Impeller 2200 1 Repeller o 4120 Gland 4200 Mechanicalseal 4590 1 Gasket cover 4590 2 Gasket impeler Notes ARD See figure 6 30 GP3 Sealmatic wet end VAN ER 1220 Item Description 1100 Casing 1220 Cover flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE 8 5 Mark 3 Unitized Self Priming pump Group 2 6572 1 4590 2 6580 1 He J Item Description 1100 Casing 2200 Impeller 8 6 Mark 3 Recessed Impeller pump Group 2 4590 1 Gasket cover 4590 2 Gasket impeller 6572 1 6572 1 Stud casing 100 6580 1 Nut casing LA
72. Hydraulic Institute 9 Sylvan Way Parsippany New Jersey 07054 3802 Flowserve Durco Pump Parts Catalog Flowserve Mark 3 Sales Bulletin Flowserve Mark 3 Technical Bulletin P 10 501 RESP73H Application of ASME B73 1M 1991 Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process Process Industries Practices Construction Industry Institute The University of Texas at Austin 3208 Red River Street Suite 300 Austin Texas 78705 Pump Handbook 2nd edition Igor J Karassik et al McGraw Hill Inc New York NY 1986 Centrifugal Pump Sourcebook John W Dufour and William E Nelson McGraw Hill Inc New York NY 1993 Pumping Manual 9th edition T C Dickenson Elsevier Advanced Technology Kidlington United Kingdom 1995 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE Notes Page 67 of 68 flowserve com M FLOWSERVE us Your Flowserve factory contacts Flowserve Pump Division 3900 Cook Boulevard Chesapeake VA 23323 1626 USA Telephone 1 757 485 8000 Fax 1 757 485 8149 Flowserve Pumps Limited PO Box 17 Newark Notts NG24 3EN United Kingdom Telephone 24 hours 44 0 1636 494 600 Sales 8 Admin Fax 44 0 1636 705 991 Repair 8 Service Fax 44 0 1636 494 833 E mail inewark flowserve com Your local Flowserve representative To find your local Flowserve representative please use the Sales Support Locator System found at www flowser
73. ISH 71569102 08 06 pressure to the inner bearing race only Never apply pressure to the outer race as this exerts excess load on the balls and causes damage N CAUTION Applying pressure to the outer race could permanently damage the bearings aa The Mark 3A design has an optional oil slinger 2541 located between the bearings If present inspect it for damage or looseness Remove if it needs to be replaced bb On Group 2 and 3 pumps the bearing housing CC e 3200 must be separated from the bearing housing adapter 1340 The adapter O ring 4610 1 should be discarded Mark 3A and ANSI SA design This is accomplished by removing the cap screws 6570 5 which thread into the bearing housing Mark 3 In Line design There is no adapter o ring 4610 1 when an oil drain tap is supplied in the adapter Mark 3 design This is accomplished by removing the hex nuts 6580 8 and the cap screws 6570 5 If lip seals 4310 1 and 4310 2 see figure 6 16 are used they should be removed from the bearing carrier and adapter and discarded Figure 6 16 dd If the bearing isolators are removed from either the bearing carrier or adapter they must not be reused discard appropriately ee If magnetic seals are used maintain the seals as specified by the manufacturer Mark 3 and Mark 3A design Remove the Trico oiler site gage 3855 figure 6 17 and oil level tag figure 6 18 from the bearing housing ANSI
74. LESS e eas III ku ue A In D C Q7 4 COUPLING MOTOR r Oe 6570 16 GUARD Item Description 6570 17 Screw foot set screw 3134 Support foot 6572 4 Stud motor 3160 Motor pedestal C Face 6575 Jackscrew 3200 Bearing housing 6580 4 Nut jackscrew 6570 15 Screw bearing housing 6580 5 Nut motor 6570 16 Screw coupling guard 8 10 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 Page 65 of 68 flowserve com M FLOWSERVE ss 9 CERTIFICATION Certificates determined from the contract requirements are provided with these instructions where applicable Examples are certificates for CE marking and ATEX marking etc If required copies of other certificates sent separately to the Purchaser should be obtained from Purchaser for retention with these User Instructions 10 OTHER RELEVANT DOCUMENTATION AND MANUALS 10 1 Supplementary User Instructions Supplementary instructions such as for a driver instrumentation controller seals sealant systems etc are provided as separate documents in their o
75. Pump speed Changing the pump speed affects flow total head power absorbed NPSHg noise and vibration levels Flow varies in direct proportion to pump speed Head varies as speed ratio squared Power varies as speed ratio cubed If increasing speed it is important to ensure the maximum pump working pressure is not exceeded the driver is not overloaded NPSH gt NPSHg and that noise and vibration are within local requirements and regulations 6 MAINTENANCE A 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 9 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 flowserve com M FLOWSERVE us If platforms stairs and guard rails are required for maintenance they must be pl
76. RNSTIGE SCHADE TOT GEVOLG HEBBEN Oil lubricated units only J218J2262 WARNING Q ATTENTION THIS MACHINE MUST BE FILLED WITH OIL BEFORE STARTING CETTE MACHINE DOIT TRE REMPLIE D HUILE AVANT LA MISE EN MARCHE ACHTUNG DIESE MASCHINE IST VOR DEM STARTEN MIT L Z FULLEN yr WAARSCHUWING DEZE MACHINE MOET VOOR HET STARTEN MET OLIE GEVULD WORDEN DurcoShield Splash Shaft Guard only THIS DEVICE 1S NOT A CONTAINMENT SYSTEM NOR A SEAL BACK UP SYSTEM IT IS A LIMITED PROTECTION DEVICE IT WILL REDUCE BUT NOT ELIMINATE THE PROBABILITY OF INJURY flowserve com M FLOWSERVE us 1 8 Noise level Attention must be given to the exposure of personnel to the noise and local legislation will define when guidance to personnel on noise limitation is required and when noise exposure reduction is mandatory This is typically 80 to 85 dBA The usual approach is to control the exposure time to the noise or to enclose the machine to reduce emitted sound You may have already specified a limiting noise level when the equipment was ordered however if no noise requirements were defined then attention is drawn to the following table to give an indication of equipment noise level so that you can take the appropriate action in your plant Pump noise level is dependent on a number of operational factors flow rate pipework design and acoustic characteristics of the building and so the values given are subject to
77. TRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE Standard hand tools SAE Prior to resizing impellers in high e Hand wrenches chrome iron and nickel please consult your local e Socket wrenches Flowserve sales representative e Allen wrenches e Soft mallet 6 2 1 Ordering of spare parts e Screwdrivers Flowserve keeps records of all pumps that have been supplied Spare parts can be ordered from your local Specialized equioment Flowserve sales engineer or from a Flowserve distributor or representative When ordering spare e Bearing pullers parts the following information should be supplied e Bearing induction heaters 1 Pump serial number e Dial indicators 2 Pump size and type e Spanner wrench 3 Part name see section 8 e Flowserve Mark 3 tool kit see below 4 Part item number see section 8 u 5 Material of construction alloy To simplify maintenance it is recommended that the 6 Number of parts required Flowserve Mark 3 tool kit shown in figure 6 1 is used The pump size and serial number can be found on This tool kit includes a handy impeller wrench which the nameplate located on the bearing housing See simplifies installation and removal of the impeller It also figure 3 1 contains nose cones which protect shaft threads and O rings during maintenance This tool kit can be ordered from your local Flowserve sales engineer or 6 3 Recommended spares and de from a Flowserve distributor or representative
78. aced for easy 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 the pump from being accidentally started Place a warning sign on the starting device Machine under repair do not start With electric drive equipment lock the main switch open and withdraw any fuses Put a warning sign on the fuse box or main switch Machine under repair do not connect Never clean equipment with flammable solvents or carbon tetrachloride Protect yourself against toxic fumes when using cleaning agents Refer to the parts list shown in section 8 for item number references used throughout this section 6 1 Maintenance schedule Ex It is recommended that a maintenance plan and schedule be implemented in accordance with these User Instructions to include the following a Any auxiliary systems installed must be monitored if necessary to ensure they function correctly b Gland packing must be adjusted correctly to give visible leakage an
79. al assemblies If the baseplate has lifting holes cut in the sides at the end Type A Group 3 Type D and Type E bases insert lifting S hooks at the four corners and use slings or chains to connect to the lifting eye Figure 2 1 Do not use slings through the lifting holes For other baseplates sling around the pump discharge nozzle and around the outboard end of the motor frame using choker hitches pulled tight Figure 2 1 The sling should be positioned so the weight is not carried through the motor fan housing Make sure the completion of the choker hitch on the discharge nozzle is toward the coupling end of the pump shaft as shown in figure 2 1 2 3 2 2 In Line assemblies If the pump is to be lifted as a complete assembly the motor lifting lugs must be used to ensure that the assembly does not flip over Check with motor supplier for lifting lug capacities If there is any uncertainty the motor should be removed prior to moving the pump Figure 2 2 Page 10 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 2 4 Storage Store the pump in a clean dry location away from vibration Leave flange covers in place to keep dirt and other foreign material out of pump casing Turn the pump shaft at regular intervals to prevent brinelling of the bearings and the seal faces if fitted from sticking The pump may be stored as above for up to 6 months Consult Flowserve for preservative actions when a longer storage peri
80. ap is present on pumps with regreasable bearings and most oil mist applications Mark 3A and ANSI SA design Thread the capscrews 6570 5 through the adapter and into the tapped holes in the bearing housing Mark 3 design Use the capscrews 6570 5 and hexnuts 6580 8 Orient the bearing housing adapter with the two holes for capscrews 6570 5 on a horizontal line g lfthe pump has lip seals install the deflector 2540 If the pump is equipped with a hook type sleeve 2400 slip it into place over the impeller end of the shaft 2100 6 9 2 Wet end assembly 6 9 2 1 Cartridge mechanical seals Review the seal assembly instructions and drawings provided by the seal manufacturer a Install a nose cone on the end of the shaft and then slide the cartridge seal 4200 onto the shaft until it lightly touches the bearing housing 3200 or adapter 1340 See figure 6 10 Page 53 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 b Install the rear cover plate 1220 to the bearing housing Group 1 or the bearing housing adapter Group 2 and 3 by using the capscrews 6570 2 Now install the cartridge seal gland to the rear cover plate 1220 using studs 6572 2 and nuts 6580 2 c Install the impeller 2200 as instructed in section 6 6 Care should be taken in the handling of high chrome iron impellers d Tighten set screws on the seal to lock the rotating unit to the shaft Finally remove centering clips f
81. art up procedure First slowly close the discharge valve shut down the driver and then close the suction valve Remember that closing the suction valve while the pump is running is a safety hazard and could seriously damage the pump and other equipment 5 9 2 Shutdown Mark 3 Self Priming At shutdown the liquid in the discharge piping falls back into the priming chamber and washes through the impeller into the suction The backflow creates a siphon effect in the casing until the liquid level falls below the bottom of the suction nozzle The inertia of the flow pulls fluid from the priming chamber to a level lower than the initial priming fill Though the level is lower there is still sufficient fluid in the priming chamber to allow the pump to reprime itself 5 10 Hydraulic mechanical and electrical duty 5 10 1 Net positive suction head NPSH Net positive suction head available NPSH is the measure of the energy in a liquid above the vapor pressure lt is used to determine the likelihood that a fluid will vaporize in the pump It is critical because a centrifugal pump is designed to pump a liquid not a vapor Vaporization in a pump will result in damage to the pump deterioration of the Total differential head TDH and possibly a complete stopping of pumping Net positive suction head required NPSHg is the decrease of fluid energy between the inlet of the pump and the point of lowest pressure in the pump This decrea
82. arts Continued running under these conditions when the suction valve is also closed can create an explosive condition due to the confined vapor at high pressure and temperature Thermostats may be used to safeguard against over heating by shutting down the pump at a predetermined temperature Safeguards should also be taken against possible operation with a closed discharge valve such as installing a bypass back to the suction source The size of the bypass line and the required bypass flow rate is a function of the input horsepower and the allowable temperature rise 5 8 3 Reduced head Note that when discharge head drops the pump s flow rate usually increases rapidly Check motor for temperature rise as this may cause overload If overloading occurs throttle the discharge 5 8 4 Surging condition A rapidly closing discharge valve can cause a damaging pressure surge A dampening arrangement should be provided in the piping 5 8 5 Operation in sub freezing conditions When using the pump in sub freezing conditions where the pump is periodically idle the pump should be properly drained or protected with thermal devices which will keep the liquid in the pump from freezing High chrome iron pumps are not recommended for applications below 18 C 0 F flowserve com M FLOWSERVE ss 5 9 Stopping and shutdown 5 9 1 Shutdown considerations When the pump is being shutdown the procedure should be the reverse of the st
83. ash force feed oil mist lubrication 3 S Viscosit st BEP NN S Oil temp range C 5 to 65 5 to 78 5 to 80 E 3 F 23 to 149 23 to 172 23 to 176 o Designation accordin i aE o uc HL HLP 32 HL HLP 46 HL HLP 68 BP BP Energol HL32 BP Energol HL46 BP Energol HL68 BP Energol HLP32 BP Energol HLP46 BP Energol HLP68 DEA Anstron HL32 Anstron HL46 Anstron HL68 Anstron HLP32 Anstron HLP46 Anstron HLP68 OLNA 32 El HYDRELEF 32 TURBELF SA46 TURBELF SA68 8 TURBELF 32 5 ELFOLNA DS32 ELFOLNA DS46 ELFOLNA DS68 Z Esso TERESSO 32 TERESSO 46 TERESSO 68 NUTO H32 NUTO H46 NUTO H68 S Mobil DTE oil light Mobil DTE oil medium Mobil DTE oil heavy medium 2 Mobil Mobil DTE13M Mobil DTE15M Mobil DTE26 s MobilDTE24 Mobil DTE25 E Q8 Q8 Verdi 32 Q8 Verdi 46 Q8 Verdi 68 O Q8 Haydn 32 Q8 Haydn 46 Q8 Haydn 68 5 Shell Shell Tellus 32 Shell Tellus 01 C 46 Shell Tellus 01 C 68 Shell Tellus 37 Shell Tellus 01 46 Shell Tellus 01 68 Terco Rando Oil HD 32 Rando Oil 46 Rando Oil 68 Rando Oil HD AZ 32 Rando Oil HD B 46 Rando Oil HD C 68 Wintershall Wiolan HN32 Wiolan HN46 Wiolan HN68 BASF Group Wiolan HS32 Wiolan HS46 Wiolan HS68 Note that some oils have a greater Viscosity Index than the minimum acceptable of 95 eg Mobil DTE13M which may extend the minimum temperature capability of the oil Always check the grade capability where the ambient is less than 5 C 23
84. ates electrical safety instructions where non compliance will involve a high risk to personal safety or the loss of life This symbol indicates safety instructions where non compliance would affect personal safety and could result in loss of life This symbol indicates hazardous and toxic fluid safety instructions where non compliance would affect personal safety and could result in loss of life Denn This symbol indicates safety instructions where non compliance will involve some risk to safe operation and personal safety and would damage the equipment or property This symbol indicates explosive atmosphere zone marking according to ATEX It is used in safety instructions where non compliance in the hazardous area would cause the risk of an explosion Note TP MP 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 saf
85. ay result in a twist of the baseplate which could make it impossible to obtain final alignment g Check the level of the baseplate to make sure that tightening the anchor bolts did not disturb the level of the baseplate If the anchor bolts did change the level adjust the jackscrews or shims as needed to level the baseplate h Continue adjusting the jackscrews or shims and tightening the anchor bolts until the baseplate is level i Check initial alignment If the pump and motor were removed from the baseplate proceed with step j first then the pump and motor should be reinstalled onto the baseplate using Flowserve s factory preliminary alignment procedure as described in section 4 5 and then continue with the following As described above pumps are given a preliminary alignment at the factory This preliminary alignment is done in a way that ensures that if the installer duplicates the factory conditions there will be sufficient clearance between the motor hold down bolts and motor foot holes to move the motor into final alignment If the pump and motor were properly reinstalled to the baseplate or if they were not removed from the baseplate and there has been no transit damage and also if the above steps where done properly the pump and driver should be within 0 38 mm 0 015 in FIM Full Indicator Movement parallel and 0 0025 mm mm 0 0025 in in FIM angular If this is not the case first check to see if the driver mou
86. ber bushings mounting holes e Desiccant bags are placed inside the tack wrapped packaging e Asolid wood box is used to cover the assembly This packaging will provide protection for up to twelve months from humidity salt laden air dust etc flowserve com M FLOWSERVE us After unpacking protection will be the responsibility of the user Addition of oil to the bearing housing will remove the inhibitor If units are to be idle for extended periods after addition of lubricants inhibitor oils and greases should be used Every three months the pump shaft should be rotated approximately 10 revolutions 2 5 Recycling and end of product life At the end of the service life of the product or its parts the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and in accordance with local regulations If the product contains substances that are harmful to the environment these should be removed and disposed of in accordance with current local regulations This also includes the liquids and or gases that may be used in the seal system or other utilities Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used The safety specifications must be in accordance with the current local regulations at all times 3 DESCRIPTION 3 1 Configurations The Durco Mark 3 chemical process pumps are metallic single stage seale
87. ct the ambient conditions Where there is a risk from such tools or materials maintenance must be conducted in a safe area It is recommended that a maintenance plan and schedule is adopted See section 6 Maintenance 1 7 Name plate and safety labels 1 7 1 Nameplate For details of nameplate see the Declaration of Conformity and section 3 1 7 2 Safety labels FLOWSERVE b J218JZ250 WARNING ESSENTIAL PROCEDURES BEFORE STARTING U ENSURE ALL EXTERNAL CONNECTIONS TO INSTALL AND OPERATE EQUIPMENT IN THE PUMP SHAFT SEALING AND DRIVER ACCORDANCE WITH THE INSTRUCTION 4 ARE CONNECTED AND OPERATIONAL MANUAL SUPPLIED SEPARATELY O FULLY PRIME UNIT AND SYSTEM ENSURE GUARDS ARE SECURELY IN DO NOT RUN UNIT DRY Ml PLACE ENSURE CORRECT DIRECTION OF ROTATION FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN PERSONAL INJURY AND OR EQUIPMENT DAMAGE J218JZ265 KONTROLLE VORGESCHRIEBENER DREHRICHTUNG HIERZU KUPPLUNGSZWISCHENST CK KUPPLUNGSBOLZEN ENTFERNEN ANDERENFALLS ERNSTHAFTE SCHADEN ENSURE CORRECT DRIVER DIRECTION OF ROTATION WITH COUPLING ELEMENT PINS REMOVED OTHERWISE SERIOUS DAMAGE MAY RESULT VERIFIER LE SENS CORRECT DE ROTATION DU MOTEUR POMPE DESACCOUPLEE ENTRETOISE DEMONTEE NE PAS SUIVRE CETTE RECOMMANDATION PEUT CONDUIRE A DE GRAVES DOMMAGES POUR LA POMPE ZORG VOOR JUISTE ROTATIERICHTING VAN DRIJFAS WAARBIJ DE KOPPELELEMENTEN PENNEN VERWIJDERD ZIJN VERZUM KAN E
88. d centrifugal pumps The horizontal family conforms to ASME B73 1M which has a centerline discharge and is represented by our Standard Sealmatic Unitized self priming Recessed impeller and Lo Flo pump models The vertical pump or In Line conforms to ASME B73 2M Figure 3 1 Nameplate mounted to housing Pump Division FLOWSERVE hn Serial No Equipment No Purchase Order Model 2K6X4 M 13A 12 5 RV Size MDP Material Date DD MMM YY The Prima is an ANSI 3A power end adapted to other pump models from Flowserve as well as from other pump manufacturers Only the information in this manual involving the ANSI 3A power end may be used when Installing Operating or Maintaining a pump that has been upgraded to a Prima All other information regarding the pump type must be obtained from the original pump manufacturer s User Instructions Page 11 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 3 2 Nomenclature The pump size will be engraved on the nameplate typically as below 2K6X4M 13A 12 5 RV e Frame size 2 indicates a medium size pump frame in this example a Group 2 1 lt Group 1 small frame 2 Group 2 medium frame 3 Group 3 large frame e Power end K Mark 3 style power end Mark 3A Standard ANSI 3A Optional 3 year guarantee J Mark 3 style PE arranged for Mark 2 wet end No letter and no preceding number indicates a Mark 2 power end e 6 nominal suction
89. d concentric alignment of the gland follower to prevent excessive temperature of the packing or follower c Check for any leaks from gaskets and seals The correct functioning of the shaft seal must be checked regularly d Check bearing lubricant level and the remaining hours before a lubricant change is required e Check that the duty condition is in the safe operating range for the pump Page 40 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 f Check vibration noise level and surface temperature at the bearings to confirm satisfactory operation g Check dirt and dust is removed from areas around close clearances bearing housings and motors h Check coupling alignment and re align if necessary 6 1 1 Preventive maintenance The following sections of this manual give instructions on how to perform a complete maintenance overhaul However it is also important to periodically repeat the Pre start up checks listed in section 5 1 These checks will help extend pump life as well as the length of time between major overhauls 6 1 2 Need for maintenance records A procedure for keeping accurate maintenance records is a critical part of any program to improve pump reliability There are many variables that can contribute to pump failures Often long term and repetitive problems can only be solved by analyzing these variables through pump maintenance records 6 1 3 Cleanliness One of the major causes of pump failure is t
90. dicator placed on the coupling reading in the vertical direction should not indicate Page 32 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 more than 0 05 mm 0 002 in movement when any driver fastener is loosened Align the driver first in the vertical direction by shimming underneath its feet f When satisfactory alignment is obtained the number of shims in the pack should be minimized It is recommended that no more than five shims be used under any foot Final horizontal alignment is made by moving the driver Maximum pump reliability is obtained by having near perfect alignment Flowserve recommends no more than 0 05 mm 0 002 in parallel and 0 0005 mm mm 0 0005 in in angular misalignment See section 6 8 4 7 g Operate the pump for at least an hour or until it reaches final operating temperature Shut the pump down and recheck alignment while the pump is hot Piping thermal expansion may change the alignment Realign pump as necessary 4 8 2 Close coupled pumps Alignment between the pump shaft and motor shaft is built in by precise machining of the parts that position these shafts Parallel alignment of 0 018 mm 0 007 in and angular alignment of 0 002 mm mm 0 002 in in can be expected If a more refined alignment is desired it can be accomplished with the C Plus optional alignment feature The C Plus option requires that a spacer as shown in section 8 9 be installed Four adjusting screws are
91. e Re center the fasteners and perform a preliminary alignment to the above tolerances by shimming under the motor for vertical alignment and by moving the pump for horizontal alignment e Ifthe fasteners are centered then the baseplate may be twisted Slightly adjust one turn of the adjusting nut the stilts at the driver end of the baseplate and check for alignment to the above tolerances Repeat as necessary while maintaining a level condition as measured from the pump discharge flange f Lockthe stilt adjusters The remaining steps are as listed for new grouted baseplates Page 20 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 4 4 Grouting a The pump foundation should be located as close to the source of the fluid to be pumped as practical b There should be adequate space for workers to install operate and maintain the pump The foundation should be sufficient to absorb any vibration and should provide a rigid support for the pump and motor c Recommended mass of a concrete foundation should be three times that of the pump motor and base Refer to figure 4 5 Foundation bolts are imbedded in the concrete inside a sleeve to allow some movement of the bolt Figure 4 5 Baseplate Plastic Tubing Around Bolt Grout SAANNAN S NNI Dam id P i NU an a uh a OB te el eee M NUUSUOM Heatetkt BR o nose no Wedge mb rut DE O 4D tD ae eet oR Og NASPA PE Sleeve x die rei id e cR Concrete Loc
92. e 3 2 is the Alloy cross reference chart for all Mark 3 pumps 3 4 2 Pressure temperature ratings The pressure temperature P T ratings for Mark 3 pumps are shown in figures 3 3 and 3 4 Determine the appropriate casing Material Group No in Figure 3 2 Interpolation may be used to find the pressure rating for a specific temperature Example The pressure temperature rating for an ANSI standard GP2 10 in pump with Class 300 flanges and CF8M construction at an operating temperature of 149 C is found as follows a he correct pressure temperature chart is Figure 3 40 b From Figure 3 2 the correct material group for CF8M is 2 2 c From Figure 3 4C the pressure temperature rating is 21 5 bar The maximum discharge pressure must be less than or equal to the P T rating Discharge pressure may be approximated by adding the suction pressure and the differential head developed by the pump 3 4 3 Suction pressure limits The suction pressure limits for Mark 3 pumps with reverse vane impellers is limited by the values given in figure 3 5 and by the P T ratings Suction pressure for pump sizes 10x8 14 8x6 16A 10x8 16 and 10x8 16H up to a maximum liquid specific gravity of 2 0 is limited only by the P T ratings Suction pressure for pumps with open impellers is also limited only by the P T ratings The suction pressure limits for Sealmatic pumps are determined by the repeller head capability found in Bulletin P 18 102e
93. e 5 16 This guard can be used in place of the existing clamshell guard described above Disassembly of the ClearGuard is accomplished by removing the fasteners that hold the two guard halves together followed by removing the foot bolts and rotating the support leg out of the slot on the guard Figure 5 16 5 5 3 Trimming instructions In order to correctly fit the pump motor configuration each guard must be trimmed to a specific length This trimming is done on the motor end of the guard a Measure minimum distance from the center of mounting hole in the baseplate to the motor If clam shell guard proceed to step c b Locate a reference center in the slot of the ClearGuard coupling guard flange see figure 5 17 Transfer the length measurement to the guard using this reference center c Trim the motor end of the guard according to the above measurement Trimming is best done with a band saw but most other types of manual or power saws give acceptable results Care must be taken to ensure that there is no gap larger than 6 mm 0 24 in between the motor and the coupling guard Page 37 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 d If motor diameter is smaller than guard diameter trim guard so that it extends over the end of the motor as far as possible e Deburr the trimmed end with a file or a sharp knife if ClearGuard Care must be taken to eliminate all sharp edges v Reference cente
94. ed N NEVER APPLY HEAT TO REMOVE IMPELLER Trapped lubricant or vapor could cause an explosion HOT and cold PARTS If hot or freezing components or auxiliary heating equipment can present a danger to operators and persons entering the immediate area action must be taken to avoid accidental contact such as shielding If complete protection is not possible the machine access must be limited to maintenance staff only with clear visual warnings and indicators to those entering the immediate area Note bearing housings must not be insulated and drive motors and bearings may be hot If the temperature is greater than 68 C 175 F or below 5 C 20 F in a restricted zone or exceeds local regulations action as above shall be taken flowserve com J N CAUTION PIPE LOAD Do not use pump as a support for piping Do not mount expansion joints unless allowed by Flowserve in writing so that their force due to internal pressure acts on the pump flange N CAUTION ENSURE CORRECT LUBRICATION See section 5 Commissioning startup operation and shutdown A CAUTION NEVER EXCEED THE MAXIMUM DESIGN PRESSURE MDP AT THE TEMPERATURE SHOWN ON THE PUMP NAMEPLATE oee section 3 for pressure versus temperature ratings based on the material of construction ZN CAWON NEVER OPERATE THE PUMP WITH THE DISCHARGE VALVE CLOSED Unless otherwise instructed at a specific point in the User Instructions See section 5 Commissioni
95. ed between the repeller 2200 1 and the repeller cover 1220 1 Page 45 of 68 p MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 If a component type inside mechanical seal 4200 is used loosen the set screws on the rotating unit and remove it from the shaft see figure 6 11 Then pull the gland 4120 and stationary seat off the shaft Remove the stationary seat from the gland Discard all O rings and gaskets 2 a 4 Figure 6 11 Ifa Remb type puiside mechanical seal is used remove the gland and the stationary seat Remove the stationary seat from the gland Loosen the set screws in the rotating unit and remove it from the shaft Discard all O rings and gaskets If packing 4130 is used remove it and the seal cage lantern ring 4134 Remove the gland 4120 If the pump has a hook type sleeve 2400 it can now be removed Unit now appears as shown in figure 6 12 Figure 6 12 If the power end is oil lubricated remove the drain plug 6569 1 and drain the oil from the bearing housing 3200 If the pump has lip seals a deflector 2540 will be present Remove it Loosen the three set screws 6570 3 on the bearing carrier 3240 The bearing carrier must be completely unscrewed from the bearing housing Do not pry against the shaft Mark 3A and ANSI 3A design The face of the bearing carrier has three square lugs that protrude from the surface The bearing carrier is turned by using an open end wrench
96. ed hole at the top of the cover Use either a sling or hook through the eye bolt Page 9 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 2 3 1 3 Bearing housing 3200 Group 1 insert a sling between the upper and lower support ribs between the housing barrel and the casing attachment flange Use a choker hitch when slinging Make sure there are no sharp edges on the bottom side of the ribs that could cut the sling Group 2 and 3 insert either a sling or hook through the lifting lug located on the top of the housing 2 3 1 4 Power end Same as bearing housing 2 3 1 5 Bare pump Horizontal pumps sling around the pump discharge nozzle and around the outboard end of the bearing housing with separate slings Choker hitches must be used at both attachment points and pulled tight Make sure the completion of the choker hitch on the discharge nozzle is toward the coupling end of the pump shaft as shown in figure 2 1 The sling lengths should be adjusted to balance the load before attaching the lifting hook Figure 2 1 In Line pumps lift with two slings through the pump adapter on opposite sides of the shaft Figure 2 2 Bare pump with motor adapter In Line only lift with two slings through the motor adapter shaft holes This method is also used to lift the bare motor adapter Figure 2 2 flowserve com FLOWSERVE b Figure 2 2 2 3 2 Lifting pump motor and baseplate assembly 2 3 2 1 Horizont
97. er RO k 18 OU 20 4 5 Initial alignment sso ea cei eee re a Een dos 21 AO PIDIN RR 22 4 7 Electrical connections 31 4 8 Final shaft alignment check 32 4 9 Protection systems 32 5 COMMISSIONING STARTUP OPERATION AND SHUTDOWN isst sind tuti mac la bool inm 33 5 1 Pre commissioning procedure 33 5 2 Pump lubricants xu udo de orit 33 5 3 Impeller clearance 36 5 4 Direction of rotation 36 5 5 BROS 36 5 6 Priming and auxiliary supplies 37 5 7 Starting the pump 38 5 8 Running or operation 38 5 9 Stopping and shutdown 39 5 10 Hydraulic mechanical and electrical duty 39 Page 2 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Page 6 MAINTENJANGI x eve deese em rea ties 39 6 1 Maintenance schedule 40 6 2 DANS Daisies enc idc bo geb la SER 40 6 3 Recommended spares and consumable items 41 6 4 Tools required s sccesces touto opcris Lem Ex eov evite 41 6 5 Fastener torques 41 6 6 Setting impeller clearance and impeller replacement 42 6 7 Disasse
98. eratures ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE Pump liquid temperature Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate These are based on a maximum ambient temperature of 40 C 104 F 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 depends on the temperature class and must not exceed the values in the table applicable below The temperature rise at the seals and bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated Maximum permitted liquid temperature for pumps Maximum Temperature limit of liquid Temperature surface handled depending on class to temperature material and construction EN 19151 permitted variant check which is lower T6 85 C 185 F Consult Flowserve T5 100 C 212 F Consult Flowserve T4 135 C 275 F 115 C 239 F T3 200 C 392 F 180 C 356 F T2 300 C 572 F 275 C 527 F T1 450 C 842 F 400 C 752 F Page 6 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Maximum permitted liquid temperature for pumps with self priming casing Maximum Temperature limit of liquid binh surface handled depending on EN 13463 1 temperature material and construction permitted variant check which is lower
99. etaining ring clamp type 4590 2 Gasket impeller 6572 3 Stud pedestal casing 2540 Deflector inboard optional 4590 3 Gasket gand 6575 Jackscrew 3011 Ballbearing inboard 4610 1 O ring adapter 65802 Nut gland 3013 Ball bearing outboard 4610 2 O ring bearingcarier 6580 3 Nut pedestal casing 3160 Motor pedestal 6521 Plug bearing housing vent 6580 4 Nut jackscrewjamnut 3170 Pumpstand 6541 1 Lockwasher bearing 6700 Key shafi coupling 3200 Bearing housing 65413 Washer JJ 6569 1 Plug Not shown Page 64 of 68 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE 8 9 Mark 3 C Face Adapter Group 1 and Group 2 DOXD 62004 J r E er CHEER xE Te KA
100. ety and health laws and regulations 1 6 3 Safety action This is a summary of conditions and actions to help prevent injury to personnel and damage to the environment and to equipment For products used in potentially explosive atmospheres section 1 6 4 also applies Page 4 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 AN pancer NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER Lock out DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous FLUOROELASTOMERS When fitted When a pump has experienced temperatures over 250 C 482 F partial decomposition of fluoroelastomers example Viton will occur In this condition these are extremely dangerous and skin contact must be avoided HANDLING COMPONENTS Many precision parts have sharp corners and the wearing of appropriate safety gloves and equipment is required when handling these components To lift heavy pieces above 25 kg 55 Ib use a crane appropriate for the mass and in accordance with current local regulations NEVER OPERATE THE PUMP WITHOUT THE COUPLING GUARD AND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED GUARDS MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL THERMAL SHOCK Rapid changes in the temperature of the liquid within the pump can cause thermal shock which can result in damage or breakage of components and should be avoid
101. fied for the classification of the specific atmosphere in which they are to be installed Where Flowserve has supplied only the bare shaft pump the Ex rating applies only to the pump The party responsible for assembling the pump set shall select the coupling driver seal and any additional equipment with the necessary CE Certificate Declaration of Conformity establishing it is suitable for the area in which it is to be installed The output from a variable frequency drive VFD can cause additional heating affects in the motor On pump installations controlled by a VFD the ATEX Certification for the motor must state that it covers the situation where electrical supply is from the VFD This particular requirement still applies even if the VFD is in a safe area flowserve com M FLOWSERVE us 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 Il 2 GD c IIC 135 C T4 Equipment Group lt Mining Il 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 1 6 4 3 Avoiding excessive surface temp
102. fittings and vent pipe olugs are installed inboard and outboard LA umon The orientation of the bearing shields is different for horizontal pumps Standard Sealmatic Unitized Recessed and Lo Flo see figure 5 7 and In Line pumps see figure 5 8 Figure 5 7 Horizontal pump shield orientation Shield Outboard Inboard Bearing Bearing Figure 5 8 In Line pump shield orientation Shield eae Outboard Bearing Bearing Horizontal pump bearings are packed with Exxon POLYREX EM grease prior to assembly For relubrication a grease with the same type base polyurea and oil mineral should be used In the case of the In Line pump the bearings are packed with Exxon Unirex N3 grease For relubrication a grease with the same type base lithium and oil mineral should be used To regrease remove the pipe plug from both the inboard and outboard bearing location See figure 5 9 After relubricating the bearings three times it is typically recommended that the bearing housing is cleaned out N CAUTION To regrease bearings under coupling guard stop pump lock the motor remove coupling guard and then regrease the bearings The amount of grease reguired for horizontal pumps is shown in figure 5 10 and for In Line pumps in figure 5 11 Page 35 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 5 9 Regreasable configuration 1 8 NPT Grease Fitting and Relief Pipe Plug
103. flowserve com M FLOWSERVE s c Install the outboard bearing Double row bearings Install the outboard bearing 3013 firmly against the shoulder as shown in figure 6 22 If hot bearing mounting techniques are used steps must be taken to ensure the outboard bearing is firmly positioned against the shaft shoulder The outboard bearing while still hot is to be positioned against the shaft shoulder Duplex angular contact bearings Duplex angular contact bearings must be mounted back to back with the wider thrust sides of the outer races in contact with each other as shown in figure 6 25 Only bearings designed for universal mounting should be used The SKF designation is BECB NTN s designation is G ee A special shaft is required when using duplex angular contact bearings IQ vs THRUST SIDES PA Figure 25 The orientation of the bearing shields is different for horizontal pumps figure 5 7 and In Line pumps figure 5 8 It must be understood that fixtures and equipment used to press the bearing must be designed so no load is ever transmitted through the bearing balls This would damage the bearing d After the bearing has cooled below 38 C 100 F the bearing should be pressed against the shaft shoulder Figure 6 26 identifies the approximate force needed to seat the bearing against the shaft shoulder If a press is not available the locknut 371
104. ft foot with by adjusting the support feet and or rotating the motor adapter slightly Bolt the unit to the baseplate and tighten the support feet set screws 6570 17 d Reinstall the motor coupling and coupling guard 6 9 5 Reassemble to casing a Install a new rear cover gasket 4590 1 between the rear cover plate 1220 and the casing 1100 b Use studs 6572 1 and nuts 6580 1 to complete the rebuild of your Flowserve Mark 3 pump Page 56 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE 7 FAULTS CAUSES AND REMEDIES The following is a guide to troubleshooting problems with Flowserve Mark 3 pumps Common problems are analyzed and solutions offered Obviously it is impossible to cover every possible scenario If a problem exists that is not covered by one of the examples then refer to one of the books listed in section 10 Additional sources of information or contact a Flowserve sales engineer or distributor representative for assistance FAULT SYMPTOM Pump not reaching design flow rate n Pump not reaching design head TDH U No discharge or flow with pump running U Pump operates for short period then loses prime KU Excessive noise from power end U Excessive noise from wet end tt MM Py Tt ee Py yt ty ee Tt EE LL
105. hanges in parallel alignment Angular alignment is controlled by machining tolerances but cannot prevent uneven cover gasket compression a Check angular alignment Additional torque may be applied to the appropriate casing bolts to correct angularity b Check parallel alignment within a plane defined by the adjusters at opposite corners of the motor adapter To make corrections the motor adapter nuts 6580 3 must be slightly loosened to allow the motor adapter to move All adjusters except for the one in the desired direction of motor movement should be loosened during adjustment Tighten the adjuster slowly against the stud until desired alignment numbers are reached c Check parallel alignment within a plane 90 degrees from the first Corrections are made as described in the previous step d Several iterations between planes may be necessary Tighten all fasteners and recheck alignment Page 22 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 4 7 B iii Il 4 6 Piping Protective covers are fitted to both the suction and discharge flanges of the casing and must be removed prior to connecting the pump to any pipes 4 6 1 Suction and discharge piping All piping must be independently supported accurately aligned and preferably connected to the pump by a short length of flexible piping The pump should not have to support the weight of the pipe or compensate for misalignment It shou
106. harges by proper grounding or consider belt material that is less up NN PUN ANT RII UNS NN AI generative Bearing damage due to improper 1 Be sure the lubricant is clean lubrication identified by one or more 2 Be sure proper amount of lubricant is used The constant level of the following oiler supplied with Durco pumps will maintain the proper oil level if 1 Abnormal bearing temperature it is installed and operating properly In the case of greased rise lubricated bearings be sure that there is space adjacent to the 2 A stiff cracked grease appearance bearing into which it can rid itself of excessive lubricant otherwise 3 A brown or bluish discoloration of the bearing may overheat and fail prematurely the bearing races 3 Be sure the proper grade of lubricant is used Page 58 of 68 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE 8 PARTS LIST AND DRAWINGS 8 1 Standard Mark 3 pump Group 1 6 00 5240 16570 3 4310 241 5 12 6541 6209 3013 6521 2530 1 3011 4310 1 2540 2400 4120 4200 4590 2 2200 PT ILNA PE PEI 2209 STANDARD REVERSE VANE IMPELLER 7 6560 2 SESA 6580 1 1220 4154 14590 5 141 50 4610 2 3036 3855 3126 6570 4 4154 6569 4120 6570 2 4590 1 Optional duplex arrangement JU
107. hat all rotating parts move freely and that there are no foreign objects in the pump casing 5 2 Pump lubricants 5 2 1 Oil bath Oil bath is available on all product lines with the exception of the In Line pump The standard bearing housing bearings are oil bath lubricated and are not lubricated by Flowserve Before operating the pump fill the bearing housing to the center of the oil sight glass with the proper type oil See figure 5 2 for approximate amount of oil required do not overfill On the Mark 3A design an optional oil slinger is available The oil slinger is not necessary however If used it provides an advantage by allowing a larger tolerance in acceptable oil level Without an oil slinger the oil level in the bearing housing must be maintained at 3 mm in from the center of the sight glass The sight glass has a 6 mm 1 4 in hole in the center of its reflector The bearing housing oil level must be within the circumference of the center hole to ensure adequate lubrication of the bearings See figure 5 3 for recommended lubricants DO NOT USE DETERGENT OILS The oil must be free of water sediment resin soaps acid and fillers of any kind It should contain rust and oxidation inhibitors The proper oil viscosity is determined by the bearing housing operating temperature as given in figure 5 4 To add oil to the housing clean and then remove the vent plug 6521 at the top of the bearing housing pour
108. he presence of contaminants in the bearing housing This contamination can be in the form of moisture dust dirt and other solid particles such as metal chips Contamination can also be harmful to the mechanical seal especially the seal faces as well as other parts of the pump For example dirt in the impeller threads could cause the impeller to not be seated properly against the shaft This in turn could cause a series of other problems For these reasons it is very important that proper cleanliness be maintained Some guidelines are listed below e After draining the oil from the bearing housing periodically send it out for analysis If it is contaminated determine the cause and correct e The work area should be clean and free from dust dirt oil grease etc e Hands and gloves should be clean e Only clean towels rags and tools should be used 6 2 Spare parts The decision on what spare parts to stock varies greatly depending on many factors such as the criticality of the application the time required to buy and receive new spares the erosive corrosive nature of the application and the cost of the spare part Section 8 identifies all of the components that make up each pump addressed in this manual Please refer to the Flowserve Mark 3 Pump Parts Catalog for more information A copy of this book can be obtained from your local Flowserve sales engineer or distributor representative flowserve com MARK 3 USER INS
109. he 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 is carried out 5 COMMISSIONING STARTUP OPERATION AND SHUTDOWN CAUTION f These operations must be carried out by fully qualified personnel 5 1 Pre commissioning procedure 5 1 1 Pre start up checks Prior to starting the pump it is essential that the following checks be made These checks are all described in detail in the Maintenance section of this manual e Pump and motor properly secured to the baseplate e Remove the temporary motor supports installed for shipping close coupled pumps e All fasteners tightened to the correct torque e Coupling guard in place and not rubbing Rotation check see section 5 4 This is absolutely essential Impeller clearance setting Shaft seal properly installed Seal support system operational Bearing lubrication Bearing housing cooling system operational Support leg cooling for centerline mounting option operational e Heating cooling for jacketed casing cover operational e Pump instrumentation is operational e Pump is primed e Rotation of shaft by hand Page 33 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 As a final step in preparation for operation it is important to rotate the shaft by hand to be certain t
110. ier set screws in 16 Nm 12 Ibf ft vein 41 Nm 30 Ibfeft Yin 41 Nm 30 lbfeft 6570 4 Cap screw foot Ve in 54 Nm 40 Ibfeft in 217 Nm 160 Ibf ft 1 in 300 Nm 228 Ibf ft 6570 13 Cap screws repeller cover to cover n a in 16 Nm 12 lbfeft Ya in 41 Nm 80 lbfeft 6570 15 Cap screw bearing housing Ve in 54 Nm 40 Ibfeft 72 in 54 Nm 40 Ibfeft n a 8712 Bearing Locknut 27 4 0 Nm 20 5 0 Ibfeft 54 7 0 Nm 40 5 0 Ibfeft 95 7 0 Nm 70 5 0 Ibfeft Notes 1 For lubricated or PTFE coated threads use 75 of the values given 2 Gasket joint torque values are for unfilled PTFE gaskets Other gasket materials may require additional torque to seal Exceeding metal joint torque values is not recommended Page 41 of 68 flowserve com FLOWSERVE us 6 6 Setting impeller clearance and impeller replacement A new impeller gasket 4590 2 must be installed whenever the impeller has been removed from the shaft Impeller clearance settings may be found in section 5 3 Impeller balancing instruction may be found in section 6 8 Mark 3 Unitized Self Priming pumps require that the outside diameter of the impeller be 3 mm 0 125 in from the casing cutwater If this close clearance is not maintained the pump may not prime N CAUTION Do not adjust the impeller clearance with the seal set Doing so may result in sea
111. inal torque value to lock the bearing carrier in place 6 6 2 Installation and clearance setting for front vane open style impeller on Mark 3 Standard Unitized self priming Lo Flo and In Line pumps Like all front vane open style impellers the Flowserve open impeller clearance must be set off the casing The casing must be installed to accurately set the impeller clearance Realizing that this can be very difficult Flowserve strongly promotes the use of reverse vane impellers which do not require the presence of the casing to be properly set Attach the power end rear cover plate assembly to the casing Now set the impeller clearance by loosening the set screws 6570 3 and rotating the Page 43 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 bearing carrier 3240 to obtain the proper clearance Turn the bearing carrier clockwise until the impeller comes into light rubbing contact with the casing Rotating the shaft at the same time will accurately determine this zero setting Now rotate the bearing carrier counter clockwise to get the proper clearance Refer to figure 5 12 for the proper impeller clearance Rotating the bearing carrier the width of one of the indicator patterns cast into the bearing carrier moves the impeller axially 0 1 mm 0 004 in See figure 6 5 Determine how far to rotate the bearing carrier by dividing the desired impeller clearance by 0 1 mm 0 004 in one indicator pattern Tightening
112. ing as defined in the User Instructions and the maximum permitted surface temperature of the T Class could be exceeded it is recommended that user install an external surface temperature protection device 1 6 4 4 Preventing the build up of explosive mixtures Ex ENSURE PUMP IS PROPERLY FILLED AND VENTED AND DOES NOT RUN DRY Ensure that the pump and relevant suction and discharge piping is totally filled with liquid at all times during the pumps operation so that an explosive atmosphere is prevented flowserve com M FLOWSERVE us In addition it is essential to make sure that seal chambers auxiliary shaft seal systems and any heating and cooling systems are properly filled If the operation of the system can not avoid this condition it is recommended that you fit an appropriate dry run protection device for example liquid detection or a power monitor To avoid potential hazards from fugitive emissions of vapor or gas to atmosphere the surrounding area must be well ventilated 1 6 4 5 Preventing sparks Ex To prevent a potential hazard from mechanical contact the coupling guard must be non sparking To avoid the potential hazard from random induced current generating a spark the earth contact on the baseplate must be used ia 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 m
113. ing guard is not installed Flowserve coupling guards are safety devices intended to protect workers from inherent dangers of the rotating pump shaft motor shaft and coupling Itis intended to prevent entry of hands fingers or other body parts into a point of hazard by reaching through over under or around the guard No standard coupling guard provides complete protection from a disintegrating coupling Flowserve cannot guarantee their guards will completely contain an exploding coupling 5 5 1 Clam shell guard standard The standard coupling guard for all Mark 3 pumps is the clam shell design and is shown in figure 5 15 Itis hinged at the top and it can be removed by loosening one of the foot bolts and sliding the support leg out from under the cap screw Note that the foot is slotted The leg can then be rotated upward and half of the guard can be disengaged unhinged from the other flowserve com M FLOWSERVE us Only one side of the guard needs to be removed To reassemble simply reverse the above procedure AA se Figure 5 15 The coupling guard shown in figure 5 15 conforms to the USA standard ASME B15 1 Safety standard for mechanical power transmission apparatus Flowserve manufacturing facilities worldwide conform to local coupling guard regulations 5 5 2 ClearGuard optional Flowserve offers as an option a ClearGuard which allows you to see the condition of the coupling see figur
114. ing installation Mounting of bearings on shafts must be done in a clean environment Bearing and power end life can be drastically reduced if even very small foreign particles work their way into the bearings Wear clean gloves Bearings should be removed from their protective packaging only immediately before assembly to limit exposure to possible contamination After removing the packaging they should only come in contact with clean hands fixtures tools and work surfaces The chart shown in figure 6 23 gives the SKF part numbers for bearings in Flowserve Mark 3 pumps Note that the term inboard bearing refers to the bearing nearest to the casing Outboard bearing refers to the bearing nearest to the motor See figure 6 22 LA cumov Both bearings have a slight interference fit which requires that they be pressed on the shaft with an arbor or hydraulic press Figure 6 20 identifies the bearing fits Even force should be applied to only the inner race Never press on the outer race as the force will damage the balls and races An alternate method of installing bearings is to heat the bearings to 93 C 200 F by means of an oven or induction heater With this approach the bearing must be quickly positioned on the shaft Never heat the bearings above 110 C 230 F To do so will likely cause the bearing fits to permanently change leading to early failure flowserve com M FLOWSERVE us a Instal
115. ings threaded impeller end and keyed drive end 3 3 4 Pump bearings and lubrication Ball bearings are fitted as standard and may be either oil or grease lubricated 3 3 5 Bearing housing Large oil bath reservoir 3 3 6 Seal chamber cover plate The seal chamber has a spigot rabbet fit between the pump casing and bearing housing adapter for optimum concentricity The design enables a number of sealing options to be fitted 3 3 7 Shaft seal The mechanical seal s attached to the pump shaft seals the pumped liquid from the environment Gland packing may be fitted as an option 3 3 8 Driver The driver is normally an electric motor Different drive configurations may be fitted such as internal combustion engines turbines hydraulic motors etc driving via couplings belts gearboxes drive shafts etc 3 3 9 Accessories Accessories may be fitted when specified by the customer 3 4 Performance and operation limits This product has been selected to meet the specification 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 liquid being pumped temperature material of construction and seal type may influence this data If required a definitive statement for your application can be obtained from Flowserve Page 12 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 3 4 1 Alloy cross reference chart Figur
116. install or use authorized Flowserve parts and accessories is considered to be misuse Damage or failure caused by misuse is not covered by the Flowserve warranty In addition any modification of Flowserve products or removal of original components may impair the safety of these products in their use 1 4 Copyright All rights reserved No part of these instructions may be reproduced stored in a retrieval system or transmitted in any form or by any means without prior permission of Flowserve Pump Division 1 5 Duty conditions This product has been selected to meet the specifications of your 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 the user seeks the written agreement of Flowserve before start up flowserve com M FLOWSERVE ss 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 PANOJE This symbol indic
117. is eliminates problems due to thermal expansion as the pump is designed to withstand forces that the piping is normally capable of transmitting 4 3 3 Rigid baseplates overview The function of a baseplate is to provide a rigid foundation under a pump and its driver that maintains alignment between the two Baseplates may be generally classified into two types e Foundation mounted grouted design Figure 4 1 e Stili mounted or free standing Figure 4 2 Figure 4 1 Baseplates intended for grouted installation are designed to use the grout as a stiffening member Stilt mounted baseplates on the other hand are designed to provide their own rigidity Therefore the designs of the two baseplates are usually different Regardless of the type of baseplate used it must provide certain functions that ensure a reliable installation Three of these requirements are 1 The baseplate must provide sufficient rigidity to assure the assembly can be transported and installed given reasonable care in handling without damage It must also be rigid enough when properly installed to resist operating loads 2 The baseplate must provide a reasonably flat mounting surface for the pump and driver Uneven surfaces will result in a soft foot condition that may make alignment difficult or impossible Experience indicates that a baseplate with a top surface flatness of 1 25 mm m 0 015 in ft across the diagonal corners of the baseplate pro
118. ischarge flange Mys designates the moment about the y axis on the suction flange The absolute value of the applied suction load divided by the corresponding adjusted load must be less than or equal to one Also the absolute value of the applied discharge load divided by the corresponding adjusted load must be less than or equal to one b e c For example F Dhs eo LS AN Mzd c1p Fx adj Fy adj Mz adj flowserve com M FLOWSERVE us Figure 4 19 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 4 6 4 2C Pump stand limitations In cases where the pump is rigidly mounted by the pump stand both the casing limitations and the pump stand limitations must be satisfied Due to the limited load capacity of the pump stands it may be necessary to restrain the piping to prevent loads a Ensure all applied loads are within the allowable limits of the casing b Translate the flange loads using the formulae found in figure 4 21 Dimensional variables Sps Spo and Rs can be found in figure 4 20 c Calculate Fr and Fy using the formulae found in figure 4 21 d Fr and FN must be less than FTMAx and FNMAx found in figure 4 22 e Fy and Fy must meet the combination formulae found in figure 4 22 o SD SRd SRs Rs Fx Fy Fz Mx My Mz 1824 17 685 1824 692 976 692 125 0 625 0 625 0 53 410 8976 410 510 720 510 1601 17 685 1601 692 976 69
119. ividually supported and that the spring mounted baseplate is not intended to support total static pipe loads Figure 4 4 D STILT BOLT amp BOTTOM SPRING 3 4 in 83 mm OD X 4 in 102 mm FL CUPS TOP SPRING 2 in 51 mm OD X 4 in 102 mm FL CUPS 2 NUTS 5 FLAT WASHER Tm A BO A rn IE GREEN LOCK WASHER FLOOR CUP P 6 z p 0 A t d 1 in 25 mm Approx Initial Height 25 4 3 4 3 Stilt spring mounted baseplates motor alignment The procedure for motor alignment on stilt or spring mounted baseplates is similar to grouted baseplates The difference is primarily in the way the baseplate is leveled a Level the baseplate by using the stilt adjusters Shims are not needed as with grouted baseplates b After the base is level it is locked in place by locking the stilt adjusters c Next the initial pump alignment must be checked The vertical height adjustment provided by the stilts allows the possibility of slightly twisting the baseplate If there has been no transit damage or twisting of the baseplate during stilt height adjustment the pump and driver should be within 0 38 mm 0 015 in parallel and 0 0025 mm mm 0 0025 in in angular alignment If this is not the case check to see if the driver mounting fasteners are centered in the driver feet holes d lfthe fasteners are not centered there was likely shipping damag
120. king Tab Anchor asher Foundation Welded to Bolt Bolt d Level the pump baseplate assembly If the baseplate has machined coplanar mounting surfaces these machined surfaces are to be referenced when leveling the baseplate This may require that the pump and motor be removed from the baseplate in order to reference the machined faces If the baseplate is without machined coplanar mounting surfaces the pump and motor are to be left on the baseplate The proper surfaces to reference when leveling the pump baseplate assembly are the pump suction and discharge flanges DO NOT stress the baseplate e Do not bolt the suction or discharge flanges of the pump to the piping until the baseplate foundation is completely installed If equipped use leveling jackscrews to level the baseplate If jackscrews are not provided shims and wedges should be used See Figure 4 5 Check for levelness in both the longitudinal and lateral directions Shims should be placed at all base anchor bolt locations and in the middle edge of the base if the base is more than 1 5 m 5 ft long Do not rely on the bottom of the baseplate to be flat Standard baseplate bottoms are not machined and it is not likely that the field mounting surface is flat flowserve com M FLOWSERVE s f After leveling the baseplate tighten the anchor bolts If shims were used make sure that the baseplate was shimmed near each anchor bolt before tightening Failure to do this m
121. l leakage and or damage CAUTION A The impeller could have sharp edges which could cause an injury Itis very important to ear heavy gloves auc It is recommended that two people install a Group 3 impeller The weight of a Group 3 impeller greatly increases the chance of thread damage and subsequent lock up concerns ZN CAUTION Do not attempt to tighten the impeller on the shaft by hitting the impeller with a hammer or any other object or by inserting a pry bar between the impeller vanes Serious damage to the impeller may result from such actions ZN CAUTION Care should be taken in the handling of high chrome iron impellers Install the impeller 2200 by screwing it onto the shaft use heavy gloves until it firmly seats against the shaft shoulder ke Tighten the impeller with the impeller wrench from the Flowserve Mark 3 tool kit To do this grasp the impeller in both hands and with the impeller wrench handle to the left viewed from the impeller end of the shaft figure 6 3 spin the impeller forcefully in a clockwise direction to impact the impeller wrench handle on the work surface to the right figure 6 4 Figure 6 3 Page 42 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Figure 6 4 6 6 1 Installation and clearance setting for reverse vane impellers on Mark 3 Standard Unitized self priming In Line and open vane impeller on the recessed impeller pump Flowserve reverse vane impe
122. l the inboard bearing 301 1 on the shaft 2100 Mark 3A and ANSI 3A design The inboard bearing must be positioned against the shoulder as shown in figure 6 22 Mark 3 design On Group 1 and Group 2 shafts the inboard bearing must be located as shown in figure 6 24 On Group 3 shafts position the inboard bearing against the shoulder Figure 6 24 Bearing position Mark 3 design Inboard bearing located against shoulder Figure 6 23 Flowserve Mark 3 bearings MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 If the power end is equipped with single shielded regreasable bearings see figures 5 7 and 5 8 for proper orientation of the shields The orientation of the bearing shields is different for horizontal pumps figure 5 7 and In Line pumps figure 5 8 b Install the outboard bearing retaining device onto the shaft Double row bearings Place the snap ring 2530 onto the outboard end of the shaft and slide down to the inboard bearing The proper orientation of the snap ring must be assured in this step The flat side of the snap ring must face away from the inboard bearing Duplex angular contact bearings Place the bearing retainer 2530 1 onto the outboard end of the shaft and slide down to the inboard bearing The proper orientation of the bearing retainer must be assured in this step The small side of the retainer must face away from the inboard bearing deep groove Inboard single ro
123. ld be possible to install suction and discharge bolts through mating flanges without pulling or prying either of the flanges All piping must be tight Pumps may air bind if air is allowed to leak into the piping If the pump flange s have tapped holes select flange fasteners with thread engagement at least equal to the fastener diameter but that do not bottom out in the tapped holes before the joint is tight 4 6 2 Suction piping To avoid NPSH and suction problems suction piping must be at least as large as the pump suction connection Never use pipe or fittings on the suction that are smaller in diameter than the pump suction size flowserve com M FLOWSERVE us Figure 4 9 illustrates the ideal piping configuration with a minimum of 10 pipe diameters between the source and the pump suction In most cases horizontal reducers should be eccentric and mounted with the flat side up as shown in figure 4 10 with a maximum of one pipe size reduction Never mount eccentric reducers with the flat side down Horizontally mounted concentric reducers should not be used if there is any possibility of entrained air in the process fluid Vertically mounted concentric reducers are acceptable In applications where the fluid is completely de aerated and free of any vapor or suspended solids concentric reducers are preferable to eccentric reducers Figure 4 9 Figure 4 10 SUCTION Avoid the use of throttling valves and strainers in
124. ll pipe threads be sealed properly PTFE tape provides a very reliable seal over a wide range of fluids but it has a serious shortcoming if not installed properly If during application to the threads the tape is wrapped over the end of the male thread strings of the tape will be formed when threaded into the female fitting These strings can then tear away and lodge in the piping system If this occurs in the seal flush system small orifices can become blocked effectively shutting off flow For this reason Flowserve does not recommend the use of PTFE tape as a thread sealant Flowserve has investigated and tested alternate sealants and has identified two that provide an effective seal have the same chemical resistance as the tape and will not plug flush systems These are La co Slic Tite and Bakerseal Both products contain finely ground PTFE particles in an oil based carrier Page 50 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 They are supplied in a paste form which is brushed onto the male pipe threads Flowserve recommends using one of these paste sealants Full thread length engagement is required for all fasteners Refer to figure 6 2 for recommended bolt torques 6 9 1 Power end assembly The Mark 3A design has an optional oil slinger If the slinger was removed during disassembly install a new slinger 2541 See figure 6 22 Outboard Bearing Bearing Figure 6 22 Slinger 6 9 1 1 Bear
125. ll the rear cover plate 1220 to the bearing housing Group 1 or the bearing housing adapter Group 2 and 3 by using the capscrews 6570 2 c Install and set the impeller 2200 clearance as outlined in section 6 6 d Install the packing rings 4130 and seal cage halves 4134 into the stuffing box as shown in figure 4 24 Always stagger the end gaps 90 degrees to ensure a better seal To speed installation of each ring have an assistant turn the pump shaft in one direction This movement of the shaft will tend to draw the rings into the stuffing box e Now attach the gland 4120 to the cover using studs 6572 2 and nuts 6580 2 f Lightly snug up the gland Final adjustments must be made after the pump has begun operation 6 9 2 4 Reassembly Sealmatic with Checkmatic seal a Remove any sharpness of edge at wet end of shaft with 400 emery cloth b Clean all exposed surfaces of the wet end of the shaft c Install a shaft guide tool from the Flowserve tool kit see figure 6 1 Do not lubricate surfaces d Slide one lip seal onto the shaft with a lip facing away from the bearing housing e Position the O ring 4610 10 over the tail of the lip seal see section 8 3 Slide it all the way to the bearing housing f Clean all surfaces of the gland and install the ceramic into the gland g Slide gland ceramic seat assembly onto the shaft and move it back to the lip seal h Slide a second lip seal onto the shaft
126. llar to stop the leak Do not over tighten the seal 6 9 3 Sealmatic pump installation of repeller cover repeller cover and impeller Group 2 pumps see figure in section 8 3 Group 3 pumps see figure 6 29 a For Group 2 pumps install the repeller cover to the adapter using capscrews 6570 2 For Group 3 pumps install the repeller cover 1220 1 over the shaft and push it all the way back until it touches the bearing housing b Install a new repeller O ring 4610 11 into the repeller groove Lubricate the O ring with liquid soap Install the slip on repeller 2200 1 onto the shaft d Install the repeller cover cover gasket 4590 9 For Group 2 pumps install the cover 1220 to the repeller cover using capscrews 6570 13 For Group 3 pumps install the cover 1220 to the adapter Attach to the adapter using capscrews 6570 2 Attach the repeller cover to the cover using the capscrews 6570 13 f The repeller and impeller may now be set following the instructions given in section 6 6 3 o 4610 11 Item Part name 4610 11 Repeller O ring 4590 9 Gasket repeller cover 6570 13 Capscrew flowserve com SR FLOWSERVE us 6 9 4 Close coupled final assembly a Install the motor adapter 3160 onto the bearing housing using three screws 6570 15 b Install unit into casing as described in section 6 9 5 C Level the unit with the adjustable support feet 3134 Eliminate so
127. llers and recessed open impellers are set off the cover This allows the impeller to be set without the casing Set the impeller clearance by loosening the set screws 6570 3 and rotating the bearing carrier 3240 to obtain the proper clearance Turn the bearing carrier counter clockwise until the impeller comes into light rubbing contact with the rear cover Rotating the shaft at the same time will accurately determine this zero setting Now rotate the bearing carrier clockwise to get the proper clearance Refer to figure 5 12 for the proper impeller clearance based on the operating temperature for the application Rotating the bearing carrier the width of one of the indicator patterns cast into the bearing carrier moves the impeller axially 0 1 mm 0 004 in See figure 6 5 Iu Indicator pattern Rotation equivalent to 0 1 mm 0 004 in axial movement Figure 6 5 Determine how far to rotate the bearing carrier by dividing the desired impeller clearance by 0 1 mm 0 004 in one indicator pattern Tightening the set screws 6570 3 will cause the impeller to move 0 05 mm 0 002 in closer to the rear cover because of the internal looseness in the bearing carrier threads This must be considered when setting the impeller clearance Rotate the bearing carrier clockwise the required amount to get the desired clearance to the cover flowserve com Q FLOWSERVE ss Lastly uniformly tighten the set screws
128. long coupled pumps equation sets 1 through 5 must be satisfied For close coupled and C face pumps only equation sets 1 and 2 must be satisfied Figure 4 11 Casing material correction factors i MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Equation set 1 Each applied load is divided by the corresponding adjusted figure 4 15 value The absolute value of each ratio must be less than or equal to one Equation set 2 The summation of the absolute values of each ratio must be less than or equal to two The ratios are the applied load divided by the adjusted figure 4 16 values Equation sets 3 and 4 These equations are checking for coupling misalignment due to nozzle loading in each axis Each applied load is divided by the corresponding adjusted load from figure 4 17 and 4 18 The result of each equation must be between one and negative one Equation set 5 This equation calculates the total shaft movement from the results of equations 3 and 4 The result must be less than or equal to one 10 11 21 22 24 28 32 34 35 37 38 S17 Ti Cr Austenitic steels Nickel and nickel alloys High Type Type Ti Chrome 304 316 Ti 18 to Temp Temp Carbon and and Type CD Hast Hast Alloy Pd 171 C C F DCI Steel 304L 316L 321 4MCu Nickel Monel Inconel B C 20 Zr 340 F 129 200 1 00 1 00 100 050 083
129. mbly nana o enews 44 6 8 Examination of parts 47 6 9 Assembly of pump and seal 50 7 FAULTS CAUSES AND REMEDIES 57 8 PARTS LIST AND DRAWINGS 59 8 1 Standard Mark 3 pump Group 1 59 8 2 Standard Mark 3 pump Group 2 and Groub Scare wets uius 60 8 3 Mark 3 Sealmatic pump Group 2 61 8 4 Mark 3 Lo Flo Group 2 61 8 5 Mark 3 Unitized Self Priming pump GOUD 2 estate 62 8 6 Mark 3 Recessed Impeller pump Group 2 62 8 7 Mark 3 In Line pump Group 1 63 8 8 Mark 3 In Line pump Group 2 64 8 9 Mark 3 C Face Adapter Group and Group 2 xxt eae etes 65 8 10 General arrangement drawing 65 9 GEPRTIPIGATIOBNL oiii tatam mta apt ondas 66 10 OTHER RELEVANT DOCUMENTATION ANDMAINU ABS itia Satur Ni eti 66 10 1 Supplementary User Instructions 66 10 2 Charge NOTES nan eoe uvas ae ea ee 66 10 3 Additional sources of information 66 flowserve com M FLOWSERVE ss 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 products are designed developed and manufactured with state of the art technologies in modern facilities The unit is produced with great care and
130. ment flowserve com M FLOWSERVE us Many companies today are using laser alignment which is a more sophisticated and accurate technique With this method a laser and sensor measure misalignment This is fed to a computer with a graphic display that shows the required adjustment for each of the motor feet See section 4 8 for recommended final shaft alignment limits Vibration analysis Vibration analysis is a type of condition monitoring where a pump s vibration signature is monitored on a regular periodic basis The primary goal of vibration analysis is extension on MTBPM By using this tool Flowserve can often determine not only the existence of a problem before it becomes serious but also the root cause and possible solution Modern vibration analysis equipment not only detects if a vibration problem exists but can also suggest the cause of the problem On a centrifugal pump these causes can include the following unbalance misalignment defective bearings resonance hydraulic forces cavitation and recirculation Once identified the problem can be corrected leading to increased MTBPM for the pump Flowserve does not make vibration analysis equipment however Flowserve strongly urges customers to work with an equipment supplier or consultant to establish an on going vibration analysis program See note 3 under figure 6 19 regarding acceptance criteria 6 9 Assembly of pump and seal It is important that a
131. nance LA cumov When fluid velocity in the pipe is high for example 3 m s 10 ft sec or higher a rapidly closing discharge valve can cause a damaging pressure surge A dampening arrangement should be provided in the piping 4 6 3 1 Mark 3 Self Priming Pumps During the priming cycle air from the suction piping is evacuated into the discharge piping There must be a way for this air to vent If air is not able to freely vent out the discharge pipe it is typically recommended to install an air bleed line The air bleed line is typically connected from the discharge pipe to the sump Car must be taken to prevent air from re entering suction pipe 4 6 4 Allowable nozzle loads Flowserve chemical process pumps meet or exceed the allowable nozzle loads given by ANSI HI 9 6 2 The following paragraphs describe how to calculate the allowable loads for each pump type and how to determine if the applied loads are acceptable The first configuration covered is ASME B73 1M pumps including the Mark 3 Standard Sealmatic Lo Flo Recessed Impeller and Unitized Self Priming pumps The second configuration covered is the ASME B73 2M vertical Mark 3 In Line pump 4 6 4 1 Mark 3 horizontal pumps ASME B73 1M The following steps are based upon ANSI HI 9 6 2 All information necessary to complete the evaluation is given below For complete details please review the standard a Determine the appropriate casing Material Group No from fig
132. ne None 2 2 K3005 Durco CY40 DINC CY40 Inconel 600 A494 Gr CY40 35 K3007 Durco M35 DMM M351 Monel 400 A494 Gr M35 1 34 K3008 Nickel DNI CZ100 Nickel 200 A494 Gr CZ100 3 2 K4007 Chlorimet 2 DC2 N7M Hastelloy B A494 Gr N7M ME K4008 Chlorimet 3 DC3 CW6M Hastelloy amp C A494 Gr CWeM 38 E3041 Duriron D None None A518 Gr 1 No load E3042 Durichlor 518 D51 None None A518 Gr 2 No load E4035 Superchlor SD51 None None A518 Gr 2 No load D4036 Durco DC8 DC8 None None None H3004 Titanium Ti None Titanium B367 Gr C3 Ti H3005 Titanium Pd TiP None Titanium Pd B367 Gr C8A Ti H3007 Zirconium Zr None Zirconium B752 Gr 702C Ti Duriron Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation Ferralium is a registered trademark of Langley Alloys Hastelloy is a registered trademark of Haynes International Inc Inconel and Monel are registered trademarks of International Nickel Co Inc Notes Page 13 of 68 flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE Figure 3 3 Class 150 flanges o 10 11 24 22 28 32 34 35 37 38 347 Ti Cr p ey eue Josse JL vle d 73 190 190 197 97
133. ng start up operation and shutdown AN CAUTION NEVER RUN THE PUMP DRY OR WITHOUT PROPER PRIME Casing flooded ZA CAUTION NEVER OPERATE THE PUMP WITH THE SUCTION VALVE CLOSED It should be fully opened when the pump is running AN CAUTION NEVER OPERATE THE PUMP AT ZERO FLOW OR FOR EXTENDED PERIODS BELOW THE MINIMUM CONTINUOUS FLOW ZN CAUTION THE PUMP SHAFT MUST TURN CLOCKWISE WHEN VIEWED FROM THE MOTOR END It is absolutely essential that the rotation of the motor be checked before installation of the coupling spacer and starting the pump Incorrect rotation of the pump for even a short period can unscrew the impeller PREVENT EXCESSIVE EXTERNAL f oO Page 5 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 1 6 4 Products used in potentially explosive atmospheres Ex 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 certi
134. ns nana Electrical connections must be made by a qualified Electrician in accordance with relevant local national and international regulations 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 It is important to be aware of the EUROPEAN DIRECTIVE on electromagnetic compatibility when wiring up and installing equipment on site Attention must be paid to ensure that the techniques used during wiring installation do not increase electromagnetic emissions or decrease the electromagnetic immunity of the equipment wiring or any connected devices If in any doubt contact Flowserve for advice flowserve com M FLOWSERVE us LN pancer 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 ani supply is appropriate See section 5 4 Direction of rotation before connecting the motor to the electrical supply For close coupled pumps it is necessary to wire the motor with flexible conduit of sufficient length to allow the motor power end assembly to be moved back from the casing for maintenance 4 8 Final shaft alignment check 4 8 1 Horizontal pumps a Level basepla
135. nstalled If the casing cover impeller or shaft is replaced this method must not be used 6 6 3 Installation and clearance setting for Sealmatic pumps Install the repeller 2000 1 and covers 1220 and j 1220 1 as described in section 6 9 3 Install a seal guide from the Mark 3 tool kit to hold the repeller in place Set the repeller 0 38 to 0 51 mm 0 015 to 0 020 in off the cover following the instruction above in section 6 6 1 Uniformly tighten the set screws 6570 3 in incremental steps up to the final torque value to lock the bearing carrier in place Remove the seal guide and install the impeller Check the impeller setting with a feeler gage The gap should be 0 38 to 0 51 mm 0 015 to 0 020 in If the gap is outside of the correct setting it may be readjusted to get the beat gap at the repeller and impeller 6 7 Disassembly 6 7 1 Power end removal a Before performing any maintenance disconnect the driver from its power supply and lock it off line LA umov is out power to driver to prevent personal injury b Close the discharge and suction valves and drain all liquid from the pump c Close all valves on auxiliary equipment and piping then disconnect all auxiliary piping d Decontaminate the pump as necessary If Flowserve Mark 3 pumps contain dangerous chemicals it is important to follow plant safety guidelines to avoid personal injury or death Page 44 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 7
136. nting fasteners are centered in the driver feet holes If not re center the fasteners and perform a preliminary alignment to the above tolerances by shimming under the motor for vertical alignment and by moving the pump for horizontal alignment j Grout the baseplate A non shrinking grout should be used Make sure that the grout fills the area under the baseplate After the grout has cured check for voids and repair them Jackscrews shims and wedges should be removed from under the baseplate at this time If they were to be left in place they could rust swell and cause distortion in the baseplate k Run piping to the suction and discharge of the pump There should be no piping loads transmitted to the pump after connection is made Recheck the alignment to verify that there are no significant loads Page 21 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 4 5 Initial alignment 4 5 1 Horizontal initial alignment procedure The purpose of factory alignment is to ensure that the user will have full utilization of the clearance in the motor holes for final job site alignment To achieve this the factory alignment procedure specifies that the pump be aligned in the horizontal plane to the motor with the motor foot bolts centered in the motor holes This procedure ensures that there is sufficient clearance in the motor holes for the customer to field align the motor to the pump to zero tolerance This philosophy requires
137. o damage in transportation Any shortage and or damage must be reported immediately to Flowserve Pump Division and must be received in writing within ten days of receipt of the equipment Later claims cannot be accepted Check any crate boxes or wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to side walls of the box or equipment Each product has a unique serial number Check that this number corresponds with that advised and always quote this number in correspondence as well as when ordering spare parts or further accessories 2 2 Handling Boxes crates pallets or cartons may be unloaded using fork lift vehicles or slings dependent on their size and construction N CAUTION Pumps and motors often have integral lifting lugs or eye bolts These are intended for use in only lifting the individual piece of eguipment N CAUTION Do not use eye bolts or cast in lifting lugs to lift pump motor and baseplate assemblies N CAUTION To avoid distortion the pump unit should be lifted as shown A sca Care must be taken to lift components or assemblies above the center of gravity to prevent the unit from flipping This is especially true with In Line pumps N CO st 5 o 2 3 1 Lifting pump components 2 3 1 1 Casing 1100 Use a choker hitch pulled tight around the discharge nozzle 2 3 1 2 Rear cover 1220 Insert an eye hook in the drilled and tapp
138. od is needed 2 4 1 Short term storage and packaging Normal packaging is designed to protect the pump and parts during shipment and for dry indoor storage for up to six months or less The following is an overview of our normal packaging e All loose unmounted items are packaged in a water proof plastic bag and placed under the coupling guard e Inner surfaces of the bearing housing shaft area through bearing housing and bearings are coated with Cortec VCI 329 rust inhibitor or equal Bearing housings are not filled with oil prior to shipment e Regreasable bearings are packed with grease EXXON POLYREX EM for horizontal pumps and EXXON UNIREX N3 for In Line pumps e The internal surfaces of ferrous casings covers flange faces and the impeller surface are sprayed with Cortec VCI 389 or equal e Exposed shafts are taped with Polywrap e Flange covers are secured to both the suction and discharge flanges e in some cases with assemblies ordered with external piping components may be disassembled for shipment e The pump must be stored in a covered dry location 2 4 2 Long term storage and packaging Long term storage is defined as more than six months but less than 12 months The procedure Flowserve follows for long term storage of pumps is given below These procedures are in addition to the short term procedure e Each assembly is hermetically heat sealed from the atmosphere by means of tack wrap sheeting and rub
139. oler flowserve com M FLOWSERVE us 5 2 3 Oil mist The inlet port for all horizontal pumps is the plugged a in NPT located at the top of the bearing housing A vent fitting has been supplied on the bearing carrier as well as a plugged in NPT bottom drain on the bearing housing See section 4 6 6 7 Oil mist lubrication system Do not allow oil level to remain above the center of the bearing housing sight glass window with purge mist wet sump systems The optional oil slinger must not be used with an oil mist system There are two inlet ports for In Line pumps In addition to the connection described above a second inlet is made at the 7s in NPT plugged port on the bearing carrier 3240 A vent fitting has been supplied on the bearing carrier as well as a plugged 7s in NPT bottom drain on the bearing housing for Group 1 pumps and on the adapter 1340 for Group 2 pumps 5 3 Impeller clearance The impeller clearance was set at the factory based on the application temperature at the time the pump was purchased See figure 5 12 For a reverse vane impeller the clearance is set to the cover while the open impeller clearance is set to the casing If the process temperature changes the impeller clearance must be reset See section 6 6 Figure 5 12 Impeller clearance settings 93 200 0 46 0 08 0 018 0 003 98to 121 200 to 250 0 53 0 021 122 to 149 251 to 300 0 61 0 024 15
140. pment for Potentially Explosive Atmospheres ATEX Where applicable the Directives and any additional Approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions Where applicable this document incorporates information relevant to these Directives and Approvals Page 3 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 To confirm the Approvals applying and if the product is CE marked check the serial number plate markings and the Certification See section 9 Certification 1 3 Disclaimer Information in these User Instructions is believed to be reliable In spite of all the efforts of Flowserve Pump Division to provide sound and all necessary information the content of this manual may appear insufficient and is not guaranteed by Flowserve as to its completeness or accuracy Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance organizations Genuine parts and accessories have been designed tested and incorporated into the products to help ensure 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
141. r Trim this end __ Measurement step a Figure 5 17 5 5 4 Assembly instructions Clam shell guard a Mount support leg to each clam shell figure 5 15 b Attach one half of the guard to the baseplate c Engage the tabs of guard halves together d Attach the second support leg to the baseplate ClearGuard a Place the bottom and top halves of the guard around the coupling b Install the support legs by inserting and then rotating the tab on the leg through the slot in the guard until it comes through and locks the top and bottom halves of the guard together c Attach the support legs to the baseplate using the fasteners and washers provided d Install fasteners in the holes provided to secure the guard flanges together 5 6 Priming and auxiliary supplies The Mark 3 standard Sealmatic Recessed Impeller Lo Flo and In Line centrifugal pump will not move liquid unless the pump is primed A pump is said to be primed when the casing and the suction piping are completely filled with liquid Open discharge valves a slight amount This will allow any entrapped air to escape and will normally allow the pump to prime if the suction source is above the pump When a condition exists where the suction pressure may drop below the pump s capability it is advisable to add a low pressure control device to shut the pump down when the pressure drops below a predetermined minimum flowserve com M FLOWSERVE us
142. riginal format If further copies of these are required they should be obtained from the supplier for retention with these User Instructions 10 2 Change notes If any changes agreed with Flowserve Pump Division are made to the product after it is supplied a record of the details should be maintained with these User Instructions 10 3 Additional sources of information The following are excellent sources for additional information on Flowserve Mark 3 pumps and centrifugal pumps in general Pump Engineering Manual H E Syska J R Birk Flowserve Corporation Dayton Ohio 1980 Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process ASME B73 1M The American Society of Mechanical Engineers New York NY Specification for Vertical In Line Centrifugal Pumps for Chemical Process ASME B73 2M The American Society of Mechanical Engineers New York NY American National Standard for Centrifugal Pumps for Nomenclature Definitions Design and Application ANSI HI 1 1 1 3 Hydraulic Institute 9 Sylvan Way Parsippany New Jersey 07054 3802 Page 66 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 American National Standard for Vertical Pumps for Nomenclature Definitions Design and Application ANSI HI 2 1 2 3 Hydraulic Institute 9 Sylvan Way Parsippany New Jersey 07054 3802 American National Standard for Centrifugal Pumps for Installation Operation and Maintenance ANSI HI 1 4
143. rom the seal 6 9 2 2 Component type mechanical seal Review the seal assembly instructions and drawings seal set dimension provided by the seal manufacturer In order to properly set a component seal it is necessary to first locate the shaft in its final axial position This is accomplished in the following manner a Install the rear cover plate 1220 to the bearing housing Group 1 or the bearing housing adapter Group 2 and 3 by using the capscrews 6570 2 b Install and set the impeller 2200 clearance as outlined in section 6 6 Put blueing on the shaft sleeve in the area near the face of the seal chamber rear cover 1220 Scribe a mark on the shaft at the face of the seal chamber figure 6 27 s Figure 6 27 c Remove the impeller and seal chamber rear cover following the instructions given in section 6 7 and install a nose cone onto the end of the shaft Single internal seal installation d Place the gland 4120 and stationary seat onto the shaft until it lightly touches the bearing housing Group 1 or adapter Group 2 and 3 e Install a gland gasket 4590 3 into the gland Figure 6 28 flowserve com SR FLOWSERVE a f Locate the rotary seal unit onto the shaft or sleeve according to the set dimension provided by the seal manufacture Tighten set screws on the seal to lock the rotating unit to the shaft sleeve g Install the rear cover plate 1220 to the bearing housing Group 1
144. rops per minute for clean fluid For abrasive applications the regulated flow rate should be 0 06 to 0 13 l s 1 to 2 US gpm Figure 4 23 Grease lubrication when compatible with the liquid being pumped may be used Again introduced into tap V In non abrasive applications the liquid being pumped may be sufficient to lubricate the packing without need for external lines Tap V should be plugged 4 6 6 3b Abrasive packing arrangement The installation procedures are the same as the standard packing with some exceptions A special lip seal is installed first followed by two seal cage assemblies then two of the packing rings provided figure 4 24 A flush line from a clean external source should be connected via tap V in the top of the stuffing box Lip Seal Seal Cage Packing Figure 4 24 flowserve com M FLOWSERVE us 4 6 6 4 Piping connection bearing housing cooling system Make connections as shown below Liquid at less than 32 C 90 F should be supplied at a regulated flow rate of at least 0 06 l s 1 US gpm Ln 1 2 in 0 D Tubing Figure 4 25 4 6 6 5 Piping connection support leg cooling for centerline mounting option If the casing is centerline mounted and the process temperature is over 178 C 350 F then the casing support legs may need to be cooled Cool water less than 32 C 90 F should be run through the legs at a flow rate of at least 0 06 l s
145. s the lowest flow at which the pump can operate and still meet the bearing life shaft deflection and bearing housing vibration limits documented in the latest version of ASME B73 1M Pumps may be operated at lower flows but it must be recognized that the pump may exceed one or more of these limits For example vibration may exceed the limit set by the ASME standard The size of the pump the energy absorbed and the liquid pumped are some of the considerations in determining the minimum continuous flow MCF The minimum continuous flow capacity is established as a percentage of the best efficiency point BEP See section 3 4 4 Page 38 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 5 8 2 Minimum thermal flow All Mark 3 pumps also have a minimum thermal flow This is defined as the minimum flow that will not cause an excessive temperature rise Minimum thermal flow is application dependent A SAVIN Do not operate the pump below minimum thermal flow as this could cause an excessive temperature rise Contact a Flowserve sales engineer for determination of minimum thermal flow Avoid running a centrifugal pump at drastically reduced capacities or with discharge valve closed for extended periods of time This can cause severe temperature rise and the liquid in the pump may reach its boiling point If this occurs the mechanical seal will be exposed to vapor with no lubrication and may score or seize to the stationary p
146. se occurs because of friction losses and fluid accelerations in the inlet region of the pump and particularly accelerations as the fluid enters the impeller vanes The value for NPSHg for the specific pump purchased is given in the pump data sheet and on the pump performance curve For a pump to operate properly the NPSH must be greater than the NPSHg Good practice dictates that this margin should be at least 1 5 m 5 ft or 2095 whichever is greater Ensuring that NPSH is larger than NPSHp by the suggested margin will greatly enhance pump performance and reliability It will also reduce the likelihood of cavitation which can severely damage the pump Page 39 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 5 10 2 Specific gravity SG Pump capacity and total head in meters feet of liquid 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 important to check that any change in SG will not overload the pump driver or overpressurize the pump 5 10 3 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 the 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 10 4
147. te if appropriate b Mount and level pump if appropriate Level the pump by putting a level on the discharge flange If not level adjust the footpiece as follows Mark 3A and ANSI 3 design Add or delete shims 3126 1 between the footpiece and the bearing housing Mark 3 design Use the adjuster nut 6576 to adjust the footpiece up or down c Checkinitial alignment If pump and driver have been remounted or the specifications given below are not met perform an initial alignment as described in section 4 5 This ensures there will be sufficient clearance between the motor hold down bolts and motor foot holes to move the motor into final alignment The pump and driver should be within 0 38 mm 0 015 in FIM full indicator movement parallel and 0 0025 mm mm 0 0025 in in FIM angular Stilt mounted baseplates If initial alignment cannot be achieved with the motor fasteners centered the baseplate may be twisted Slightly adjust one turn of the adjusting nut the stilts at the driver end of the baseplate and check for alignment to the above tolerances Repeat as necessary while maintaining a level condition as measured from the pump discharge flange d Run piping to the suction and discharge to the pump There should be no piping loads transmitted to the pump after connection is made Recheck the alignment to verify that there are no significant changes e Perform final alignment Check for soft foot under the driver An in
148. that the customer be able to place the base in the same condition as the factory Thus the factory alignment will be done with the base sitting in an unrestrained condition on a flat and level surface This standard also emphasizes the need to ensure the shaft spacing is adequate to accept the specified coupling spacer The factory alignment procedure is summarized below a The baseplate is placed on a flat and level workbench in a free and unstressed position b The baseplate is leveled as necessary Leveling is accomplished by placing shims under the rails of the base at the appropriate anchor bolt hole locations Levelness is checked in both the longitudinal and lateral directions c The motor and appropriate motor mounting hardware is placed on the baseplate and the motor is checked for any planar soft foot condition If any is present it is eliminated by shimming d The motor feet holes are centered on the motor mounting fasteners This is done by using a centering nut as shown in figure 4 6 Figure 4 6 Centering Nut Shims For Vert lignment Baseplate For Horizontal Alignmeni e The motor is fastened in place by tightening the nuts on two diagonal motor mounting studs f The pump is put onto the baseplate and leveled The foot piece under the bearing housing is adjustable It is used to level the pump if necessary Mark 3A and ANSI 3A design If an adjustment is necessary add or remove shims 3126 1 bet
149. the suction line Start up strainers must be removed shortly before start up When the pump is installed below the source of supply a valve should be installed in the suction line to isolate the pump and permit pump inspection and maintenance However never place a valve directly on the suction nozzle of the pump Refer to the Durco Pump Engineering Manual and the Centrifugal Pump IOM Section of the Hydraulic Institute Standards for additional recommendations on suction piping See section 10 Refer to section 3 4 for performance and operating limits 4 6 2 1 Mark 3 Self Priming Pumps The suction piping must be as short as possible and be as close to the diameter of the suction nozzle as is practical The pump works by removing the air contained in the suction piping Once removed it operates exactly the same as a flooded suction standard pump Longer and larger the suction pipe have a greater volume of air that has to be removed resulting in longer priming time The suction piping and seal chamber must be airtight to allow priming to occur When possible it is recommended that suction piping be sloped slightly towards the casing to limit priming fluid loss down the suction line during priming and shutdown Page 23 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 4 6 3 Discharge piping Install a valve in the discharge line This valve is required for regulating flow and or to isolate the pump for inspection and mainte
150. these outside diameter OD dimensions on the bearings 6 8 4 3 Impeller balancing Shaft whip is deflection where the centerline of the impeller is moving around the true axis of the pump It is not caused by hydraulic force but rather by an imbalance with the rotating element Shaft whip is very hard on the mechanical seal because the faces must flex with each revolution in order to maintain contact To minimize shaft whip it is imperative that the impeller is balanced All impellers manufactured by Flowserve are balanced after they are trimmed If for any reason a customer trims an impeller it must be re balanced See note 1 under figure 6 19 regarding acceptance criteria 6 8 4 4 Bearing housing carrier Prior to installing the shaft into the bearing housing check the following parameters Diameter tolerance at bearing surface In order to ensure proper fit between the bearing housing carrier and the bearings verify that the ID of both the IB and OB bearing surfaces are consistently within the minimum maximum values shown in figure 6 21 An inside caliper should be used to check these ID dimensions in the bearing housing flowserve com M FLOWSERVE us Figure 6 19 ASME suggested Suggested l B73 1M by major and or Topic seal provided by standard mm in vendors Flowserve mm in mm in Shaft Diameter tolerance n s 0 005 0 0002 underbearings J y y O Impeller
151. ure 3 2 b Find the Casing material correction factor in Figure 4 11 based upon the Material Group No and operating temperature Interpolation may be used to determine the correction factor for a specific temperature c Find the Baseplate correction factor in Figure 4 12 The correction factor depends upon how the baseplate is to be installed d Locate the pump model being evaluated in Figure 4 16 and multiply each load rating by the casing correction factor Record the adjusted Figure 4 16 loads e Locate the pump model being evaluated in Figures 4 17 and 4 18 and multiply each load rating by the baseplate correction factor Record the adjusted Figure 4 17 and 4 18 loads flowserve com M FLOWSERVE us f Compare the adjusted Figure 4 16 loads to the values shown in figure 4 15 The lower of these two values should be used as the adjusted figure 4 15 values The HI standard also asks that figure 4 15 loads be reduced if figure 4 17 or 4 18 values are lower Flowserve does not follow this step Calculate the applied loads at the casing flanges according to the coordinate system found in figure 4 13 The 12 forces and moments possible are Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd and Mzd For example Fxd designates Force in the x direction on the discharge flange Mys designates the Moment about the y axis on the suction flange Figure 4 14 gives the acceptance criteria equations For
152. ust be maintained Additional requirements for pumps on non metallic baseplates When metallic components are fitted on a non metallic baseplate they must be individually earthed 1 6 4 6 Preventing leakage Ex Pumps with mechanical seal The pump must only be used to handle liquids for which it has been approved to have the correct corrosion resistance Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves which could cause dangerous excessive pressures to occur if there is heat input to the liquid This can occur if the pump is stationary or running Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump and auxiliary systems Where there is the potential hazard of a loss of a seal barrier fluid or external flush the fluid must be monitored If leakage of liquid to atmosphere can result in a hazard the installation of a liquid detection device is recommended Page 7 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 1 6 4 7 Maintenance of the centrifugal pump to avoid a hazard CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION The responsibility for compliance with maintenance instructions is with the plant operator To avoid potential explosion hazards during maintenance the tools cleaning and painting materials used must not give rise to sparking or adversely affe
153. ve com flowserve com MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 FLOWSERVE REGIONAL SALES OFFICES USA and Canada Flowserve Corporation 5215 North O Connor Blvd Suite 2300 Irving Texas 75039 5421 USA Telephone 1 972 443 6500 Fax 1 972 443 6800 Europe Middle East Africa Worthing S P A Flowserve Corporation Via Rossini 90 92 20033 Desio Milan Italy Telephone 39 0362 6121 Fax 439 0362 303 396 Latin America and Caribbean Flowserve Corporation 6840 Wynnwood Lane Houston Texas 77008 USA Telephone 1 713 803 4434 Fax 1 713 803 4497 Asia Pacific Flowserve Pte Ltd 200 Pandan Loop 06 03 04 Pantech 21 Singapore 128388 Telephone 65 6775 3003 Fax 65 6779 4607
154. vides such a mounting surface Therefore this is the tolerance to which we supply our standard baseplate flowserve com M FLOWSERVE us Some users may desire an even flatter surface which can facilitate installation and alignment Flowserve will supply flatter baseplates upon request at extra cost For example mounting surface flatness of 0 17 mm m 0 002 in ft is offered on the Flowserve Type E Ten Point baseplate shown in figure 4 1 3 The baseplate must be designed to allow the user to final field align the pump and driver to within their own particular standards and to compensate for any pump or driver movement that occurred during handling Normal industry practice is to achieve final alignment by moving the motor to match the pump Flowserve practice is to confirm in our shop that the pump assembly can be accurately aligned Before shipment the factory verifies that there is enough horizontal movement capability at the motor to obtain a perfect final alignment when the installer puts the baseplate assembly into its original top leveled unstressed condition 4 3 4 Stilt and spring mounted baseplates Flowserve offers stilt and spring mounted baseplates See figure 4 2 for stilt mounted option The low vibration levels of Mark 3 pumps allow the use of these baseplates provided they are of a rigid design The baseplate is set on a flat surface with no tie down bolts or other means of anchoring it to the floor
155. w Outboard double row angular contact deep groove Optional outboard duplex angular contact 1 Oilbath mist open 6207 C3 5306 AC3 or 3306 AC3 7306 BECBY Regreasable single shielded 6207 ZC3 5306 AZC3 or 3306 AZC3 NA Greased for life double shielded 6207 2ZC3 5306 A2ZC3 or 3306 A2ZC3 NA Sealed for life double sealed 6207 2RS1C3 5306 A2RSC3 or 3306 A2RS1C3 NA 2 Oil bath mist open 6310 C3 5310 AC3 AHC3 or 3310 AC3 7310 BECBY 6310 ZC3 5310 AZC3 or 3310 AZC3 NA Greased for life double shielded 6310 2ZC3 5310 A2ZC3 or 3310 A2ZC3 NA 3 Oilbath mist open 6314 C3 5314 AC3 or 3314 AC3 7314 BECBY Regreasable single shielded 6314 ZC3 5314 AZC3 or 3314 AZC3 NA Greased for life double shielded 6314 2ZC3 5314 A2ZC3 or 3314 A2ZC3 NA Sealed for life double sealed 6314 2RS1C3 5314 A2RSC3 or 3314 A2RS1C3 NA 1 These bearings are open on both sides They are lubricated by oil bath or oil mist 2 These bearings are pre greased by Flowserve Replacement bearings will generally not be pre greased so grease must be applied by the user They have a single shield which is located on the side next to the grease buffer or reservoir The bearings draw grease from the reservoir as it is needed The shield protects the bearing from getting too much grease which would generate heat The grease reservoir
156. ween the foot piece and the bearing housing flowserve com FLOWSERVE us Mark 3 design old If an adjustment is necessary the adjuster nut 6576 is used to move the footpiece up or down g The spacer coupling gap is verified h The parallel and angular vertical alignment is made by shimming under the motor i The motor feet holes are again centered on the motor mounting studs using the centering nut At this point the centering nut is removed and replaced with a standard nut This gives maximum potential mobility for the motor to be horizontally moved during final field alignment All four motor feet are tightened down j Ihe pump and motor shafts are then aligned horizontally both parallel and angular by moving the pump to the fixed motor The pump feet are tightened down k Both horizontal and vertical alignment is again final checked as is the coupling spacer gap See section 4 8 Final shaft alignment 4 5 2 In Line initial alignment procedure The factory alignment proceed procedure ensures that the unit may be aligned in the field The initial alignment is no more than 0 38 mm 0 015 in parallel and 0 0025 mm mm 0 0025 in in angular misalignment The Mark 3 In Line incorporates motor alignment capabilities Parallel alignment is achieved by moving the motor adapter and motor as an assembly relative to the power end Four adjustment screws as shown in figures 4 7 and 4 8 allow for precise c
157. y are not typically checked by our customers although they are monitored by Flowserve during the manufacturing and or design process 6 8 4 1 Shaft and sleeve if fitted Replace if grooved pitted or worn Prior to mounting bearings or installing the shaft into the bearing housing check the following parameters Page 47 of 68 MARK 3 USER INSTRUCTIONS ENGLISH 71569102 08 06 Diameter tolerance under bearings In order to ensure proper fit between the shaft and bearings verify that both the inboard IB and outboard OB shaft diameter is consistently within the minimum maximum values shown in figure 6 20 A micrometer should be used to check these outside diameter OD dimensions on the shaft 6 8 4 2 Bearings It is recommended that bearings not be re used after removal from the shaft Prior to mounting bearings check the following parameters Diameter tolerance inside diameter In order to ensure proper fit between bearings and the shaft verify that the inside diameter ID of both the IB and OB bearing are consistently within the minimum maximum values shown in figure 6 20 An inside caliper should be used to check these ID diameters on the bearings Diameter tolerance outside diameter In order to ensure proper fit between bearings and the bearing housing verify that the OD on both the IB and OB bearings are consistently within the minimum maximum values shown in figure 6 21 A micrometer should be used to check

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