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HP Flowserve 71576286 User's Manual

1. y Li Bina handling always wear gloves safety boots and an industrial safety helmet A For masses above 25 kg 55 Ib manual handling is forbidden FP USER INSTRUCTIONS ENGLISH 71576286 07 06 2 4 Storage CAUTION A caution ore the pump in a clean dry location away from vibration Leave piping connection covers in place to keep dirt and other foreign material out of pump casing Turn pump at intervals to prevent brinelling of the bearings and the seal faces if fitted from sticking Do not store pumps starting on the fan guard The pump may be stored as above for up to 6 months Consult Flowserve for preservative actions when a longer storage period is needed 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 local regulations If the product contains substances which are harmful to the environment these should be removed and disposed of in accordance with current regulations This also includes the liquids and or gases in the seal system or other utilities Make sure that hazardous substances or toxic fluid are disposed of safely and that the correct personal protective equipment is used The safety specifications must be in accordance with the current regulations at all times 3 P
2. eH J pee Fz MU l LH ett 4 2 Foundation sn There are many methods of installing pump units to their foundations The correct method depends on the size of the pump unit its location and noise vibration limitations Non compliance with the provision of correct foundation and installation may lead to failure of the pump and as such would be outside the terms of the warranty The base plate should be mounted onto a firm foundation either an appropriate thickness of quality concrete or sturdy steel framework It should NOT be distorted or pulled down onto the surface of the foundation but should be supported to maintain the original alignment Anchor bolts must be in accordance with the foot bolt holes Use anchor bolts of accepted standards and sufficient to ensure seave fitting in the foundation Particularly this applies to individual plates where the anchor bolts have to withstand the driving torque FP USER INSTRUCTIONS ENGLISH 71576286 07 06 NF E 27 811 Provide sufficient space in the foundation to accommodate the anchor bolts If necessary provide concrete risers Usually the pump and its drive are mounted on a common base plate If not individual base plates underneath each machine foot shall be installed Base plates are to b
3. Priming of sump suction pump with foot valve Without foot valve Priming may be accomplished by means of venting system Note Foot valves are not recommended when the pumped liquid has suspended solid particles They may lodge between foot valve seat and shutter 5 4 Starting the pump 5 4 1 Bring controls and preparation before the first starting and after each service call Necessarily a Check the tightening of the different plugs b Check that the gland lightly tightens the packing rings CAUTION c Risk of seal ring overheating d Check the direction of rotation of the motor Refer to the rotation arrow of the pump e A Install all protection systems and more particularly the coupling guard and the shield grid reference 9331 of the bearing f Open all suction valves if existing g Close the outlet valve and the bypass valve h Ensure inlet pipe and pump casing are completely full of liquid 5 4 2 First pump start up CAUTION Suction valves must be fully open when pump is running Never run the pump dry it will cause damage Page 18 of 35 FLOWSERVE a Start motor and check outlet pressure b If pressure is satisfactory slowly OPEN outlet valve c Do not run the pump with the outlet valve closed for a period longer than 30 seconds d If NO pressure or LOW pressure STOP the pump Refer to faultfinding chart for fault
4. Motor size 3550 r min 2900 r min 1750 r min 1450 r min and speed Pump and Pump Pump and Pump Pump and Pump Pump and Pump motor only motor only motor only motor only kW hp dBA dBA dBA dBA dBA dBA dBA dBA lt 0 55 lt 0 75 71 66 64 62 64 62 63 62 0 75 1 74 66 67 62 67 62 63 62 1 1 1 5 74 68 67 64 67 64 65 64 1 5 2 77 70 70 66 70 66 66 66 2 2 3 78 72 71 68 71 68 68 68 3 4 81 74 74 70 74 70 70 70 4 5 82 75 75 71 75 71 71 71 5 5 7 5 90 99 77 83 73 76 73 72 71 7 5 10 90 99 78 83 74 77 74 73 72 11 15 91 100 80 84 76 78 76 74 73 15 20 92 101 83 85 94 79 80 79 76 75 18 5 25 92 101 83 85 94 79 80 79 76 75 22 30 92 101 83 85 94 79 81 79 77 75 30 40 100 709 85 94 93 102 81 84 80 80 76 37 50 100 109 86 95 93 102 82 84 80 80 76 45 60 100 109 87 96 93 102 83 84 80 80 76 55 75 100 109 88 97 95 104 84 86 95 81 82 77 75 100 100 109 90 99 95 104 86 95 88 97 81 83 78 90 120 100 109 90 99 95 104 86 95 90 99 81 85 94 78 110 150 100 109 91 100 95 104 87 96 91 100 83 86 95 79 150 200 101 170 92 101 96 105 88 97 91 100 83 86 95 79 Page 9 of 35 FLOWSERVE In areas where the staff has to intervene remember that when the level of the sound pressure is Below 70 dBA Itis not necessary to take special precautions Above 70 dBA People working continuously in the machine roo
5. After setting the last packing ring secure the packing with the gland and tighten the nut by hand After tightening the shaft should turn by hand as easily as before the setting of the packing yy D4 FP USER INSTRUCTIONS ENGLISH 71576286 07 06 DIMENSIONS IN MILLIMETERS PACKING D1 a Lgth 24 a8 600 24 a8 600 32 p 800 32 63 800 45 p 850 40 60 1000 55 78 1100 65 ot 1200 For arrangement of packing see section 8 1 Sectional drawings 6 2 6 Internal coating If the pump has an internal coating this coating must be inspected periodically Any wear or cracks of the coating found must be immediately repaired Failure to do this may lead to accelerated wear of the coating during operation and corrosion of the exposed base metal depending on the material and pumped liquid Special attention must be paid to the coating edges Any loss of coating material is considered to be normal wear and tear on the pump and is not considered as warranty Flowserve has applied the coatings according to the supplier s instructions but will not be held responsible for coating wear or cracks that may develop over time 6 3 Spare parts 6 3 1 Ordering of spares Flowserve keeps records of all pumps that have been supplied When ordering spares the following information should be quoted 1 Pump serial number Pump size Part name Part number Number of parts required B28
6. 2905 3011 01 ae 6577 02 3011 02 6700 04 cs 4590 02 a 6515 4610 04 2450 1160 1410 02 4610 03 6700 03 4610 02 6577 03 4130 6572 6581 02 1500 1500 1500 1500 ae ed ead inte was Aa eh BY with wear rings Page 29 of 35 FLOWSERVE FP USER INSTRUCTIONS ENGLISH 71576286 07 06 8 1 4 50 FP Pumps 6578 1150 4610 6571 1140 1470 6581 02 4120 6581 03 3853 6572 2520 4530 3200 2250 3011 02 1130 3260 2905 6700 01 EEEEEEEEEE 2110 2910 2020 6700 02 6544 2410 3011 01 a m 6515 1410 450 W132 4130 Q331 6531 01 6577 2540 1309 Pump 50 FP H EN with wear rings Page 30 of 35 FLOWSERVE FP USER INSTRUCTIONS ENGLISH 71576286 07 06 8 1 5 65 FP 80 FP 100 FP 125 FP Pumps 6578 1150 4610 6571 1140 14706581 02 4120 6581 03 3853 6572 2520 4590 3200 i Ti cH T A Ls CS 2250 2S eae 3011 02 C Ponen SS B 1130 3260 2905 ii 6700 01 2910 2110 6700 02 6544 2410 3011 01 6577 02 6581 04 2540 3134 651 1410 e450 4132 4130 9331 6581 01 6577 01 Pump 65 80 100 125 FP INJECTION PACKING FOR SINGLE STAGE PUMP 65 FP HO FP 100 FP Senge with wear rings Page 31 of 35 FLOWSERVE 8 2 Sectional drawings part list 8 2 1 Parts list pumps 122 FP N DESIGNATION a DESIGNATION 1130 Suction casing
7. A well run in and correctly adjusted packing gland requires little maintenance If after some time the leakage becomes too great the gland should be tightened again in order to return these to a normal level If re tightening is not possible new packing must be installed 6 2 5 2 Gland packing inspection and removal a Remove the shield guards b Slide back the gland c Remove the packing rings with an extractor designed for this purpose including the lantern ring if it exists note its position and its direction of rotation d Inspect the state of the sleeve surface the presence of many marked grooves will indicate that it must be replaced e Carefully clean the different pieces of the packing gland 6 2 5 3 Gland packing fitting If the packing is supplied as cord the packing must be cut so that the external diameter is lightly tightened and there is an initial gap between the sleeve and the packing ring For that purpose wind the packing helically around the shaft sleeve or a chuck of the same diameter Take precautions to avoid damaging sleeve Page 23 of 35 FLOWSERVE Example of straight Example of bevel cut CAUTION l Ensure a tightening on the stuffing box housing and not on the sleeve SETTING OF PACKING Follow the instructions a Assemble of the packing in S b Stagger by about 90 between two rings c Assemble packing after packing
8. C a warning plate must be clearly placed on the pump Page 19 of 35 ia FLOWSERVE LX pancer It is strictly forbidden to open switch cupboards switch boxes or all other live electric equipment If it is necessary to open them in order to take readings to carry out tests or adjustments for example only a skilled technician may do them with adapted tools Make sure that physical protections against electrical risks are used 5 5 4 Bearings D If the pumps are working in a potentially explosive atmosphere temperature or vibration monitoring at the bearings is recommended If bearing temperatures are to be monitored it is essential that a benchmark temperature is recorded at the commissioning stage and after the bearing temperature has stabilized e Record the bearing temperature t and the ambient temperature ta e Estimate the likely maximum ambient temperature tb e Set the alarm at t tb ta 5 C t tb ta 10 F and the trip at 100 C 212 F for oil lubrication and 105 C 220 F for grease lubrication It is important particularly with grease lubrication to keep a check on bearing temperatures After start up the temperature rise should be gradual reaching a maximum after approximately 1 5 to 2 hours This temperature rise should then remain constant or marginally reduce with time 5 5 5 Normal vibration levels alarm and trip For guidance pumps generally fall under a classification for rigid
9. OPERATION AND SHUTDOWN 00 cece ceeeeceeeeeeeeeeeaeteeeeeaeeeaeeseeeeeeaes 17 5 1 Direction of rotation s es 17 5 2 GUANGING iieiea nannaa anant 17 5 3 Priming and auxiliary supplies 18 5 4 Starting the PUMP ccceeeeeeseeeeeee centres 18 5 5 Running the PUMP eecceeeeeeeeeeeeeeeeeeeeeees 19 5 6 Stopping and shutdown ceeeeseeeeeees 20 5 7 Hydraulic mechanical and electrical duty 21 5 8 Pumps for Food Use or Potable Water 21 FP USER INSTRUCTIONS ENGLISH 71576286 07 06 PAGE 6 MAINTENANCE cccccceceecceeesseeeeseseeeeesseaeens 21 6 1 Generalerna 21 6 2 Maintenance schedule cceeeeeeees 22 6 3 Spare parts ccceeececeeeeeseeeeeeeeeseeeeeeeeeeeees 24 6 4 Recommended spares and consumable HEMS rrean aa aaa aaa a Aias 25 6 5 Disassembly ciascsccdescavcveesaacccatsaneatosacenenvencees 25 7 FAULTS CAUSES AND REMEDIES 26 8 PARTS LIST AND DRAWINGS 0 cceeereees 27 8 1 Sectional drawings eseeeesseeeeeeee eeren 27 8 2 Sectional drawings part list eee 32 8 3 General arrangement drawing 34 9 CERTIFICATION ccccceccsececessteeeeeeceeeeeseeeeeeaaes 34 10 OTHER RELEVANT DOCUMENTATION AND MANUALS biccesvaaedeces accctentaaetccudacvtaandcareascedevtaantaaviale 34 10 1 Supplementary User Instructions 34 10 2 Change notes ceeceeeseeceeeeeeeeeeeeeeeeees 34 10 3 Additional sources of i
10. diagnosis The pump should run smoothly and without vibration The pump must never run at a capacity of less than 10 of that at the best efficiency A Never remove a plug when the pump is running 5 5 Running the pump 5 5 1 Venting the pump A the pump to enable all trapped air to escape taking due care with hot or hazardous liquids Under normal operating conditions after the pump has been fully primed and vented it should be unnecessary to re vent the pump 5 5 2 Pump fitted with a stuffing box If the pump has a packed gland there must be some leakage from the gland Gland nuts should initially be finger tight only Leakage should take place soon after the stuffing box is pressurized If no leakage takes place the packing will begin to overheat If overheating takes place the pump should be stopped and allowed to cool before being restarted When the pump is restarted it should be checked to ensure leakage is taking place at the packed gland LN wren adjusting an operating stuffing box shield grids removed for this operation the operator must be very careful Safety gloves are compulsory and loose clothes are not allowed above all to the arms to avoid being caught by the pump shaft The pump should be run for ten minutes with steady leakage and the gland nuts tightened by 10 degrees at a time until leakage is reduced to an acceptable level The temperature of the gland should be checked after each round of tighten
11. 03 Key 6700 04 Key Cover plate FLOWSERVE FP USER INSTRUCTIONS ENGLISH 71576286 07 06 8 2 3 Parts list pumps 202 FP 1130 1140 1160 1410 01 1410 02 1500 2110 2250 2410 2450 2540 2905 2910 3011 01 3011 02 3200 3260 3853 4110 4120 4130 4131 DESIGNATION Suction casing Discharge casing Stage casing Diffuser Diffuser Casing wear ring Pump shaft Impeller Interstage sleeve Shaft sleeve Thrower Washer Shaft nut Radial ball bearing Radial ball bearing Bearing housing Bearing cover Grease nipple Stuffing box housing Stuffing box gland Gland packing Follower DESIGNATION Gasket Gasket oC section joint fe section joint ate section joint aa section joint Drain plug Plug Tie bolt 6572 Stud 6577 01 Hexagon head bolt 6577 02 Hexagon head bolt 6577 03 Hexagon head bolt 6578 01 Threaded plug 6578 02 Threaded plug 6581 01 Hexagon nut 6581 02 Hexagon nut 6700 01 Key 6700 02 Key 6700 03 Key 6700 04 Key Cover plate 8 2 4 Parts list pumps 50 FP 1130 1140 1150 1410 1470 1500 2110 2250 2410 2450 2520 2540 2905 2910 3011 01 3011 02 3200 3260 Page 33 of 35 DESIGNATION DESIGNATION Suction casing Grease nipple Discharge casing Gland Stage casing Gland packing Stuffing box neck Diffuse
12. 4 4 Initial alignment ieee Before connecting the couplings verify the motor rotation direction FP USER INSTRUCTIONS ENGLISH 71576286 07 06 4 4 1 Thermal expansion The pump and motor will normally have to be aligned at ambient temperature and should be corrected to allow for thermal expansion at operating temperature In pump installations involving high liquid temperatures the unit should be run at the actual operating temperature shut down and the alignment checked immediately 4 4 2 Alignment methods AN DANGER Ensure pump and driver are isolated electrically and the half couplings are disconnected Ensure that the pump pipework suction and discharge is disconnected The alignment MUST be checked Although the pump will have been aligned at the factory it is most likely that this alignment will have been disturbed during transportation or handling If necessary align the motor to the pump not the pump to the motor Alignment Parallelism and concentricity check CAUTION Check the alignment at three or four points before pipeworks assembly with a rule with a comparator Admissible margin for a motor with roller bearings 0 15 mm parallel checking 0 1 mm angular checking Angular checking with a sliding rule with a caliper gauge Th
13. Refer Where duty and standby pumps are installed it is recommended that they are run alternately every week 5 6 Stopping and shutdown 5 6 1 Stopping and restarting in continuous running According to hydraulic conditions of the installation and its automation degree stop and restart procedures can have different forms Nevertheless all of them must respect imperatively the following rules Stopping a Avoid that the unit turns in the opposite direction to the normal running b Make sure that the discharge line pressure does not reach the foot valve c Avoid a continuous running below the authorized flow rate see 5 4 2 Restart a Ensure that the pump is completely full of liquid b Ensure a continuous supply with a sufficient available NPSH c Ensure a backpressure so that the motor power is not in excess CAUTION d Respect the starting frequency imposed by the motor manufacturer e A Protect the pump against water hammer when stopping or starting Page 20 of 35 FLOWSERVE Shutdown CAUTION A canon olose the outlet valve and stop the motor Eventually close the inlet valve N For prolonged shutdowns and especially when ambient temperatures are likely to drop below freezing point the pump and any cooling and flushing arrangements must be drained or otherwise protected 5 7 Hydraulic mechanical and electrical duty This product has been supplied to me
14. The pump size and serial number are shown on the pump nameplate To ensure continued satisfactory operation replacement parts to the original design specification should be obtained from Flowserve Any change to the original design specification modification or use of a non standard part will invalidate the pump s safety certification Page 24 of 35 FLOWSERVE 6 3 2 Storage of spares Spares should be stored in a clean dry area away from vibration Inspection and re treatment of metallic surfaces if necessary with preservative is recommended at 6 monthly intervals 6 4 Recommended spares and consumable items 50 FP 65 FP 80 FP 100 FP 125 FP 2250 3011 01 3011 02 4130 4590 4610 122 FP 152 FP 202 FP 2250 3011 01 3011 02 4130 4590 01 4590 02 4610 01 4610 02 4610 03 4610 04 a Destroy all the gaskets after dismantling replace them when reassembling CAUTION b A caon y IS RECOMMENDED THAT BEARINGS ARE NOT REUSED AFTER ANY REMOVAL FROM THE SHAFT c After serving during two years replace the gland packing 6 5 Disassembly A Refer to section 1 6 Safety and section 6 Maintenance before dismantling the pump CAUTION A caution tore dismantling the pump for overhaul ensure genuine Flowserve replacement parts are available Refer to sectional drawings for part numbers and identification REPAIR OF THE PUMP 4 If the pump prese
15. hammer 5 COMMISSIONING START UP OPERATION AND SHUTDOWN A These operations must be carried out by fully qualified personnel 5 1 Direction of rotation Starting or operating pumps with the wrong direction of rotation can be harmful to the pumps Ensure that the pump rotation is the same as the arrow on the pump casing It is preferable to check the direction of rotation before installing the coupling If not the pump must be filled in with the liquid before start up CAUTION i lf maintenance work has been carried out to the site s electricity supply the direction of rotation should be re checked as above in case the supply phasing has been altered 5 2 Guarding Pr curdi is supplied fitted to the pump set If this has been removed or disturbed ensure that all the protective guards around the pump coupling and exposed parts of the shaft are securely fixed Page 17 of 35 FLOWSERVE 5 3 Priming and auxiliary supplies ies there is any risk of the pump being run against a closed valve generating high liquid and casing external surface temperatures it is recommended that users fit an external surface temperature protection device CAUTION A caution cure all electrical hydraulic pneumatic sealant and lubrication systems as applicable are connected and operational m Ensure the inlet pipe and pump casing are completely full of liquid before starting continuous duty operation The
16. initial operation and after the installation of spare parts that are in contact with the liquid Cleaning once the pump has been commissioned will depend on the application and operating conditions The user must ensure that the cleaning procedures are suitable for the application and operating conditions and local regulations 6 MAINTENANCE 6 1 General x If a belt drive is used the assembly and tension of the belts must be verified during regular maintenance procedure In dirty or dusty environments regular checks must be made and dirt removed from areas around close clearances bearing housings and motors Page 21 of 35 FLOWSERVE NA 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 6 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 A Oil and grease leaks may make the ground slippery Machine maintenance m
17. of the suction pipe e Ifan inlet valve is necessary choose a model with direct crossing CAUTION Do not tighten flanges before the final check see 4 5 4 4 5 2 2 Design of a suction lift line The inlet pipe must be as short and as direct as possible never place an elbow directly on the pump inlet nozzle Valve _ Non return valve a a ok A Lil Ti ait I SUFFICIENT IMMERSION E Valve strainer Sump suction configuration a Avoid sharp elbows or sudden narrowing Use convergent lt 20 total angle with upright generating b Arrange that the suction pipework is inclined upwards towards the pump ensuring that there are no peaks FP USER INSTRUCTIONS ENGLISH 71576286 07 06 c If afoot valve is necessary do not oversize it because it would generate pulsations valve beating CAUTION Do not tighten flanges before the final check see 4 5 4 4 5 3 Discharge piping 4 5 3 1 Design of a discharge line a If discharge line is provided with a divergent its total angle will be between 7 and 12 b Install the discharge valve after the non return valve downstream c The non return valve will be set in the discharge pipe to protect the
18. plan and schedule is adopted See section 6 Maintenance 1 7 Safety labels summary 1 7 1 Nameplate For details of nameplate see the Declaration of Conformity or separate documentation included with these User Instructions 1 7 2 Warning labels a FLOWSERVE WARNING J218JZ250 ESSENTIAL PROCEDURES BEFORE STARTING i ENSURE ALL EXTERNAL CONNECTIONS TO INSTALL AND OPERATE EQUIPMENT IN THE PUMP SHAFT SEALING AND DRIVER ACCORDANCE WITH THE INSTRUCTION ARE CONNECTED AND OPERATIONAL MANUAL SUPPLIED SEPARATELY ok FULLY PRIME UNIT AND SYSTEM ENSURE GUARDS ARE SECURELY IN DO NOT RUN UNIT DRY PLACE FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN PERSONAL INJURY AND OR EQUIPMENT DAMAGE ENSURE CORRECT DIRECTION OF ROTATION J218 268 PUMP MUSS AUF FESTEM FUNDAMENT STEHEN KUPPLUNGSH LFTEN KORREKT AXIAL AUSRICHTEN DANN PUMPE AUF GRUNDPLATTE FESTSPANNEN UND ANSSCHLUSSLEITUNGEN BEFESTIGEN TOLERANZEN BEDIEUNGSANLEITUNG ENSURE UNIT ON A FIRM FOUNDATION AND THAT COUPLING FACES ARE IN CORRECT ALIGNMENT PRIOR TO AND AFTER BOLTING BASEPLATE DOWN AND FIXING PIPEWORK SEE MANUAL FOR TOLERANCES ZORG DAT POMPEENHEID OP EEN STEVIGE ONDERGROND OPGESTELD STAAT EN DAT KOPPELING CORRECT UITGELIJNT IS ZOWEL VOOR ALS NADAT DE GRONDPLAAT MET BOUTEN IS VASTGEZET EN DE LEIDINGEN ane S ASSURER QUE LE GROUPE ELECTROPOMPE EST FERMEMENT INSTALLE SUR SON MASSIF VERIFIER LE LIGNAGE DE L ACCOUPLEMENT AVANT ET AP
19. pump from any excessive pressure surge and from reverse rotation If necessary a control manometer can be connected on the pipework ZA k Control manometer ll a att y AE Simm F lh a p ea oe I i 1 ad 1 1 Pil E l a Setting of the control manometer Do not tighten flanges before the final check see 4 5 4 4 5 4 Final checks a Check the tightening of anchor bolts Tighten them if necessary b Check that protective covers on suction and discharge flanges are removed c Check that holes of pipework flanges are parallel and correspond to those of the pump d Tighten suction and discharge flanges 4 6 Electrical connections AN DANGER l Electrical connections must be made by a qualified Electrician in accordance with relevant local national and international regulations This includes any grounding x 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 Page 16 of 35 ia FLOWSERVE DN mechanical hydraulic or electrical overload by using motor overload trips or a power monitor and make routine vibration monitoring A It is important to be aware of the EUROPEAN DIRECTIVE on electr
20. support machines within the International rotating machinery standards and the recommended maximum levels below are based on those standards ee Alarm and trip values for installed pumps should be based on the actual measurements N taken on site on the bearing housings of the pump in the fully commissioned as new condition The example N value is given for the preferred operating flow region typically this may extend to 70 to 120 of the pump best efficiency point outside the preferred flow region the actual vibration experienced may be multiplied by up to 2 These standard values can vary with the rotational speed and the power absorbed by the pump For any special case do not hesitate to consult us Measuring vibration at regular intervals will then show any deterioration in pump or system operating conditions FP USER INSTRUCTIONS ENGLISH 71576286 07 06 Horizontal Configuration Vibration Velocity unfiltered mm s in s r m s Normal N lt 5 6 0 22 Alarm Nx 1 25 lt 7 1 0 28 Shutdown Trip N x 2 0 lt 11 2 0 44 5 5 6 Stop start frequency Pump sets are normally suitable for the number of equally spaced stop starts per hour shown in the table below Check actual capability of the driver and control starting system before commissioning Motor rating kW hp eae rahi Starts Up to 15 20 15 Between 15 20 and 90 120 10 90 120 to 150 200 6 Above 150 200
21. 0 2900 min A re me 60 Hz 1750 3500 min e Maximum number of stages according to rotation speed 3500 min 50 FP 6 65 FP 4 80 FP 3 100 FP 3 122 FP 125 FP 2 152 FP amp 202 FP A CAUTION The maximum speed is shown on the pump nameplate Characteristics shown on the nameplate fixed on the pump are as shown below Each pump is supplied with the following nameplate Speed of rotation Pump type PIPS Type Ju ass Flow rate Max Pr Maxi sf Q 3h min at 20 C har aximum admissible oa zs m aie i Pressure at 20 C u m max min cf C Maximum minimum Radial thrust bearing ___ Bearing rad thr Year of construction Year of con Manufacture number Manuf N E FLOWSERVE POMPES 72234 ARNAGE CEDEX FRANCE temperature Each pump unit is supplied with the following nameplate Mass of the set Page 12 of 35 ia FLOWSERVE ee 4 INSTALLATION D Equipment operated in hazardous locations must comply with the relevant explosion protection regulations See section 1 6 4 Products used in potentially explosive atmospheres D equipment must be grounded 4 1 Location The pump should be located to allow room for access ventilation maintenance and inspection with ample headroom for lifting and should be as close as practicable to the supply of liquid to be pumped i
22. 0 01 2410 4610 02 1410 02 1140 4130 5578 6577 4131 4120 4610 03 3853 9331 6581 92 0 6544 6578 3200 6578 3853 3011 02 2250 6544 2905 m p 2910 7 ms 1130 l oe es Xu 4590 6515 6700 03 6700 4530 6379 245 581 01 540 260 11 01 260 6700 01 with wear rings am PDA ORS OES C HS Page 27 of 35 FLOWSERVE N 8 1 2 152 FP Pumps FP USER INSTRUCTIONS ENGLISH 71576286 07 06 4610 01 8571 24104 1140 4110 6578 02 6577 01 4130 9331 4131 4120 3200 6578 01 Eseg 4590 01 lt Zo 3853 6581 01 1410 01 3260 6700 02 a Y e 2110 COR 2910 pi _ 6700 01 2905 _ 3011 01 1130 6577 02 2230 3011 02 6700 04 3260 4590 02 2540 6515 4610 04 1160 1410 02 4610 03 6700 03 2450 4610 02 6577 03 4130 6572 6581 02 1500 01 1500 02 1500 02 1500 01 AL JEFE with wear rings ae Page 28 of 35 FLOWSERVE FP USER INSTRUCTIONS ENGLISH 71576286 07 06 8 1 3 202 FP Pumps 4610 01 16571 24105 11405 4110 lt 6578 02 6577 01 4130 9331 4131_ 4120 3200 6578 01 4590 01 6569 3853 6581 01 1410 01 ae 6700 02 sui 2910 6700 01
23. 239 F T3 200 C 392 F 180 C 356 F T2 300 C 572 F 275 C 527 F Ti 450 C 842 F 400 C 752 F FP USER INSTRUCTIONS ENGLISH 71576286 07 06 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 If an explosive atmosphere exists during the installation do not attempt to check the direction of rotation by starting the pump unfilled Even a short run time may give a high temperature resulting from contact between rotating and stationary components Furthermore confinement of liquid in the pump and pipes must be avoided valve closed If the liquid heats up this may cause excessive pressure and lead to bursting of pump components Where there is any risk of the pump being run against a closed valve generating high liquid and casing external surface temperatures it is recommended that users fit an external surface temperature protection device Avoid mechanical hydraulic or electrical overload by using motor overload trips temperature monitor or a power monitor and make routine vibration monitoring checks In dirty or dusty environ
24. 4 22 125 125 100 110 44 52 63 92 3 150 150 120 135 53 62 75 110 200 200 162 180 69 79 97 144 40 35 30 40 60 23 27 34 49 50 45 40 50 27 30 37 54 65 58 50 68 30 33 40 60 2 80 70 60 75 32 36 44 65 100 90 80 100 36 41 50 74 g 125 110 100 125 44 52 63 92 2 150 135 120 150 53 62 75 110 T 200 180 162 200 69 79 97 144 CAUTION Ensure piping and fittings are flushed before use Ensure piping for hazardous liquids is arranged to allow pump flushing before removal of the pump Page 15 of 35 FLOWSERVE 4 5 2 Suction piping 4 5 2 1 Design of a flooded suction line The suction line must be as short and direct as possible never mount an elbow directly on the inlet flange of the pump Valve_ Non return valve gla J Continous flow valve N rie SS VON I hy eSa Ne TEHA A H IHH 4 J a Flooded suction configuration a Avoid sharp elbows or sudden narrowing Use convergent lt 20 total angle b Arrange the pipework so that there are no air pockets no bulges c If high points cannot be avoided in suction line provide them with air relief cocks d Ifa strainer is necessary its net area should be three or four times the area
25. Ca N FLOWSERVE N FP centrifugal pump Multi stage single suction and radial joint plan pump type centrifugal pump PCN 71576286 07 06 E Experience In Motion USER INSTRUCTIONS Installation Operation Maintenance FLOWSERVE N CONTENTS PAGE 1 INTRODUCTION AND SAFETY ose 4 VA Generalinei aaia 4 1 2 CE marking and approvals cceseeeees 4 13 Disclaimer nunna 4 14 COPYN asia iniaie ankran niaii 4 1 5 Duty conditons s secnssicrsnennnmo ana 4 IREEN E E EE 5 1 7 Safety labels SUMMATLY ceeeeeeteeetee eee 8 1 8 Specific machine performance 008 8 1 9 Noise level esec 9 2 TRANSPORT AND STORAGE aeee 10 2 1 Consignment receipt and unpacking 10 2 2 Handling esensi 10 2 9 LN siine ina EE 11 24 Storage enan eaten 11 2 5 Recycling and end of product life 11 3 PUMP DESCRIPTION 11 3 1 Configurations cccccceeeeeeeeeeeeeeeeeeteeeees 11 3 2 Nomenclature eee eect eee eeteeeeeeteeeenaeeeeeeaes 12 4 INSTALLATION 00 c cceeeeeeeeeeeeeeseeeeeeaeeeeneeeeees 13 44 GOCatON seis ciate ed een eee 13 4 2 Foundation vi3 scieivciceerreancce eid deveeceeiadeeeetie 13 4 3 Grouting ersun ain coated 14 4 4 Initial alignment oe eee ee ester eeneeeeeeaee 14 45 PIPING esasen in ansan a AENA 15 4 6 Electrical connections 16 4 7 Final shaft alignment check 17 4 8 Protection Systems eeeeeesteeeeeeneeeeeee 17 5 COMMISSIONING START UP
26. RES FIXATION DU SOCLE ET DE LA TUYAUTERIE GEINSTALLEERD ZIJN ZIE HANDLEIDING VOIR LES TOLERANCES D ALIGNMENT VOOR TOELAABARE SPELINGEN SUR LA NOTICE CDC 603 604 610 612 621 623 624 Oil lubricated units only J218JZ262 WARNING THIS MACHINE MUST BE FILLED WITH OIL BEFORE STARTING Q ATTENTION CETTE MACHINE DOIT TRE REMPLIE D HUILE AVANT LA MISE EN MARCHE ACHTUNG DIESE MASCHINE IST VOR DEM STARTEN MIT L Z FULLEN ey WAARSCHUWING DEZE MACHINE MOET VOOR HET STARTEN MET OLIE GEVULD WORDEN CDC 603 604 610 612 621 623 624 1 8 Specific machine performance For performance parameters see section 1 5 Duty conditions When the contract requirement specifies these to be incorporated into User Instructions these are included here Where performance data has been supplied separately to the purchaser these should be obtained and retained with these User Instructions if required Page 8 of 35 FLOWSERVE N 1 9 Noise level When pump noise level exceeds 85dBA attention must be given to prevailing Health and Safety Legislation to limit the exposure of plant operating personnel to the noise The usual approach is to control exposure time to the noise or to enclose the machine to reduce emitted sound You may have already specified a limiting noise level when the equipment was ordered however if no noise requirements were defined then machines above a certain power level will exceed 85 dB A In such situatio
27. Stuffing box gland 1140 Gland packing 1160 Follower 1410 01 Gasket 1410 02 Diffuser 4610 01 Emi sectonijomt 1500 01 beei section joint 1500 02 a section joint 1500 03 Drain plug 1500 04 Casing wear ring 6544 Circlip 2110 Pump shaft 6571 Tie bolt 2410 Hexagon head bolt 2450 Threaded plug 2540 Hexagon nut 2905 Hexagon nut 3260 Grub screw 3853 Cover plate FP USER INSTRUCTIONS ENGLISH 71576286 07 06 8 2 2 Parts list pumps 152 FP N DESIGNATION 1130 Suction casing 1140 Discharge casing 1160 Stage casing 1410 01 Diffuser 1410 02 Diffuser 1500 01 Casing wear ring 1500 02 Casing wear ring 2110 Pump shaft 2250 Impeller 2410 Interstage sleeve 2450 Shaft sleeve 2540 Thrower 2905 Washer 2910 Shaft nut 3011 01 Radial ball bearing 3011 02 Radial ball bearing 3200 Bearing housing 3260 Bearing cover 3853 Grease nipple ay Stina box 4120 Stuffing box gland 4130 Gland packing 4131 Follower Page 32 of 35 DESIGNATION 4134 Lantern ring 4590 01 Gasket 4590 02 Gasket 4610 01 Round section joint ring 4610 02 Round section joint ring 4610 03 Round section joint ring 4610 04 Round section joint ring 6515 Drain plug 6569 Plug 6571 Tie bolt 6572 Stud 6577 01 Hexagon head bolt 6577 02 Hexagon head bolt 6577 03 Hexagon head bolt 6578 01 Threaded plug 6578 02 Threaded plug Hexagon nut 6581 02 Hexagon nut 6700 01 Key 6700 02 Key 6700
28. UMP DESCRIPTION 3 1 Configurations The multi stage centrifugal pump is designed for the pumping of cold water or all clear liquids which are not solid and liquid mixtures non corrosive non abrasive or non explosive when in contact with the pump motor unit and its working parts Important for other liquids consult FLOWSERVE for beforehand advice The FP type pump is a centrifugal multi stage single suction and radial joint plan pump The modular design 2 hydraulics by pump type number of stages variation enables an accurate pump adjustment to the required operating conditions It can be driven by electric motor steam turbine or petrol or diesel motor AN the pump must be stored in a non explosive ventilated location sheltered from bad weather dust and vibrations Page 11 of 35 ia FLOWSERVE e Maximum working pressure at discharge see ced ce A E AA 25 bars e Maximum working pressure at suction 16 bars except 122 152 and 202 FP 10 bars e Maximum pumped fluid temperature 105 C impeller and diffuser for CAST IRON or BRONZE e Minimum pumped fluid temperature 10 C e Maximum ambient temperature 40 C 3 e Maximum solid suspension 00 50 g m 3 2 Nomenclature FP USER INSTRUCTIONS ENGLISH 71576286 07 06 DONSit ye sis esvdext ciesitiiee coaieiestetiee eee tae 1 e VISCOSILY secscnciiinaenieie indirect 1 mm s e Frequency 50 Hz 145
29. ant systems if fitted are full and operating normally c Pump fitted with a stuffing box leakage of 20 drops per minute d Pump fitted with a mechanical seal no leakage e Check the level and condition of oil lubricant On grease lubricated pumps check running hours since last recharge of grease or complete grease change 6 2 3 Periodic inspection six monthly CAUTION a A caution neck foundation bolts for security of attachment and corrosion b Check pump running records for hourly usage to determine if bearing lubricant requires changing c The coupling should be checked for correct alignment and worn driving elements FP USER INSTRUCTIONS ENGLISH 71576286 07 06 If a check shows a bad running of the motor pump unit the user must a L Refer to the fault finding chart chapter 7 of this leaflet to apply the recommended solutions b Ensure that your equipment corresponds to the arrangements of this leaflet c Contact FLOWSERVE after sales Department if the problem persists 6 2 4 Mechanical seals The current maintenance is limited to seal control It is necessary to detect any small leakage which announces the beginning of the deterioration of friction faces or secondary seal elements rings bellows synthetic membranes It is advisable to stop the pump as soon as possible Have an approved seal vendor replace or repair the seal 6 2 5 Gland packing 6 2 5 1 Pump fitted with a packed gland
30. applicable Low Voltage Equipment Electromagnetic Compatibility EMC Pressure Equipment Directive PED and Equipment for Potentially Explosive Atmospheres ATEX Where applicable the Directives and any additional Approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions Where applicable this document incorporates information relevant to these Directives and Approvals FP USER INSTRUCTIONS ENGLISH 71576286 07 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 adverse
31. ccordance with current local regulations Au ERMAL SHOCK Rapid changes in the temperature of the liquid within the pump can cause thermal shock which can result in damage or breakage of components and should be avoided A NEVER APPLY HEAT TO REMOVE IMPELLER Trapped lubricant or vapour could cause an explosion A HOT and cold PARTS If hot or freezing components or auxiliary heating supplies can present a danger to operators and persons entering the immediate area action must be taken to avoid accidental contact If complete protection is not possible the machine access must be limited to 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 Page 5 of 35 ia FLOWSERVE HAZARDOUS LIQUIDS When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by appropriate sitting of the pump limiting personnel access and by operator training If the liquid is flammable and or explosive strict safety procedures must be applied Gland packing must not be used when pumping hazardous liquids PREVENT EXCESSIVE EXTERNAL PIPE LOAD Do not use pump as a support for piping Do not mount expansion joint
32. d manufactured with state of the art technologies in modern facilities The unit is produced with great care and commitment to continuous quality control utilizing sophisticated quality techniques and safety requirements Flowserve is committed to continuous quality improvement and being at 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 and regulations A 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
33. e alignment will be definitive only after pipework connection see 4 5 1 Page 14 of 35 ia FLOWSERVE If necessary improve the machine alignment Complete unit mounted on common base plate The machines are first aligned accurately in our workshops Usually any misalignment observed on site is due to a wrong adjustment under the base plate disturbed during transport or because of forces exerted by the pipework It is only necessary to rectify the adjustment under base plate If it proves to be insufficient modify the motor and the pipeworks adjustment Pump and motor mounted on individual base plates Machines are or must be first mounted on their own base plate in the workshop Once the pump is set it will be regarded as the fixed piece Any alignment necessary shall be carried out on the motor ZA pancer Never connect the electric motor before the setting has been completely finished 4 5 Piping x The user must verify that the equipment is isolated from any external sources of vibration Protective covers are fitted to the pipe connections to prevent foreign bodies entering during transportation and installation Ensure that these covers are removed from the pump before connecting any pipes 4 5 1 Suction and discharge pipework The dimensions of the pipes do not directly depend on suction and discharge diameters of the pump a First choose a flow speed lt 2 m s at suctio
34. e fully grouted Ada gp ey 2 Pre ie l E E J 4 2 1 Setting the base plate for anchoring a Clean the foundation surface thoroughly b Put shims on the foundation surface approx 20 25 mm thick one on each side of the bolt hole as an alternative leveling screws can be used YHOO UMMM SS c Lay the base plate and level in both directions with extra shims The base plate should be level to within 0 5 mm per 1 m d If anchor bolts have been pre cast in the foundation slightly tighten the anchor bolts Otherwise let them hang in the foundation holes Page 13 of 35 ia FLOWSERVE ee 4 3 Grouting 4 3 1 Base plate grouting a Prepare the site for grouting Before grouting clean the foundation surface thoroughly and provide external barriers as shown b Prepare grouting product concrete resin in accordance with manufacturers instructions c T c Use grouting products with anti shrinking components d To grout up to the required level Polish surfaces Take necessary precautions to avoid air bubbles e Lay down the barrier break external angles and polish the different surfaces f After grout starts to cure definitively tighten anchor bolts g Control the alignment such as described as follows
35. eck the available NPSH gt the required NPSH Reduce geometrical suction lift Reduce head losses in pipes and in fittings diameter increase and appropriate fitting positions Check valves and strainers Check the immersion head of the suction valve Wrong rotation Reverse 2 phases on motor terminal boxes The motor is running on 2 phases only Check and control the motor electrical power supply Motor running too low Check the connection in the terminal box according to the voltage Total manometric head system higher than Check the discharge head pump differential head Check the head losses in discharge pipes partly closed valve foreign particles back pressure too high Modify the installation or change the pump set Total manometric head system lower than Throttle at discharge valve or trim the impeller contact our pump differential head local agent CONSULT FLOWSERVE Pipes valves filter Control dismantle and clean Insufficient flow rate Check the suction and discharge pipes valves back pressure Worn wear ring surfaces Foresee pump mending CONSULT FLOWSERVE Seizure jamming CONSULT FLOWSERVE Excessive strains on flanges Check the flange connections and eliminate strains pipe positioning or elastic sleeves mounting Check and replace all the gland packing parts Mechanical seal CONSULT FLOWSERVE CONSULT FLOWSERVE Consult our local agent to analyze the problem Check the al
36. ection systems x The following protection systems are recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous liquid If in doubt consult Flowserve If there is any possibility of the system allowing the pump to run against a closed valve or below minimum continuous safe flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsafe level FP USER INSTRUCTIONS ENGLISH 71576286 07 06 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 the pump or its associated sealing system can cause a hazard it is recommended that an appropriate leakage detection system is installed To prevent excessive surface temperatures at bearings it is recommended that temperature or vibration monitoring are carried out See sections 5 5 4 and 5 5 5 If a defect of cooling can lead to temperature higher than those acceptable a system of cooling surveillance must be installed Except when explicitly required by the customer in the specifications when a possibility of reverse rotation exists the customer must install a reverse rotation protection device The customer must install all equipment required to avoid water
37. eececeeeeceeeeeeeeeneeteeeeeeeeees 5 FP USER INSTRUCTIONS ENGLISH 71576286 07 06 PAGE Safety markings 1 6 1 c ccesceseeesseeseeeeeereeeeeees 5 Safety protection systems see 1 6 and 4 8 Sectional drawings 8 1 c cccecceseeeeseeeeee cette 27 Sound level see 1 9 Noise level ceeeeeee 9 Sources additional information 10 3 34 Spare parts 6 3 eccceeseeceeeeeseeeeeeeeeeeeeeeeeeeeeeees 24 Specific machine performance 1 8 seeeee 8 Standard maintenance 6 2 1 aseeseen 22 Starting the PUMP 5 4 cceteeeeeeeeseeteeeeeeeeeeees 18 Stop start frequency 5 5 6 cccesseeeeeseeeeteeeeees 20 Stopping and shutdown 5 6 cccesscessesteeeeees 20 Storage PUMP 2 4 oo eeeeceeececeteeeeeeeeeeeeeeeeeeeenaees 11 Storage spare parts 6 3 2 ccccceccessseeeeeesteeees 25 Suction piping 4 5 2 ceeceeeeeeeseeeseeeeeesee ceeeeeeeeees 16 Supplementary manuals or information sources 34 Thermal expansion 4 4 1 ccceeeeeeeeeseeeeeenee eee 14 Transport and storage 2 eeeeseeeeesneeeeenteeeeees 10 Trouble shooting see 7 nenn 26 Vibration 5 5 5 mererien nie naene 20 Warning labels 1 7 2 sssssesrreesrresrerreseerresrrnens 8 Page 3 of 35 FLOWSERVE N 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 an
38. enson Elsevier Advanced Technology United Kingdom 1995 Reference 3 Pump Handbook 2 edition Igor J Karassik et al McGraw Hill Inc New York 1993 Reference 4 ANSI HI 1 1 1 5 Centrifugal Pumps Nomenclature Definitions Application and Operation Reference 5 ANSI B31 3 Process Piping Page 34 of 35 FLOWSERVE Your Flowserve factory contacts Flowserve Pompes Route d Angers 72234 ARNAGE BP 305 72001 LE MANS Cedex France Telephone 24 hours 33 2 43 40 58 47 Sales amp Admin 33 2 43 40 57 57 Repair amp Service Fax 33 243 40 58 17 Local Flowserve factory representatives North America Flowserve 5310 Taneytown Pike PO Box 91 Taneytown MD 21787 0091 USA Telephone 1 410 756 2602 Customer Service FAX 1 410 756 2615 Parts inquiry Order PH 1 800 526 3569 South America Flowserve do Brasil Ltda Av Don Helder Camara 5451 20771 001 Rio de Janerio Tel 55 21 2108 4000 Fax 55 21 2108 4184 To find your local Flowserve representative please use the Sales Support Locator System found at www flowserve com flowserve com FP USER INSTRUCTIONS ENGLISH 71576286 07 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 Desi
39. eration of sparks Prevent leakages e 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 x Use equipment only in the zone for which it is appropriate Always check that the driver drive coupling assembly seal and pump equipment are suitably rated and or certified for the classification of the specific atmosphere in which they are to be installed Where Flowserve has supplied only the bare shaft pump the Ex rating applies only to the pump The party responsible for assembling the pump set shall select the coupling driver and any additional equipment with the necessary CE 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 and so for pumps sets with a VFD the ATEX Certification for the motor must state that it is covers the situation where electrical supply is from the VFD This particular requirement still applies even if the VFD is in a safe area Page 6 of 35 FLOWSERVE 1 6 4 2 Marking An example of ATEX equipment marking is shown below The actual classification of the pump will be engra
40. et the performance specifications of your purchase order however it is understood that during the life of the product these may change The following notes may help the user decide how to evaluate the implications of any change If in doubt contact your nearest Flowserve office 5 7 1 Specific gravity SG Pump capacity and total head in meters feet do not change with SG however pressure displayed on a pressure gauge is directly proportional to SG Power absorbed is also directly proportional to SG It is therefore important to check that any change in SG will not overload the pump driver or over pressurize the pump 5 7 2 Viscosity For a given flow rate the total head reduces with increased viscosity and increases with reduced viscosity Also for a given flow rate the power absorbed increases with increased viscosity and reduces with reduced viscosity It is important that checks are made with your nearest Flowserve office if changes in viscosity are planned 5 7 3 Pump speed Changing pump speed effects flow total head power absorbed NPSHp noise and vibration Flow varies in direct proportion to pump speed head varies as speed ratio squared and power varies as speed ratio cubed The new duty however will also be dependent on the system curve If increasing the speed it is important therefore to ensure the maximum pump working pressure is not exceeded the driver is not overloaded NPSHa gt NPSHp and that noise and vib
41. ial problems If any problems are found the following sequence of actions should take place a Refer to section 7 Faults causes and remedies for fault diagnosis b Ensure equipment complies with the recommendations in this manual c Contact Flowserve if the problem persists 6 2 1 Standard maintenance Roller bearing The bearings fitted are prepacked with grease at the factory When the regreasing period is reached it is necessary to remove as much of the old grease as possible with a clean lint free cloth and repack the bearings with fresh grease Page 22 of 35 FLOWSERVE N LUBRICATION QUANTITY gr PUMP FREQUENCY h z TYPE oupling 1 750 2900 opposed Coupling min min side side 50 FP 8000 5500 16 10 65 FP 8000 5500 16 10 80 FP 8000 5500 16 10 100 FP 8000 5500 16 10 122 FP 7500 30 17 125 FP 7500 4000 30 17 152 FP 3000 50 30 202 FP 3000 50 30 At least once a year The grease used in factory for first filling is SHELL ALVANIA R2 Its equivalents MOBIL Mobilux EP 2 TOTAL Multis 2 ELF ELF MULTI 6 2 2 Routine inspection daily weekly The following checks should be made and the appropriate action taken to remedy any deviations a Check operating behavior Ensure noise vibration and bearing temperatures are normal b Check that there are no abnormal fluid or lubricant leaks static and dynamic seals and that any seal
42. ignment of the pump and of its driver Check the setting of base plates tightening bad adjustment seal Defective gland packing on the shaft Defective motor bearings Specific gravity or viscosity of liquid too high Misalignment Foundations not sufficiently rigid Insufficient pressure Pump looses prime after starting POSSIBLE CAUSES SOLUTIONS Rotation speed too low check the driver Check the connection in the terminal box according to the voltage Presence of air Suction pressure insufficient Mechanical defects Air leak in the suction pipe Restriction in suction pipe Suction level too low Obstruction of suction pipe Defective gland packing on the shaft Defective gasket Check and de aerate Check the available NPSH gt the required NPSH CONSULT FLOWSERVE Check suction pipe is airtight Check diameter of suction pipe Check the NPSH gt NPSH Reduce geometrical suction lift Reduce head losses in pipes and in fittings diameter increase and appropriate fitting positions Check valves and strainers Check the immersion head of the suction valve Check condition of pipe Check and replace all the gland packing Mechanical seal CONSULT FLOWSERVE CONSULT FLOWSERVE Page 26 of 35 FLOWSERVE FP USER INSTRUCTIONS ENGLISH 71576286 07 06 8 PARTS LIST AND DRAWINGS 8 1 Sectional drawings 8 1 1 122 FP Pumps 6571 1160 4610 01 6700 03 141
43. ing If the temperature starts to climb rapidly then back off the gland nuts until the temperature drops down Wait for the temperature to stabilize before tightening again The leakage must not be reduced below a rate of 20 drops per minute Bedding in of the packing may take several hours FP USER INSTRUCTIONS ENGLISH 71576286 07 06 Ess A LNN KK DD NF 1 Uj a Z Ae grids being removed during installation of the gland packing it must be ensured that they are replaced as soon as this operation is completed 5 5 3 Pump fitted with mechanical seal A mechanical seal ensures a seal without leakage and does not need any adjustment Nevertheless if a light leakage occurs during start up it should disappear after the initial running in of the friction faces 2110 2445 4200 4610 4240 4213 if Vv NEVER RUN A MECHANICAL SEAL DRY EVEN FOR A SHORT WHILE SAFETY INSTRUCTIONS WHEN THE PUMP IS RUNNING A If hot or freezing components of the machine can present a danger to operators they must be shielded to avoid accidental contact If a 100 protection is not possible the machine access must be confined to the maintenance staff only Ai the temperature is greater than 80
44. ly affect the performance and safety features of the products The failure to properly select install or use authorized Flowserve parts and accessories is considered to be misuse Damage or failure caused by misuse is not covered by 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 A 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 Page 4 of 35 FLOWSERVE 1 6 Safety 1 6 1 Summary of safety markings These User Instructions contain specific safety markings where non observance
45. m must be supplied with protective devices against noise Below 85 dBA No particular measures need to be taken for casual visitors staying in the room during a limited period Above 85 dBA The room must be considered as a dangerous area because of the noise and a warning sign must be fixed at each entry warning the people coming into the room even for a short period that they must wear hearing protection Above 105 dBA Special hearing protection adapted to this noise level and to the spectral noise components must be installed and a warning sign to this effect erected at each entry The staff in the room must wear ear protection Make sure that the noise which travels through the walls and windows does not generate too high noise levels in the machine room s surroundings 2 TRANSPORT AND STORAGE 2 1 Consignment receipt and unpacking Immediately after receipt of the equipment it must be checked against the delivery and shipping documents for its completeness and that there has been no damage in transportation Any shortage and or damage must be reported immediately to Flowserve Pump Division and received in writing within one month of receipt of the equipment Later claims cannot be accepted Check any crate boxes and wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to sidewalls of the box or equipment Each product has a unique serial number Check that thi
46. ments regular checks must be made and dirt removed from areas around close clearances bearing housings and motors 1 6 4 4 Preventing the build up of explosive mixtures x ENSURE PUMP IS PROPERLY FILLED AND VENTED AND DOES NOT RUN DRY Ensure pump and relevant suction and discharge pipeline system is totally filled with liquid at all times during the pump operation so that an explosive atmosphere is prevented In addition it is essential to make sure that seal chambers auxiliary shaft seal systems and any heating and cooling systems are properly filled If the operation of the system cannot avoid this condition the fitting of an appropriate dry run protection device is recommended eg liquid detection or power monitor To avoid potential hazards from fugitive emissions of vapour or gas to atmosphere the surrounding area must be well ventilated Page 7 of 35 ia FLOWSERVE 1 6 4 5 Preventing sparks Ok 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 ground contact on the baseplate must be used s TN Avoid electrostatic charge do not rub non metallic surfaces with a dry cloth ensure cloth is damp The coupling must be selected to comply with 94 9 EC and correct alignment must be maintained Additional requirements for metallic pumps on non metallic baseplates When metallic comp
47. n and about 3 m s at discharge Take into account the available NPSH which must be superior to the required NPSH of the pump A CAUTION Never use pump as a support for piping CAUTION OESS Do not mount expansion joints in such a way that their force due to internal pressure may act on the pump flange oJ Maximum forces and moments allowed on the pump flanges vary with the pump size and type These external strains may cause misalignment hot bearings worn couplings vibrations and the possible failure of the pump casing FP USER INSTRUCTIONS ENGLISH 71576286 07 06 When designing the pipes 4 5 2 1 4 5 2 2 4 5 3 1 take necessary precautions in order not to exceed maximum allowed strains Forces and moments applied to the pump flanges must never exceed the values shown in the table below Pipe DN Forces daN Moments daN m Layout flanges F Fz Fx My Mz Mx M E 40 30 40 35 23 27 34 49 S 50 40 50 45 27 30 37 54 g 65 50 68 58 30 33 40 60 2e 80 60 75 70 32 36 44 65 F 100 80 100 90 36 41 50 74 gt 3 125 100 125 110 44 52 63 92 amp 150 120 150 135 53 62 75 110 a 200 162 200 180 69 79 97 144 40 40 30 35 60 23 27 34 49 50 50 40 45 27 30 37 54 ge 65 68 50 58 30 33 40 60 z2 80 75 60 70 32 36 44 65 85 100 100 80 90 36 41 50 7
48. nd packing 6 2 5 sseeeeeseesresresre ereere 23 Grouting 4 3 rierien eeraa ea an 14 Guarding 5 2 cecccecceeeeseeeeeeeeeeeeeeeeeenaeeeneeeeeeees 17 Handling 2 2 erinin rinnan ARE AR 10 Hydraulic mechanical and electrical duty 5 7 21 Inspection 6 2 2 ANd 6 2 3 oo eceeeeeeeeeeeeeeeeeees 23 Installation 4 eeue 13 Internal coating 6 2 6 eeeeeeeeeteeeeeeneeeeneeeeeenaes 24 Lifting 253 Vine esiin scence sie nndir aiias 11 LOCATION 4 Teearu 13 Maintenance B ererecreneienniinini 21 Maintenance schedule 6 2 senses 22 Mechanical seal 6 2 4 0 eeeceeeeeeeeeeeeenteeneeees 23 Nomenclature 3 2 ccccccceeeeeeeeeeeeeeeeeeeeenaeeeeeeaas 12 Nameplate 1 7 1 0 ceeccceeessceeeeeseceeeseeeeeeeseeeeneneees 8 Operating limits see 3 1 eee eeeeeeeeeeeeeeeteeeees 12 Ordering spare parts 6 3 1 cccceseeeeseeeteeeees 24 Parts lists 8 2 i iceecetecedeeeeessateeadie aes adetantaeeeeerd 32 Pipmng Jk ko eee 15 Protection systems 4 8 17 Pump MASSES 2 2 2 ooo eeeececeeeeeteeeteeeeeeeeeeceeeeeeaeees 10 Receipt and unpacking 2 1 10 Recommended fill quantities See 6 2 1 23 Recommended grease lubricants see 6 2 1 23 Recommended spares 6 4 cccceeeeeteeeeeesteeeeees 25 RRECYCIING 2 5 sieieescoitlewsssdeedtsd ptdes ied ecdeisieacioes 11 Replacement parts see 6 3 and 6 4 ee 24 Running the PUMP 5 5 oo eeeeeeeeeseeeeeeeeteeeeneeeeeeee 19 Safety action 1 6 3 c
49. nd rendered inert before any disassembly operation b Any auxiliary systems installed must be monitored if necessary to ensure they function correctly c During cleaning of the pump ensure the compatibility between the cleaning products and the gaskets d Verify the condition of the gaskets e Gland packings must be adjusted correctly to give visible leakage and concentric alignment of the gland follower to prevent excessive temperature of the packing or follower Mechanical seals should present no leakage f Check for any leaks from gaskets and seals The correct functioning of the shaft seal must be checked regularly g Check bearing lubricant level and if the hours run show a lubricant change is required h Check that the duty condition is in the safe operating range for the pump i Check vibration noise level and surface temperature at the bearings to confirm satisfactory operation j Check the tightness of the connections k Check dirt and dust is removed from areas around close clearances bearing housings and motors I Check coupling alignment and re align if necessary m Verify the correct operation of the system The equipment used for maintenance and disassembly in an ATEX zone must be in conformity with the requirements zone Our specialist service personnel can help with preventative maintenance records and provide condition monitoring for temperature and vibration to identify the onset of potent
50. nformation 34 Page 2 of 35 FLOWSERVE INDEX PAGE Additional Sources 10 3 eeeceeeeeeeeeeeeeeeeeneeees 34 Alignment of shafting see 4 2 4 4 and 4 7 ATEX marking 1 6 4 2 rsrsrs 7 CE marking and approvals 1 2 ccsceseeeeeee 4 Certification 9 c iceccsseeeieseenettaseeavenitiseubtaancnk 34 Change notes 10 2 ceeccceseeeeeeeeeeeeseeeteeteneeeeees 34 Cleaning prior to operation 5 8 1 cceeeeee 21 Commissioning start up operation 5 17 Compliance ATEX 1 6 4 1 c cccccccseeeeseeseereeesees 6 Configurations 3 1 cescecesceeseeeeeseeeeeeeeeeeeeennees 11 Copyright 14 aasian iaaa 4 Direction of rotation 5 1 17 Disassembly 6 5 oo ee eeeeeeeteeeeeenneeeeeeeeeeeaeeeeeeaas 25 Discharge piping 4 5 3 oo eeeeeeeeseeeeeeeneeeeaaes 16 Disclaimer 1 3 ccceeeeeeeeeeeneeeeeeeeeeeeaeeeeeeaeeeeeeaas 4 Dismantling see 6 5 Disassembly ee 25 Drawings 8 1 ccccceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeaeeeeneaas 27 Duty Conditions 1 5 4 Electrical connections 4 6 cessere 16 End of product life 2 5 0 eceeeeseeeeeeeteeeeneeeeeene 11 Faults causes and remedies 7 nescence 26 Final checks 4 5 4 eecceeeeeseeeeeesteeeeeeneeeseeeeeenaes 16 First pump Start up 5 4 2 oo eeeeeeeeeeeeeeeeeeees 18 Foundation 4 2 isens secede caver a AS 13 Forces and moments see 4 5 1 15 General arrangement drawing 8 3 eseese 34 Gla
51. ns consideration must be given to the fitting of an acoustic enclosure to meet local regulations Pump noise level is dependent on a number of factors the type of motor fitted the operating capacity pipework design and acoustic characteristics of the building Typical sound pressure levels measured in dB and A weighted are shown in the table below The figures are indicative only they are subject to a 3 dB tolerance and cannot be guaranteed FP USER INSTRUCTIONS ENGLISH 71576286 07 06 The values are based on the noisiest ungeared electric motors which are likely to be encountered They are Lpa Sound pressure levels at 1m 3 3ft from the directly driven pump for free field over a reflecting plane For estimating Lwa sound power level re 1 pW add 14 dB A to the sound pressure value If a pump only has been purchased for fitting with your own driver then the pump only noise levels from the table should be combined with the level for the driver obtained from the supplier If the motor is driven by an inverter it may show an increase in noise level at some speeds Consult a Noise Specialist for this calculation LJ For units driven by equipment other than electric motors or units contained within enclosures see the accompanying information sheets and manuals Typical sound pressure level dBA Lpaat 1 m reference 20 Pa Lwa sound power1 pW where Lpa gt 85 dBA
52. nts abnormalities or a persistent malfunction contact immediately FLOWSERVE After sales Service Tel 02 43 40 57 57 33 2 43 40 57 57 Fax 02 43 40 58 17 33 2 43 40 58 17 According to the After sales Service instructions disassembly will be limited to the dismantling of the pump ZAN pancer DISCONNECT THE UNIT FROM POWER b Close the inlet valve if fitted and outlet valve FP USER INSTRUCTIONS ENGLISH 71576286 07 06 c Wait for the moment when the pump casing is cooled and at ambient temperature d A DRAIN PUMP e Dismantle inlet and outlet pipeworks as well as all pipeworks f a PUMP TAKING INTO ACCOUNT SAFETY 1 AND HANDLING 2 2 PROCEDURES A ANY DISASSEMBLY REPAIR OR REASSEMBLY WILL BE CARRIED OUT UNDER FLOWSERVE RESPONSABILITY EITHER DIRECTLY BY THE AFTER SALES SERVICE OR BY OTHER FLOWSERVE AGENTS WHO WILL GET THE REQUIRED INSTRUCTIONS AND APPROVALS THIS IS THE CASE OF AUTHORIZED REPAIRERS WHOSE ADDRESSES AND TELEPHONE NUMBERS WILL BE GIVEN ON REQUEST Page 25 of 35 FLOWSERVE FP USER INSTRUCTIONS ENGLISH 71576286 07 06 7 FAULTS CAUSES AND REMEDIES Insufficient flow rate Irregular pump running Driver overloaded Mechanical seal leak Equipment vibration Excessive pump casing temperature POSSIBLE CAUSES SOLUTIONS Pump or suction pipe not completely filled Check and complete filling Air bubbles in pipes Check and desecrate the pipes Suction level too low Ch
53. o Milan Italy Telephone 39 0362 6121 Fax 39 0362 303396 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
54. of an instruction would cause hazards The specific safety markings are A DANGER This symbol indicates electrical safety instructions where non compliance will involve a high risk to personal safety or the loss of life Dn symbol indicates safety instructions where non compliance would affect personal safety and could result in loss of life This symbol indicates hazardous substances and toxic fluid safety instructions where non compliance would affect personal safety and could result in loss of life CAUTION LA caon symbol indicates safety instructions where non compliance will involve some risk to safe operation and personal safety and would damage the equipment or property D 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 TN This symbol is used in safety instructions to remind not to rub non metallic surfaces with a dry cloth ensure cloth is damp It is used where non compliance in the hazardous area would cause the risk of an explosion Note 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 no
55. omagnetic 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 LX 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 power supply is appropriate A device to provide emergency stopping shall be fitted Carry out the ground connections according to the current local regulations Ae avoid any risk of jamming the direction of rotation will be checked after priming of the pump 5 3 1 5 3 2 and before the first start 5 4 2 4 7 Final shaft alignment check a Check the alignment pump motor according to the procedure 4 4 2 Rectify if necessary by adjusting the motor only b Check by hand that the pump turns freely A binding indicates a distortion of the pump which is due to excessive pipes strains If necessary the pipework design must be re examined c If it provided connect auxiliary pipe systems hydraulic pneumatic sealing system d Control tightness and functionality of auxiliary piping 4 8 Prot
56. onents are fitted on a non metallic baseplate they must be individually earthed 1 6 4 6 Preventing leakage x 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 ancillary systems Where there is the potential hazard of a loss of a seal barrier fluid or external flush the fluid must be monitored If leakage of liquid to atmosphere can result in a hazard the installation of a liquid detection device is recommended 1 6 4 7 Maintenance to avoid the hazard CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION The responsibility for compliance with maintenance instructions is with the plant operator To avoid potential explosion hazards during maintenance the tools cleaning and painting materials used must not give rise to sparking or adversely affect the ambient conditions Where there is a risk from such tools or materials maintenance must be conducted in a safe area FP USER INSTRUCTIONS ENGLISH 71576286 07 06 It is recommended that a maintenance
57. r bush Diffuser plate Gasket Round section joint Casing wear ring fing Pump shaft Drain plug Impeller Circlip Tie bolt 6572 Stud Interstage sleeve Shaft sleeve Loose collar Hexagon head bolt Thrower Threaded plug Washer Hexagon nut Shaft nut Hexagon nut Radial ball bearing Hexagon nut Cover plate Radial ball bearing Bearing housing Bearing cover FLOWSERVE 8 2 5 Parts list pumps 65 FP 80 FP 100 FP 125 FP N DESIGNATION ra DESIGNATION 4120 Gland 1140 Discharge casing 4130 Gland packing Stuffing box neck bush 4590 Gasket 4610 Round section joint ring 1500 Casing wear ring 6515 Drain plug 2110 Pump shaft Circlip 6571 Tie bolt 2410 Interstage sleeve 6572 Stud 1130 Suction casing 1150 Stage casing 1410 Diffuser 1470 Diffuser plate 2250 Impeller 2450 Shaft sleeve 6577 01 Hexagon head bolt 2520 Loose collar 6577 02 Hexagon head bolt 2540 Thrower 6578 Threaded plug 2905 Washer 6581 01 Hexagon nut 2910 Shaft nut 6581 02 Hexagon nut 3011 01 Radial ball bearing 6581 03 Hexagon nut 3011 02 Radial ball bearing 6581 04 Hexagon nut 3134 Support foot 6700 01 Key 3200 Bearing housing 6700 02 Key 3260 Bearing cover 9331 Cover plate 3853 Grease nipple 8 3 General arrangement drawing The typical general arrangement drawing and any specific drawings required by the contract will be sent to the Purchaser separatel
58. ration are within local requirements and regulations 5 7 4 Net positive suction head NPSHa NPSH available NPSH is the head available at the impeller inlet above the vapour pressure of the pumped liquid FP USER INSTRUCTIONS ENGLISH 71576286 07 06 NPSH required NPSHp is the minimum head required at the impeller inlet above the vapour pressure of the pumped liquid to avoid excessive cavitation and extreme performance degradation It is important that NPSH gt NPSHp The margin between NPSHa gt NPSHr should be as large as possible If any change in NPSH j is proposed ensure these margins are not significantly eroded Refer to the pump performance curve to determine exact requirements particularly if flow has changed If in doubt please consult your nearest Flowserve office for advice and details of the minimum allowable margin for your application 5 7 5 Pumped flow Flow must not fall outside the minimum and maximum continuous safe flow shown on the pump performance curve and or data sheet 5 8 Pumps for Food Use or Potable Water If the pump has not been specifically ordered for a food or drinking water application it must not be used for these types of applications If it has been ordered for this type of application the following recommendations are to be followed 5 8 1 Cleaning prior to operation Pumps that are to be used for a food or drinking water application should be cleaned before being put into
59. s unless allowed by Flowserve in writing so that their force due to internal pressure acts on the pump flange ENSURE CORRECT LUBRICATION See section 5 Commissioning startup operation and shutdown START THE PUMP WITH OUTLET VALVE PART OPENED Unless otherwise instructed at a specific point in the User Instructions This is recommended to minimize the risk of overloading and damaging the pump motor at full or zero flow Pumps may be started with the valve further open only on installations where this situation cannot occur Pump outlet valve shall may need to be adjusted to comply with the duty following the run up process See section 5 Commissioning start up operation and shutdown NEVER RUN THE PUMP DRY CAUTION INLET VALVES TO BE FULLY OPEN WHEN PUMP IS RUNNING Running the pump at zero flow or below the recommended minimum flow continuously will cause damage to the seal DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES Operating at a flow rate higher than normal or at a flow rate with no backpressure on the pump may overload the motor and cause cavitations Low flow rates may cause a reduction in pump bearing life overheating of the pump instability and cavitations vibration FP USER INSTRUCTIONS ENGLISH 71576286 07 06 1 6 4 Products used in potentially explosive atmospheres D Measures are required to Avoid excess temperature Prevent build up of explosive mixtures Prevent the gen
60. s number corresponds with that advised and always quote this number in correspondence as well as when ordering spare parts or further accessories FP USER INSTRUCTIONS ENGLISH 71576286 07 06 2 2 Handling 2 2 1 General instructions concerning handling Boxes crates pallets or cartons may be unloaded using forklift vehicles or slings dependent on their size and construction See 2 3 1 for positioning of slings To lift heavy pieces above 25 kg 55 Ib use a winch adapted to the mass and in accordance with the current local regulations To lift machines or pieces with one or several suspension rings only use hooks and chains in compliance with the local regulations concerning safety Never put cables chains or ropes directly on or in the suspension rings Cables chains or lifting ropes must never present excessive bending Never bend the lifting hooks suspension rings chains etc which should only be made to endure stresses within calculated limits Remember that the capacity of a lifting device decreases when the direction of the lifting force direction makes an angle with the device axis To increase the safety and the efficiency of the lifting device all the lifting elements must be as perpendicular as possible If necessary a lifting beam can be placed between the winch and the load When heavy pieces are lifted up never stay or work under the load or in the area which could be in the path of the load if it were
61. se operations must be carried out by personnel with approved qualifications 5 3 1 Priming of a flooded pump a As discharge valve is closed fill the pump by opening the valve at suction b Let air escape by removing the plugs situated on the flange of the discharge casing and suction casing for the 122 152 to 202 FP pumps For the 50 to 125 FP pumps plugs are located on pipework c The discharge pipe is headed and there is a by pass valve on the check valve open slightly the discharge valve and the by pass of the check valve d When the pump is totally free of air bubbles replace the plugs lt Air escape iiD Bay Le O T ia M JIll li S Hih F D Priming of a flooded pump 5 3 2 Priming of a sump suction pump With foot valve a Fill suction pipe and casing with liquid from an independent source pressure 1 to 2 bars b Let air escape by removing the plugs situated on the flange of the discharge casing and suction casing for the 122 152 to 202 FP pumps For the 50 to 125 FP pumps plugs are located on pipes FP USER INSTRUCTIONS ENGLISH 71576286 07 06 c When the pump is totally free of air bubbles replace the plugs Air escape T m AHHH ia T Z FA Hh a atl AH M A t l o
62. t already possess the necessary knowledge and skill appropriate training and instruction must be provided If required the operator may commission the manufacturer supplier to provide applicable training Always coordinate repair activity with operations and health and safety personnel and follow all plant safety requirements and applicable safety and health laws and regulations FP USER INSTRUCTIONS ENGLISH 71576286 07 06 1 6 3 Safety action This is a summary of conditions and actions to prevent injury to personnel and damage to the environment and to equipment For products used in potentially explosive atmospheres section 1 6 4 also applies AN cancer NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER A ens MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL A DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous FLUORO ELASTOMERS When fitted When a pump has experienced temperatures over 250 C 482 F partial decomposition of fluoro elastomers example Viton will occur In this condition these are extremely dangerous and skin contact must be avoided A 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 a
63. to swing or fall away Never leave a load hanging from a winch The acceleration or the slowing down of lifting equipment must stay in the safety limits for the staff A winch must be positioned in such a way that the load will be raised perpendicularly Where possible necessary precautions must be taken to avoid the swing of the load using for example two winches making approximately the same angle below 30 with the vertical 2 2 2 Pump masses All masses are in kg Mass of 122 bareshaft FP oump 125 152 FP FP 205 530 240 605 275 680 310 755 345 Page 10 of 35 FLOWSERVE An motors for masses see the motor description plate must be handled with a winch A For masses above 25 kg 55 1b manual handling is forbidden 2 3 Lifting 2 3 1 Slinging of motor pumps units A Use handling means in accordance with motor pump unit mass mentioned on the CE plate For the masses of the pumps bare end of shaft see table 2 2 2 and nameplate CAUTION A samon i avoid distortion the pump unit should be lifted as shown Motor pump unit SS p DU a y a p aia f ome a p j ey Lhe Se Bareshaft pump TN TR Ges Pb
64. ust always begin and finish by cleaning the ground and the exterior of the machine If platforms stairs and guardrails are required for maintenance they must be placed 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 EN ihon air or compressed inert gas is used in the maintenance process the operator and anyone in the vicinity must be careful and have the appropriate protection DO NOT SPRAY air or compressed inert gas on skin DO NOT DIRECT an air or gas jet towards other people Never use air or compressed inert gas to clean clothes Before working on the pump take measures to prevent an uncontrolled start Put a warning board on the starting device with the words Machine under repair do not start With electric drive equipment lock the main switch open and withdraw any fuses Put a warning board on the fuse box or main switch with the words Machine under repair do not connect Never clean equipment with inflammable solvents or carbon tetrachloride Protect yourself against toxic fumes when using cleaning agents 6 2 Maintenance schedule x It is recommended that a maintenance plan and schedule is adopted in line with these User Instructions It should include the following FP USER INSTRUCTIONS ENGLISH 71576286 07 06 a The pump must be completely vented and drained a
65. ved on the nameplate x ll 2 GD c IIC 135 C T4 Equipment Group _ 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 prEn13463 5 Gas Group Equipment Category 2 onl 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 temperatures E ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate These are based on a maximum ambient of 40 C 104 F refer to Flowserve for higher ambient temperatures The surface temperature on the pump is influenced by the temperature of the liquid handled The maximum permissible liquid temperature depends on the temperature class and must not exceed the values in the table that follows The temperature rise at the seals bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated Madim m Temperature limit of liquid Temperature surface handled depending on material and construction class to temperature aie prEN 13463 1 ermitted variant check which is P lower T6 85 185 F Consult Flowserve T5 100 212 F Consult Flowserve T4 135 275 F 115 C
66. y 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 FP USER INSTRUCTIONS ENGLISH 71576286 07 06 9 CERTIFICATION Certificates determined from the Contract requirements are provided with these instructions where applicable Examples are certificates for CE marking ATEX marking etc If required copies of other certificates sent separately to the Purchaser should be obtained from the 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 system etc are provided as separate documents in their original 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 its supply a record of the details should be maintained with these User Instructions 10 3 Additional sources of information Reference 1 NPSH for Rotor dynamic Pumps a reference guide Euro pump Guide No 1 Euro pump amp World Pumps Elsevier Science United Kingdom 1999 Reference 2 Pumping Manual 9 edition T C Dick

HP Flowserve 71576286 User's Manual

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