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HP 8-UB-1 User's Manual

1. Pump overheats and seizes J Bearings have short life U Pump vibrates or is noisy Mechanical seal has short life Mechanical seal leaks excessively J Pump requires excessive power Pump loses prime after starting Insufficient pressure developed Insufficient capacity delivered i Pump does not deliver liquid t PROBABLE CAUSES POSSIBLE REMEDIES A SYSTEM TROUBLES 3 Pump not primed Check complete filling e e ele ie or suction pipe not completely filled with Check and complete filling e e e Suction lift too high or level too low ia a i a submergence 0j ojo Excessive amount of air or gas in liquid Check and purge from pipes e Air or vapour pocket in suction line Check suction line design for pockets e e Air leaks into suction line Check airtight pipe then joints and gaskets e e Air leaks into pump through mechanical seal Check airtight assembly then joints and gaskets sleeve joints casing joint or pipe lugs e e Foot valve too small Investigate replacing the foot valve e e Foot valve partially clogged Clean foot valve e 3 Inlet of suction pipe insufficiently submerged Check cut out system design e e e ae of system higher than differential head discnarde oie ie Wane ete neal b ck pressure is not too high e Total head of system lower than pump design Throttle at disch
2. 3 3 Design of major parts 3 3 1 Pump casing The pump has its main casing gasket axial to the shaft allowing maintenance to the rotating element by removing the top half casing Suction and discharge branches are in the bottom half and therefore remain undisturbed 3 3 2 Impellers The impellers are fully shrouded and may be fitted with optional hub rings 3 3 3 Shaft The large diameter stiff shaft mounted on bearings has a keyed drive end 3 3 4 Pump bearings and lubrication Ball bearings are fitted as standard and may be either oil or grease lubricated UB USER INSTRUCTIONS ENGLISH 71569247 07 04 3 3 5 Bearing housing Two grease nipples enable grease lubricated bearings to be replenished between major service intervals 3 3 6 Seal housing The design enables one of 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 operating limits This product has been selected to meet the specifications of your purchase order see section 1 5 The followin
3. 1 972 443 6800 Europe Middle East and Africa Asia Pacific Flowserve Limited Pump Division Flowserve Pte Ltd Pump Division Harley House 94 Hare Lane 200 Pandan Loop 06 03 04 Claygate Esher Surrey KT10 ORB Pantech 21 Singapore 128388 United Kingdom Tel 65 775 3003 Tel 44 0 1372 463 700 Fax 65 779 4607 Fax 44 0 1372 460 190 Visit our web site at www flowserve com Your Flowserve factory contact Your local Flowserve representative Flowserve Pumps Limited PO Box 17 Newark Notts NG24 3EN United Kingdom Telephone 24 hours 44 0 1636 494 600 Sales amp Admin Fax 44 0 1636 705 991 i To find your local Flowserve representative please Repair 8 SENICE FaK AL UOI 400 030 use the Sales Support Locator System found at E mail O www flowserve com Page 32 of 32
4. d Check the level and condition of oil lubricant On grease lubricated pumps check running hours since last recharge of grease or complete grease change e Check any auxiliary supplies eg heating cooling if fitted are functioning correctly R LJ Refer to the manuals of any associated equipment for routine checks needed 6 2 2 Periodic inspection six monthly a Check foundation bolts for security of attachment and corrosion b Check pump running records for hourly usage to determine if bearing lubricant requires changing c The coupling should be checked for correct alignment and worn driving elements R LJ Refer to the manuals of any associated equipment for periodic checks needed 6 2 3 Re lubrication Lubricant and bearing temperature analysis can be useful in optimizing lubricant change intervals In general however the following is recommended See section 5 2 1 for grease recommendations UB USER INSTRUCTIONS ENGLISH 71569247 07 04 Regrease via grease nipples every 2 000 hours or sooner depending on the severity of the application a Itis important not to under or over grease the bearings as this will lead to over heating and premature failure Grease lubricated bearing housings have grease nipples fitted in the bearing brackets b The maximum allowable operating temperatures for anti friction bearings will vary from unit to unit depending on ambient and fluid temperature The rise above ambi
5. required Bedding in of the packing may take another 30 minutes Care must be taken when adjusting the gland on an operating pump Safety gloves are essential Loose clothing must not be worn to avoid being caught up by the pump shaft Shaft guards must be replaced after the gland adjustment is complete Never run gland packing dry even for a short time 5 7 3 Pumps fitted with mechanical seal Mechanical seals require no adjustment Any slight initial leakage will stop when the seal is run in Before pumping dirty liquids it is advisable if possible to run in the pump mechanical seal using clean liquid to safeguard the seal face External flush or quench should be started before the pump is run and allowed to flow for a period after the pump has stopped CAUTION Never run a mechanical seal dry even for a short time 5 7 4 Bearings x If the pumps are working in a potentially explosive atmosphere temperature or vibration monitoring at the pump bearings is recommended Page 18 of 32 FLOWSERVE ERY 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 adjacent to the bearing 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
6. 20 1 20 1 60 8 UB 1 1653 1299 944 3134 1659 2212 863 989 719 1622 885 1180 Notes 1 F External force tension or compression M External moment clockwise or counter clockwise 2 Forces and moments may be applied simultaneously in any direction 3 Values apply to all materials 4 Higher loads may be applicable if direction and magnitude of individual loads are known but these need written approval from Flowserve Pumps 5 Pumps must be on rigid foundations and baseplates must be fully grouted 6 Pump baseplate should not be used as pipe anchor Suction and discharge piping should be anchored as close as possible to the pump flanges to reduce vibration and prevent strain on the pump casing Expansion joints are recommended They must be properly tied and located on the side of the pipe anchor away from the pump 7 The pump mounting bolt torques specified must be used to prevent relative movement between the pump casing and baseplate See section 6 6 Fastener torques The bolt material must have a minimum yield strength of 600 N mm 87 000 Ib in 4 5 4 Discharge piping See section 4 5 2 for typical pipework design A non return valve should be located in the discharge pipework to protect the pump from excessive back pressure and hence reverse rotation when the unit is stopped Pipework reducers should have a maximum total angle of divergence of 9 degrees Fitting an isolat
7. 5 9 2 Viscosity For a given flow rate the total head reduces with increased viscosity and increases with reduced viscosity Also for a given flow rate the power absorbed increases with increased viscosity and reduces with reduced viscosity It is important that checks are made with your nearest Flowserve office if changes in viscosity are planned 5 9 3 Pump speed Changing pump speed effects flow total head power absorbed NPSHrp 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 NPSH gt NPSHp and that noise and vibration are within local requirements and regulations Page 19 of 32 FLOWSERVE ERY 5 9 4 Net positive suction head NPSH NPSH available NPSH is a measure of the head available in the pumped liquid above its vapour pressure at the pump suction branch NPSH required NPSH is a measure of the head required in the pumped liquid above its vapour pressure to prevent the pump from cavitating It is important that NPSHA gt NPSHr The margin between NPSH gt NPSHrp should be as large as possible If any change in NPSH is proposed ensure these margins are not significantly eroded Refer to the pump pe
8. Fit casing gasket to the bottom half horizontal flange using a small amount of contact adhesive to prevent movement when the top half is fitted Do not apply adhesive to the top surface of the gasket b Itis important that the external corner of the casing gasket face and the stuffing box face is as sharp as possible A alt Do not chamfer with a file c If necessary trim gasket to match volute profile Do not trim to stuffing box face at this stage 6 10 3 Rotating element and bearing bracket a Ensure all gaskets and O rings are renewed and replaced in the correct position during assembly b Assemble the impellers on the shaft It is important to mount the impellers so that the vane tips point away from the apparent flow direction Page 24 of 32 FLOWSERVE ERY DISCHARGE a SUCTION The rotor always rotates towards the expanding section of the volute The diaphragm plate complete with its bush must be fitted on to the shaft between the two impellers Fit the two shaft sleeves O rings when fitted and shaft nuts and lightly secure the impellers on the shaft Take care to protect the sleeve O rings when fitted from damage on the shaft threads The sleeves and nuts define the impeller position on the pump shaft and hence in the pump casing Initially position the impellers centrally on its keyway This position may be adjusted slightly later on in the assembly process It is recommended that gasket s
9. Warning labels 1 7 2 sessseeessssesserrsseersseerrsssenssee 8 Page 3 of 32 FLOWSERVE ERY 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 commitment to continuous quality control utilising 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 These instructions should be read prior to installing operating using and maintaining the equipment in any region worldwide The equipment must not be put into service unti
10. 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 Rotordynamic Pumps a reference guide Europump Guide No 1 Europump amp World Pumps Elsevier Science United Kingdom 1999 Reference 2 Pumping Manual gt edition T C Dickenson Elsevier Advanced Technology United Kingdom 1995 Reference 3 Pump Handbook a 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 UB USER INSTRUCTIONS ENGLISH 71569247 07 04 Page 31 of 32 UB USER INSTRUCTIONS ENGLISH 71569247 07 04 FLOWSERVE FLOWSERVE REGIONAL SALES OFFICES USA and Canada Latin America and Caribbean Flowserve Corporation Pump Division Flowserve Corporation Pump Division 5215 North O Connor Blvd Suite 2300 6840 Wynnwood Lane Irving Texas 75039 USA Houston Texas 77008 USA Tel 1 972 443 6500 Tel 1 713 803 4434 Toll free 800 728 PUMP 7867 Fax 1 713 803 4497 Fax
11. cover complete with gasket Fit the coupling distance piece and pump half coupling Fit copper lockwasher and secure coupling nut Peen a segment of the copper lockwasher over a flat on the coupling nut 6 10 4 Casing lower half If required drive in two new locating dowels on the horizontal flange Coat the faces of the bearing housing brackets with liquid sealant to protect against corrosion Place the complete rotating assembly into the casing ensuring that impeller rings and diaphragm plate are in the correct position to allow the anti rotation tongues to locate correctly in the anti rotation grooves in the casing bores The anti rotation grooves in the bottom half casing are bigger in diameter than those in the top Locate the bearing housings in the machined spigots in the casing and torque up the fixing Screws Check rotor for free rotation Centralize the impellers within the casing waterway by adjusting the shaft nut if necessary Using a C spanner fully tighten the shaft nuts and lock with the two radial socket head screws Set the seals if fitted to the correct working length and tighten the seal collar screws Lt Refer to any special instructions supplied with the mechanical seal Check for free rotation Page 25 of 32 UB USER INSTRUCTIONS ENGLISH 71569247 07 04 FLOWSERVE ERY 6 10 5 Casing upper half a Assemble the casing upper half over the lower half Take care to ensure the rene
12. due to joint failure Replace joint and check for damage o olo Mechanical seal improperly installed Check alignment of faces or damaged parts and assembly method used elele Incorrect type of mechanical seal for operating Consult Flowserve conditions e eie eie e Shaft running off centre because of worn beet a and od j T bearings or misalignment alignment satisfactory check bearings for excessive wear 0 00 o Impeller out of balance resulting in vibration Check and consult Flowserve 0j ojo Abrasive solids in liquid pumped Check and consult Flowserve ele Mechanical seal was run dry Check mechanical seal condition and source of dry running and repair o o o o o o Internal misalignment due to improper repairs Check method of assembly possible damage or causing impeller to rub state of cleanliness during assembly elele Excessive thrust caused by a mechanical failure Check wear condition of impeller its clearances inside the pump and liquid passages e e Excessive grease in ball bearings Check method of regreasing ele Lack of lubrication for bearings Check hours run since last change of lubricant the schedule and its basis ele Improper installation of bearings Check method of assembly possible damage or state of cleanliness during assembly and type of bearing used e e Damaged bearings due to contamination Check contamination Source and replace damaged bearings C ELECTRICAL TROUBLES o e e e Wrong direction of rotation Reverse 2 ph
13. induced current generating a spark the earth contact on the baseplate must be used Avoid electrostatic charge do not rub non metallic surfaces with a dry cloth ensure cloth is damp The coupling must be selected to comply with 94 9 EC and correct alignment must be maintained 1 6 4 6 Preventing leakage The pump must only be used to handle liquids for which it has been approved to have the correct corrosion resistance Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves which could cause dangerous excessive pressures to 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 co
14. removing shaft nut If difficulties in sourcing are encountered consult Flowserve 6 6 Fastener torques Bolt size Torque Nm Ibf ft iz Pump feet All other fasteners fasteners MB 46 in 10 7 M10 in 20 15 M12 in 63 46 34 25 M16 in 170 125 84 62 M20 in 340 250 165 120 M24 in 590 435 285 210 6 7 Renewal clearances As wear takes place between the impeller casing ring and diaphragm bush the overall efficiency of the pump set will decrease To maintain optimum efficiency it is recommended that rings and bush are replaced and the impeller renovated when the radial clearance detailed in section 3 4 2 has doubled 6 8 Disassembly Refer to section 1 6 Safety before dismantling the pump CAUTION A Before dismantling the pump for overhaul ensure genuine Flowserve replacement parts are available UB USER INSTRUCTIONS ENGLISH 71569247 07 04 To dismantle the pump consult the sectional drawings See section 8 Parts lists and drawings a Isolate motor and lock off electrical supply in accordance with local regulations b Isolate suction and discharge valves c Remove coupling guards and disconnect the coupling halves d Drain pump casing Remove any auxiliary piping if applicable e Release the copper lockwasher securing the coupling nut and remove the pump half coupling f Unbolt the glands seal covers from the casing If glands
15. sheets and manuals Typical sound pressure level dBA L at 1 m reference 20 Pa Lwa sound power 1 pW where Lpa gt 85 dBA 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 88 66 83 64 81 62 79 64 81 62 79 63 80 62 79 0 75 1 74 91 66 83 67 84 62 79 67 84 62 79 63 80 62 79 1 1 1 5 74 91 68 85 67 84 64 81 67 84 64 81 65 82 64 81 1 5 2 77 94 70 87 70 87 66 83 70 87 66 83 66 83 66 83 2 2 3 78 95 72 89 71 88 68 85 71 88 68 85 68 85 68 85 3 4 81 98 74 91 74 91 70 87 74 91 70 87 70 87 70 87 4 5 82 99 75 92 75 92 71 88 75 92 71 88 71 88 71 88 5 5 7 5 90 107 77 94 83 100 73 90 76 93 73 90 72 89 71 88 7 5 10 90 107 78 95 83 100 74 91 77 94 74 91 73 90 72 89 11 15 91 108 80 97 84 101 76 93 78 95 76 93 74 91 73 90 15 20 92 109 83 100 85 102 79 96 80 97 79 96 76 93 75 92 18 5 25 92 109 83 100 85 102 79 96 80 97 79 96 76 93 75 92 22 30 92 109 83 100 85 102 79 96 81 98 79 96 77 94 75 92 30 40 100 117 85 102 93 110 81 98 84 101 80 97
16. 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 situations consideration must be given to the fitting of an acoustic enclosure to meet local regulations Pump noise level is dependent on a number of factors the type of motor fitted the operating capacity pipework design and acoustic characteristics of the building Typical sound pressure levels measured in dB and A weighted are UB USER INSTRUCTIONS ENGLISH 71569247 07 04 The figures are indicative only they are subject to a 3 dB tolerance and cannot be guaranteed The values are based on the noisiest ungeared electric motors that are likely to be encountered They represent sound pressure levels at 1m 3 3 ft from the directly driven pump for free field over a reflecting plane If a pump unit only has been purchased for fitting with your own driver then the pump only noise levels from the table should be combined with the level for the driver obtained from the supplier If the motor is driven by an inverter it may show an increase in noise level at some speeds Consult a Noise Specialist for the combined calculation LH For units driven by equipment other than electric motors or units contained within enclosures see the shown in the table below accompanying information
17. the suction and discharge pipework Check also the tightness of all foundation bolts 4 6 Final shaft alignment check After connecting piping to the pump rotate the shaft several times by hand to ensure there is no binding and all parts are free Recheck the coupling alignment as previously described to ensure no pipe strain If pipe strain exists correct piping 4 7 Electrical connections DANGER 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 Avo bt contact Flowserve for advice DANGER 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 devic
18. 80 97 76 93 37 50 100 117 86 103 93 110 82 99 84 101 80 97 80 97 76 93 45 60 100 117 87 104 93 110 83 100 84 101 80 97 80 97 76 93 55 75 100 117 88 105 95 112 84 101 86 103 81 98 82 99 77 94 75 100 100 117 90 107 95 112 86 103 88 105 81 98 83 100 78 95 90 120 100 117 90 107 95 112 86 103 90 107 81 98 85 102 78 95 110 150 100 117 91 108 95 112 87 104 91 108 83 100 86 103 79 96 150 200 101 118 92 109 96 113 88 105 91 108 83 100 86 103 79 96 200 270 83 100 80 97 300 400 84 101 81 98 500 670 85 102 83 100 1000 1300 86 103 86 103 1500 2000 90 107 88 105 Motors in this range are generally job specific and noise levels should be calculated based on actual equipment installed For 960 r min reduce 1450 r min values by 5 dBA Page 9 of 32 FLOWSERVE ERY 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 crates box
19. C 212 F for oil lubrication and 105 C 220 F for grease lubrication It is important particularly with grease lubrication to keep a check on bearing temperatures After start up the temperature rise should be gradual reaching a maximum after approximately 1 5 to 2 hours This temperature rise should then remain constant or marginally reduce with time Refer to section 6 2 3 1 for further information 5 7 5 Normal vibration levels alarm and trip For guidance pumps generally fall under a classification for rigid support machines within the International rotating machinery standards and the recommended maximum levels below are based on those standards A caution sare and trip values for installed pumps should be based on the actual measurements N taken on the pump in the fully commissioned as new condition Measuring vibration adjacent to the pump bearings at regular intervals will then show any deterioration in pump or system operating conditions Vibration velocity unfiltered Horizontal Vertical mm s in s r m s pumps pumps Normal N lt 5 6 0 22 lt 7 1 0 28 Alarm N x 1 25 lt 7 1 0 28 lt 9 0 0 35 Shutdown trip N x 2 0 lt 11 2 0 44 lt 14 2 0 56 5 7 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 commiss
20. GLISH 71569247 07 04 The positioning of these accessories must not limit access or hinder the lifting of the part to be serviced When air or compressed inert gas is used in the maintenance process the operator and anyone in the vicinity must be careful and have the appropriate protection Do not spray air or compressed inert gas on skin Do not direct an air or gas jet towards other people Never use air or compressed inert gas to clean clothes Before working on the pump take measures to prevent an uncontrolled start Put a warning board on the starting device with the words Machine under repair do not start With electric drive equipment lock the main switch open and withdraw any fuses Put a warning board on the fuse box or main switch with the words Machine under repair do not connect Never clean equipment with inflammable solvents or carbon tetrachloride Protect yourself against toxic fumes when using cleaning agents 6 2 Maintenance schedule It is recommended that a maintenance plan and schedule is adopted in line with these User Instructions It should include the following a Any auxiliary systems installed must be monitored if necessary to ensure they function correctly b 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 c Check for any leaks from gaskets and seals The
21. ONS ENGLISH 71569247 07 04 8 1 3 Options parts list Ref no Description 34 Mechanical seal Mechanical seal cover Gasket mechanical seal cover Socket head screw for 38 a Seal abutment ring a Cartridge seal assembly Impeller nut Impeller wear ring 46 Socket head screw for 45 a When fitted depends on type of mechanical seal Xi J Cartridge mechanical seal 8 2 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 30 of 32 FLOWSERVE ERY 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
22. TEN KORREKT AXIAL AUSRICHTEN DANN PUMPE AUF GRUNDPLATTE FESTSPANNEN UND ANSSCHLUSSLEITUNGEN BEFESTIGEN TOLERANZEN S BEDIEUNGSANLEITUNG 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 GEINSTALLEERD ZIJN ZIE HANDLEIDING VOOR TOELAABARE SPELINGEN CDC 603 604 610 612 621 623 624 Oil lubricated units only WARNING Q ATTENTION ACHTUNG J218JZ262 THIS MACHINE MUST BE FILLED WITH OIL BEFORE STARTING CETTE MACHINE DOIT TRE REMPLIE D HUILE AVANT LA MISE EN MARCHE DIESE MASCHINE IST VOR DEM STARTEN MIT L Z FULLEN r 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 32 FLOWSERVE ERY 1 9 Noise level When pump noise level exceeds 85 dB A 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
23. TIONS ENGLISH 71569247 07 04 Suction isolating valve EN gt 5D a pet O pump suction LELELE Note Ideally reducers should be limited to one pipe diameter change ie 150 mm 6 in to 200 mm 8 in Must have a maximum total angle of divergence of 15 degrees Typical design suction lift CER Slope up from Discharge isolating valve Non return valve Concentric conical reducer Eccentric conical reducer Slope down from pump suction RY Notes 1 S Minimum submergence gt 3E 2 Ideally reducers to be limited to one pipe diameter change ie 150 mm 6 in to 200 mm 8 in Must have a maximum total angle of divergence of 15 degrees Long radius bend Page 14 of 32 FLOWSERVE ERY UB USER INSTRUCTIONS ENGLISH 71569247 07 04 4 5 3 Maximum forces and moments allowed on the pump suction and discharge flanges of horizontal shaft pumps Fz SUCTION Maximum forces F in KN Ibf and maximum moments M in kNm Ibf ft Type and size Suction Discharge Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz 7 35 5 78 4 20 4 25 2 25 3 00 3 84 4 40 3 20 2
24. a N FLOWSERVE T gt Pump Division Type 8 UB 1 CENTRIFUGAL PUMP USER INSTRUCTIONS INSTALLATION OPERATION MAINTENANCE PCN 71569247 07 04 E supercedes 6176 6511 A These instructions must be read prior to installing operating using and maintaining this equipment UB USER INSTRUCTIONS ENGLISH 71569247 07 04 FLOWSERVE CONTENTS Page 2 of 32 FLOWSERVE ERY INDEX PAGE Additional sources 10 3 31 Alignment of shafting 4 2 4 4 and 4 6 Assembly 6 10 ER 24 ATEX marking 1 6 4 2 aeesseeeseeerrsseerrsseerrsseenssns 7 CE marking and approvals 1 2 4 Certification 9 ceeecceeeseneeeeeesteeeeeeneeeeseneeeeeenaes 31 Change notes 10 2 0 eeeeeesteeeeeenteeeeeenteeeeeeaaes 31 Clearances 6 7 Renewal clearances 08 23 Commissioning and operation 5 ceeeeeeeeee 16 Compliance ATEX 1 6 4 1 6 Configurations 3 1 cceeeeecceeeesneeeeeeeieeeeeeneeeeseaaes 11 Consumable items 6 4 ceeeeeeeeeeeeeeeeeeeteeeeeeaes 22 Copyright 1 4 esnean aain 4 Design of major parts 3 3 oo eeeeeeeeeereeeeeeeneees 11 Direction of rotation 5 3 eeeeeeeseeeeeeeeeeeeteeneees 17 Disassembly 6 8 J ren aaa 23 Disclaimer 13 heei 4 Dismantling 6 8 Disassembly ceeeeeeeeeeeee 23 Drowngs 0 seraa E E 29 Duty conditions 1 5 ssrissneii aa 4 Electrical connections 4 7 o e 16 End of product life 2 5 ssssssiseisiiinnaininnniniii skias 10 Examinatio
25. allation and severity of service will determine the frequency of lubrication Lubricant and bearing temperature analysis can be useful in optimising lubricant change intervals The bearing temperature may be allowed to rise to 55 C 131 F above ambient but should not exceed 95 C 204 F For most operating conditions a quality grease having a lithium soap base and NLGI consistency of No 2 or No 3 is recommended The drop point should exceed 175 C 350 F CAUTION A Never mix greases containing different bases thickeners or additives UB USER INSTRUCTIONS ENGLISH 71569247 07 04 5 3 Direction of rotation CAUTION Ensure the pump is given the same rotation as the pump direction arrow cast on the pump casing To avoid dry running the pump must either be filled with liquid or have the flexible coupling disconnected before driver is switched on CAUTION If maintenance work has been carried out to the site s electricity supply the direction of rotation should be re checked as above in case the supply phasing has been altered 5 4 Guarding Guarding is supplied fitted to the pump set If this has been removed or disturbed ensure that all the protective guards around the pump coupling and exposed parts of the shaft are securely fixed 5 5 eal and auxiliary supplies Ensure all electrical hydraulic pneumatic sealant and lubrication systems as applicable are connected and operational EA Ens
26. are split type remove completely g With a suitable punch drive out the two locating dowels which are used on the horizontal split flange to align the upper and lower half casings h Remove the bolts which hold the upper and lower half of the casing together and remove the upper half Tapped holes are provided in the joint flange to enable the use of forcing bolts to loosen the joint i Lift the casing upper half using the two eye bolts provided Do NOT use this method to lift the bottom half or complete pump casing j Remove the 6 screws securing each bearing bracket to the bottom half casing k Lift out rotor assembly Use care in slinging handling and supporting of the rotor for subsequent dismantling Place rotor securely on two support blocks 1 When removing the rotor assembly the casing rings and diaphragm plate will be loosely attached to the rotor m Remove bearing covers and slide bearing housings off bearings n Release the copper lockwasher securing the bearing locknut at the non drive end and remove the locknut Pull off both ball bearings using a suitable puller ensuring force is applied to inner race only Retain the bearing distance pieces and coupling distance piece for future use Remove the bearing covers o Depending on configuration remove glands seal covers packing and lantern ring mechanical seal Lt Refer to any special instructions supplied with the mechanical seal p Remove the
27. arge valve or ask Flowserve if the head impeller can be trimmed e Specific gravity of liquid different from design Consult Flowserve e e e Viscosity of liquid differs from design Consult Flowserve e e Operation at very low capacity Measure value and check minimum permitted e e e Operation at high capacity Measure value and check maximum permitted B MECHANICAL TROUBLES ojoj ojojo Misalignment due to pipe strain o ae ena permitted e Improperly designed foundation A a tighten adjust grout 0 0 0j ojo Shaft bent Check shaft runouts within acceptable values 0j ojo e Rotating part rubbing on stationary part internally is a of this and consult Flowserve if j ojojo o Bearings worn Replace bearings 3 0o Wearing ring surfaces worn Replace worn wear ring surfaces Page 27 of 32 FLOWSERVE ERY FAULT SYMPTOM UB USER INSTRUCTIONS ENGLISH 71569247 07 04 Pump overheats and seizes Bearings have short life Pump vibrates or is noisy Mechanical seal has short life Mechanical seal leaks excessively J Pump requires excessive power Pump loses prime after starting J Insufficient pressure developed Insufficient capacity delivered Pump does not deliver liquid PROBABLE CAUSES POSSIBLE REMEDIES e e e Impeller damaged or eroded Replace impeller and check reason e Leakage under sleeve
28. ases on motor terminal box o e e Motor running too slow Check motor terminal box connections Page 28 of 32 FLOWSERVE ERY 8 PARTS LISTS AND DRAWINGS 8 1 Sectional drawings 8 UB 1 grease lubricated gland packed UB USER INSTRUCTIONS ENGLISH 71569247 07 04 21 29 25 26 27 28 PEPE 2 20A 10 11 9 20 2 23 24 30 Taken from A767 112 8 1 1 Parts list Ref no Description 12 Casing wear ring 22 Water shield 1 Nameplate 13 Diaphragm plate 23 Bearing cover 2 Bearing locknut 14 Diaphragm bush 24 Gasket bearing cover 3 Lockwasher bearing locknut 15 Impeller first stage 25 Ball bearing line 4 Ball bearing thrust 15A Impeller second stage 26 Grease nipple 5 Shaft collar 16 Key impeller 27 Shaft 6 Gland 17 Seal pipe assembly 28 Key coupling 7 Lantern ring 18 Shaft sleeve 29 Bearing distance piece 8 Gland packing 19 Shaft nut 30 Coupling distance piece 9 Casing upper half 20 Bearing bracket Drive end 31 Coupling nut 10 Casing lower half 20A Bearing bracket Non drive end 32 Lockwasher for coupling nut 11 Gasket horizontal split 21 Socket head screw for 19 amp 38 Page 29 of 32 FLOWSERVE ERY 8 1 2 Options 46 45 View on Z impeller ring 37 34 36 UB USER INSTRUCTI
29. ations Genuine parts and accessories have been designed tested and incorporated into the products to help ensure their continued product quality and performance in use As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products The failure to properly select install or use authorised Flowserve parts and accessories is considered to be misuse Damage or failure caused by misuse is not covered by 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 chang
30. correct functioning of the shaft seal must be checked regularly d Check bearing lubricant level and if the hours run show a lubricant change is required e Check that the duty condition is in the safe operating range for the pump 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 Page 20 of 32 FLOWSERVE ERY Our specialist service personnel can help with preventative maintenance records and provide condition monitoring for temperature and vibration to identify the onset of potential problems If any problems are found the following sequence of actions should take place a Refer to section 7 Faults causes and remedies for fault diagnosis b Ensure equipment complies with the recommendations in this manual c Contact Flowserve if the problem persists 6 2 1 Routine inspection daily weekly The following checks should be made and the appropriate action taken to remedy any deviations a Check operating behaviour Ensure noise vibration and bearing temperatures are normal b Check that there are no abnormal fluid or lubricant leaks static and dynamic seals and that any sealant systems if fitted are full and operating normally c Check that shaft seal leaks are within acceptable limits
31. e to provide emergency stopping must be fitted UB USER INSTRUCTIONS ENGLISH 71569247 07 04 If not supplied pre wired to the pump unit the controller starter electrical details will also be supplied within the controller starter For electrical details on pump sets with controllers see the separate wiring diagram Nene See section 5 3 Direction of rotation before connecting the motor to the electrical supply 4 8 Protection systems The following protection systems are recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous liquid If in doubt consult Flowserve If there is any possibility of the system allowing the pump to run against a closed valve or below minimum continuous safe flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsafe level If there are any circumstances in which the system can allow the pump to run dry or start up empty a power monitor should be fitted to stop the pump or prevent it from being started This is particularly relevant if the pump is handling a flammable liquid If leakage of product from the pump or its associated sealing system can cause a hazard it is recommended that an appropriate leakage detection system is installed To prevent excessive surface temperatures at bearings it is recommended that temperature or vibration monitoring are carried out See sections 5 7 4 a
32. ealing compound Loctite 574 or equivalent is used between sleeve and impeller mating faces to protect the shaft from the liquid pumped When mechanical seals are fitted the rotating parts can be slid onto the sleeves before the sleeves are fitted onto the shaft The seal locking collars should be left loose Lt Refer to any special instructions supplied with the mechanical seal If gland packing is used fit the glands Fit seal covers complete with seal seat water throwers and bearing covers complete with gaskets Fit the bearings onto the shaft The main thrust bearing is at the non drive end ieee Where double row bearings are fitted these must be assembled back to back as below ERN UB USER INSTRUCTIONS ENGLISH 71569247 07 04 The bearings must be heated up to 100 C 212 F using a hot plate oil bath or induction heater and slid onto the shaft Ensure bearing is fully seated against the bearing distance piece and the distance piece is located up to the shaft shoulder Fill both sides of bearing with grease Fit the bearing lockwasher and tighten the bearing shaft nut Peen a segment of the copper lockwasher over a flat on the bearing locknut Slip casing rings loosely over the impeller hubs Slide the bearing housings over the bearings Ensure bearings are located square in the bracket bore One third fill the space between bearing cover and bearing with grease Secure bearing
33. eals if fitted a The lubricant bearings and bearing housing seals are to be inspected for contamination and damage b If bearing damage is not due to normal wear and the lubricant contains adverse contaminants the cause should be corrected before the pump is returned to service c Labyrinth seals and bearing isolators should be inspected for damage but are normally non wearing parts and can be re used UB USER INSTRUCTIONS ENGLISH 71569247 07 04 d Bearing seals are not totally leak free devices Oil from these may cause staining adjacent to the bearings 6 10 Assembly To assemble the pump consult the sectional drawings see section 8 Parts list and drawings Ensure threads gasket and O ring mating faces are clean Apply thread sealant to non face sealing pipe thread fittings Coat the outside diameter of the dowel bushings with pipe compound prior to installation 6 10 1 Impeller wear rings a Impeller rings when fitted should be heated up to approximately 100 C 212 F using a hotplate or hot oil bath and then slipped onto the impeller and pressed down to the shoulder Do NOT use a steel hammer to knock them into position b Drill and tap 3 holes approximately 120 degrees apart into the diametral mating faces of the ring and impeller and insert socket head screws The existing half tapped holes from the removed impeller ring cannot be re used 46 n n 6 10 2 Pre assembly of casing gasket a
34. ed 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 32 FLOWSERVE ERY 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 DANGER This symbol indicates electrical safety instructions where non compliance will involve a high risk to personal safety or the loss of life This symbol indicates safety instructions where non compliance would affect personal safety and could result in loss of life A This symbol indicates hazardous and toxic fluid safety instructions where non compliance would affect personal safety and could result in loss of life Pe og 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 diaii 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
35. eeteeteeeeeeeeeees 16 Priming and auxiliary supplies 5 5 0 eee 17 Protection systems 4 8 cecceeeeeeeeeeeeeneeeeeeeeees 16 Reassembly 6 10 Assembly s 24 Receipt and unpacking 2 1 aseeseen 10 Recommended grease lubricants 5 2 1 17 Recommended spares 6 4 ccceeseeeeeeeeeeeseneees 22 Recycling 2 5 ooo eeeeceeeeeseeeeeeeseeeeeeeteeeeeeteeeeeeeeenaees 10 Renewal clearances 6 7 23 Replacement parts 6 3 and 6 4 22 Running the pump 5 7 cceeceeeeseeeeeeeeeeeteeeseeeeees 18 Safety action 1 6 3 oo eceeeceeeeeeeeesneeeeeenteeeeeeaes 5 Safety markings 1 6 1 eeeeceeseeeeeeesteeeeeeenteeeeeeaes 5 Safety protection systems 1 6 and 4 8 Sectional drawings 8 c eceeeeeeeeesteeeeeesteeeeeeaes 29 Sound pressure level 1 9 Noise level e ee 9 Sources additional information 10 3 ee 31 Spare Parts 6 3 ses ccccsiec desigeeceevisescdedvgedeeevinvenectees 22 Specific machine performance 1 8 n 8 Starting the pump 5 6 ee eeeeeeeeeeseeeeeeeneeeeeeaes 18 Stop start frequency 5 7 6 19 Stopping and shutdown 5 8 eseese 19 Storage PUMP 2 4 asieran 10 Storage spare parts 6 3 2 L e 22 Supplementary manuals or information sources 31 Supplementary User Instructions 10 1 31 Tools required 6 5 eeceeeeeeeeeeeeeeeeeeeneeeeeeeneeeeeeaas 23 Torques for fasteners 6 6 23 Trouble shooting see 7 27 Vibration 9 T D ennan A 19
36. emperature depends on the temperature class and must not exceed the values in the table that follows The temperature rise at the seals and bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated Maximum Temperature limit of liquid aes surface handled Seconda ch prEN 13463 1 temperature material and construction 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 The responsibility for compliance with the specified maximum liquid temperature is with the plant operator UB USER INSTRUCTIONS ENGLISH 71569247 07 04 Temperature classification Tx is used when the liquid temperature varies and the pump could be installed in different hazarous 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 Where there is any risk of the pump being run against a closed valve gen
37. ent should not normally exceed 55 C 131 F or a combined maximum of 95 C 204 F c A continuously rising temperature or an abrupt temperature rise indicates a problem If these symptoms occur stop the pump immediately and investigate the cause A TEMPERATURE TIME Grease change every 4 000 hours or sooner depending on the severity of the application a Remove the bearing bracket from the rotor assembly b Brush the bearing bracket with hot kerosene 100 to 115 C 212 to 240 F or other non toxic solvent c Clean and flush out the housing with a light mineral oil d Do not use waste oil to clean the housing To clean the bearings a Wipe off as much grease as possible with a clean lint free cloth b Brush bearings with hot kerosene 80 to 90 C 175 to 195 F while gently spinning the outer bearing ring c Spin each ball to ensure that it is clean Page 21 of 32 FLOWSERVE ERY To remove badly oxidized grease that refuses to come off a Support the rotor in a vertical position and immerse the bearing in hot kerosene or a mixture of alcohol and light mineral solvent b Gently spin the bearing outer ring Dry and reflush the bearing with clean light oil d Itis important not to under or over grease the bearings as this will lead to over heating and premature failure Itis recommended that the bearin
38. erating 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 environments regular checks must be made and dirt removed from areas around close clearances bearing housings and motors 1 6 4 4 Preventing the build up of explosive mixtures ENSURE THE PUMP IS PROPERLY FILLED AND VENTED AND DOES NOT RUN DRY Ensure the pump and relevant suction and discharge pipeline system is totally filled with liquid at all times during the pump operation so that an explosive atmosphere is prevented In addition it is essential to make sure that seal chambers auxiliary shaft seal systems and any heating and cooling systems are properly filled If the operation of the system cannot avoid this condition the fitting of an appropriate dry run protection device is recommended for example liquid detection or a power monitor To avoid potential hazards from fugitive emissions of vapour or gas to atmosphere the surrounding area must be well ventilated 1 6 4 5 Preventing sparks To prevent a potential hazard from mechanical contact the coupling guard must be non sparking and anti static for Category 2 Page 7 of 32 FLOWSERVE ERY To avoid the potential hazard from random
39. es and 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 2 3 Lifting A camon avoid distortion the pump unit should be lifted as shown UB USER INSTRUCTIONS ENGLISH 71569247 07 04 Vw KOK When there are no specific lifting points on the baseplate A A crane must be used for all pump sets in excess of 25 kg 55 Ib Fully trained personnel must carry out lifting in accordance with local regulations The driver weight is recorded on its nameplate or massplate 2 4 Saal e Store 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 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
40. g 55 Ib use a crane appropriate for the mass and in accordance with current local regulations THERMAL SHOCK Rapid changes in the temperature of the liquid within the pump can cause thermal shock which can result in damage or breakage of components and should be avoided APPLYING HEAT TO REMOVE IMPELLER There may be occasions when the impeller has either been shrunk fit on to the pump shaft or has become difficult to remove due to products of corrosion If you elect to use heat to remove the impeller it must be applied quickly to the impeller boss TAKE GREAT CARE Before applying heat ensure any residual hazardous liquid trapped between the impeller and pump shaft is thoroughly drained out through the impeller keyway to prevent an explosion or emission of toxic vapour This must be carried out with the shaft in the vertical position On some pump sizes a cavity exists in the impeller bore so on occasions a significant volume of liquid may drain out Page 5 of 32 FLOWSERVE ERY 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 mot
41. g driver 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 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 32 FLOWSERVE ERY 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 ll 2 GD c 135 C T4 Equipment Group Ooo o 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 Maximum surface temperature Temperature Class See section 1 6 4 3 1 6 4 3 Avoiding excessive surface temperatures ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate These are based on a maximum ambient of 40 C 104 F refer to Flowserve for higher ambient temperatures The surface temperature on the pump is influenced by the temperature of the liquid handled The maximum permissible liquid t
42. g data is included as additional information to help with your installation It is typical and factors such as temperature materials and seal type may influence this data If required a definitive statement for your particular application can be obtained from Flowserve 3 4 1 Operating limits 20 to 120 C 4 to 250 F 20 to 40 C 4 to 104 F up to 3 by volume refer for size limits Maximum pump speed refer to the nameplate Subject to written agreement from Flowserve Pumped liquid temperature limits Maximum ambient temperature Maximum soft solids in suspension 3 4 2 Pump and impeller data Impeller Nominal Mean Pump minimum wear radial size passage ring wear ring size diameter clearance mm in mm in mm in 8 UB 1 17 5 0 69 266 7 10 5 0 19 0 0075 May be up to 0 13 mm 0 005 in larger if casing ring and impeller have a tendency to gaul Nominal diaphragm Mean radial Pump bush diameter bush clearance size mm in mm in 8 UB 1 127 5 0 11 0 0045 Page 11 of 32 FLOWSERVE ERY 4 INSTALLATION amp Equipment operated in hazardous locations must comply with the relevant explosion protection regulations See section 1 6 4 Products used in potentially explosive atmospheres 4 1 Location The pump should be located to allow room for access ventilation maintenance and inspection wit
43. gs be filled with grease using a suitable spatula In addition the housings should be no more than half filled 6 2 4 Mechanical seals No adjustment is possible When leakage reaches an unacceptable level the seal will need replacement 6 2 5 Gland packing The stuffing box gland can be backed off for re packing or to enable the addition of extra rings of packing The stuffing box is normally supplied with a lantern ring to enable a clean or pressurised flush to the centre of the packing If not required this can be replaced by an extra 2 rings of packing There must always be a small leakage normally a minimum of 120 drops per minute to atmosphere to lubricate and cool the packing is required UB USER INSTRUCTIONS ENGLISH 71569247 07 04 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 2 Pump size 3 Part name taken from section 8 4 Part number taken from section 8 5 Number of parts required The pump size and serial number are shown on the pump nameplate To ensure continued satisfactory operation replacement parts to the original design specification should be obtained from Flowserve Any change to the original design specification modification or use of a non standard part will invalidate the pump s safety certification 6 3 2 Storage of spares S
44. h 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 Foundation A ee 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 Ensure the following are met a The baseplate 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 b Install the baseplate onto packing pieces evenly spaced and adjacent to foundation bolts c Level with shims between baseplate and packing pieces d The pump and driver have been aligned before dispatch however the alignment of pump and motor half coupling must be checked If this is incorrect it indicates that the baseplate has become twisted and should be corrected by re shimming UB USER INSTRUCTIONS ENGLISH 71569247 07 04 e If the pump is driven via a universal joint drive shaft there may be a requirement to offset the pump shaft with respect to the driver to optimize the universal joi
45. hat these covers are removed from the pump before connecting any pipes 4 5 1 Suction and discharge pipework In order to minimize friction losses and hydraulic noise in the pipework it is good practice to choose pipework that is one or two sizes larger than the pump suction and discharge Typically main pipework velocities should not exceed 2 m s 6 ft sec suction and 3 m s 9 ft sec on the discharge Take into account the available NPSH which must be higher than the required NPSH of the pump A cuon Never use the pump as a support for piping Maximum forces and moments allowed on the pump flanges vary with the pump size and type To minimize these forces and moments that may if excessive cause misalignment hot bearings worn couplings vibration and the possible failure of the pump casing the following points should be strictly followed Page 13 of 32 FLOWSERVE ERY Prevent excessive external pipe load Never draw piping into place by applying force to pump flange connections Do not mount expansion joints so that their force due to internal pressure acts on the pump flange The table in 4 5 3 summarizes the maximum forces and moments allowed on horizontal shaft pump casings A ana Ensure piping and fittings are flushed before use A Ensure piping for hazardous liquids is arranged to allow pump flushing before removal of the pump 4 5 2 Suction piping The inlet pipe should be one or two sizes la
46. ion valve will allow easier maintenance 4 5 5 Auxiliary piping 4 5 5 1 Drains Pipe pump casing drains and gland leakage to a convenient disposal point 4 5 5 2 Pumps fitted with packed gland When suction pressure is below ambient pressure it is necessary to feed the gland packing with liquid to provide lubrication and prevent the ingress of air This is normally achieved with a supply from the pump discharge volute to the stuffing box If the pumped liquid is dirty and cannot be used for sealing a separate clean compatible liquid supply to the gland at 1 bar 15 psi above suction pressure is recommended 4 5 5 3 Pumps fitted with mechanical seals Single seals requiring re circulation will normally be provided with the auxiliary piping from pump casing already fitted If the seal requires an auxiliary quench then a connection must be made to a suitable source of liquid flow low pressure steam or static pressure from a header tank Recommended pressure is 0 35 bar 5 psi or less Check General arrangement drawing Page 15 of 32 FLOWSERVE ERY Special seals may require different auxiliary piping to that described above Consult separate User Instructions and or Flowserve if unsure of correct method or arrangement For pumping hot liquids to avoid seal damage it is recommended that any external flush cooling supply be continued after stopping the pump 4 5 6 Final checks Check the tightness of all bolts in
47. ioning Motor rating kW hp ea a oR Up to 15 20 15 Between 15 20 and 90 120 10 Above 90 120 6 Where duty and standby pumps are installed it is recommended that they are run alternately every week UB USER INSTRUCTIONS ENGLISH 71569247 07 04 5 8 eae and shutdown a Close the outlet valve but ensure that the pump runs in this condition for no more than a few seconds b Stop the pump c Switch off flushing and or cooling heating liquid supplies at a time appropriate to the process d A ont For prolonged shut downs and especially when ambient temperatures are likely to drop below freezing point the pump and any cooling and flushing arrangements must be drained or otherwise protected 5 9 Hydraulic mechanical and electrical duty This product has been supplied to meet the performance specifications of your purchase order however it is understood that during the life of the product these may change The following notes may help the user decide how to evaluate the implications of any change If in doubt contact your nearest Flowserve office 5 9 1 Specific gravity SG Pump capacity and total head in metres feet do not change with SG however pressure displayed on a pressure gauge is directly proportional to SG Power absorbed is also directly proportional to SG It is therefore important to check that any change in SG will not overload the pump driver or over pressurize the pump
48. l all the conditions relating to safety noted in the instructions have been met 1 2 CE marking and approvals It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and where applicable Low Voltage Equipment Electromagnetic Compatibility EMC Pressure Equipment Directive PED and Equipment for Potentially Explosive Atmospheres ATEX Where applicable the Directives and any additional Approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions Where applicable this document incorporates information relevant to these Directives UB USER INSTRUCTIONS ENGLISH 71569247 07 04 and Approvals To confirm the Approvals applying and if the product is CE marked check the serial number plate markings and the Certification See section 9 Certification 1 3 Disclaimer Information in these User Instructions is believed to be reliable In spite of all the efforts of Flowserve 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 organis
49. n of parts 6 9 ccceeseeseereeeeeeeneees 24 Fastener torques 6 6 c cccecsseeeeenteeeeeenteeeeeeaes 23 Faults causes and remedies 7 cccceeeeeeeeeees 27 Forces and moments 4 5 3 Lassee 15 Foundation 4 2 ecsiesctecssieectivieieieeetneneestceed 12 General arrangement drawing 8 2 a e 30 General assembly drawings 8 ceeeeeeeeeeeee 29 Grouting 4 3 ccc issceectnsseeeest eeetavicetev ees namteeeiiicden 12 Guarding 9 4 ici dices scteitsccatiietevitvieest nuteeenticees 17 Handing 22 jeencucransnaneianaan 10 Hydraulic mechanical and electrical duty 5 9 19 Inspection 6 2 1 and 6 2 2 21 Installation 4 areia 12 Lifting 2 3 ease ete teal ntl eatin 10 Localo 4 Tresnani tl cheavealte sea ites 12 Lubrication 5 2 and 6 2 3 Lubrication schedule 5 2 2 sesser 17 Maintenance 6 ccccsececeeseeeeceeseeeeeeeneeeeeeeneeees 20 Maintenance schedule 6 2 L e 20 Name nomenclature 3 2 ecceeeeseeeeeenteeeeeenaes 11 Nameplate 1 7 1 oncesi a 8 Operating limits 3 4 1 0 eeeeeeeeeseeeeeeenteeeeeenaes 11 Options 8 1 2 ssrin A 30 Ordering spare parts 6 3 1 aaeeea 22 Parts lists 8 cccceeeeeeeeeeeeeeeeeeeeeeeeeeenaeeeseenaeeeeseaaes 29 Performance 3 4 ccccccceeeeeeeeeenteeeceeneeeeeeneeeeeeaaes 11 Piping 4 5 ecceceecceesceeeeceeeeeeeeseaeeeeeeeseeeeeseeeesneeenees 13 UB USER INSTRUCTIONS ENGLISH 71569247 07 04 PAGE Pre COMMISSIONING 5 1 eeeeeeeeeeeeee
50. nd 5 7 5 5 COMMISSIONING START UP OPERATION AND SHUTDOWN CAUTION These operations must be carried out by fully qualified personnel 5 1 Pre commissioning procedure Pumps and electric motors are supplied pre greased Other drivers and gearboxes if appropriate should be lubricated in accordance with their manuals Page 16 of 32 FLOWSERVE ERY 5 2 Pump lubricants 5 2 1 Recommended grease lubricants Grease Grease nipples NLGI 2 NLGI 3 Temp range C 20 to 100 20 to 100 F 4 to 212 4 to 212 Designation z according to DIN eee KR a0 BP Energrease LS2 Energrease LS3 DEA Glissando 20 Glissando 30 Elf Elfmulti 2 Elfmulti 3 Esso Beacon 2 Beacon 3 Mobil Mobilux 2 Mobilux 3 Q8 Rembrandt 2 Rembrandt 3 Alvania Fett G2 Shell Alvania Fett R2 Alvania R3 Multilak 20 Multilak 30 Texaco Multilak EP2 Multilak EP3 Wintershall BASF Group Wiolub LFK 2 SKF LGMT 2 LGMT 3 Silkolene G55 T G56 T NLGI 2 is an alternative grease and is not to be mixed with other grades Factory packed bearings for the temperature range with grease nipples 5 2 2 Lubrication schedule When grease nipples are fitted one charge between grease changes is advisable for most operating conditions ie 2 000 hours interval Normal intervals between grease changes are 4 000 hours or at least every 6 months The characteristics of the inst
51. nditions 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 UB USER INSTRUCTIONS ENGLISH 71569247 07 04 1 7 Warning 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 FLOWSERVE ESSENTIAL PROCEDURES BEFORE STARTING INSTALL AND OPERATE EQUIPMENT IN ACCORDANCE WITH THE INSTRUCTION MANUAL SUPPLIED SEPARATELY ENSURE GUARDS ARE SECURELY IN PLACE ENSURE CORRECT DIRECTION OF ROTATION WARNING 4 pk ARE CONNECTED AND OPERATIONAL J218JZ250 ENSURE ALL EXTERNAL CONNECTIONS TO THE PUMP SHAFT SEALING AND DRIVER FULLY PRIME UNIT AND SYSTEM DO NOT RUN UNIT DRY FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN PERSONAL INJURY AND OR EQUIPMENT DAMAGE 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 ate S ASSURER QUE LE GROUPE ELECTROPOMPE EST FERMEMENT INSTALLE SUR SON MASSIF VERIFIER LE LIGNAGE DE L ACCOUPLEMENT AVANT ET APRES FIXATION DU SOCLE ET DE LA TUYAUTERIE VOIR LES TOLERANCES D ALIGNMENT SUR LA NOTICE J218 268 PUMP MUSS AUF FESTEM FUNDAMENT STEHEN KUPPLUNGSHALF
52. nt drive shaft bearing life This offset will typically be in the range 0 to 4 degrees depending on shaft design Please consult the separate User Instructions before installation f Any support for the universal joint drive shaft plummer blocks must not exhibit resonant frequencies in the range 0 8 to 1 2 N where N pump running speed g If not supplied guarding shall be fitted as necessary to meet the requirements of EN292 and EN953 and or any applicable local safety regulations 4 3 Grouting Where applicable grout in the foundation bolts After adding pipework connections and rechecking the coupling alignment the baseplate should then be grouted in accordance with good engineering practice Fabricated steel cast iron and epoxy baseplates can be filled with grout Folded steel baseplates should be grouted to locate their packing pieces If in any doubt please contact your nearest service centre for advice Grouting provides solid contact between the pump unit and foundation prevents lateral movement of running equipment and dampens resonant vibrations Foundation bolts should only be fully tightened when the grout has cured 4 4 Initial alignment 4 4 1 Thermal expansion CAUTION 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
53. 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 that 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 that may be used in the seal system or other utilities A 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 regulations at all times Page 10 of 32 FLOWSERVE ERY 3 PUMP DESCRIPTION 3 1 Configurations The 8 UB 1pump is a horizontal split casing two stage volute type centrifugal pump designed for water works drainage general service and circulating applications It can be used with motor steam turbine and gasoline or diesel engine drive It has the following horizontal configuration 3 2 Name nomenclature The pump size will be engraved on the nameplate typically as below 8 UB 1 Nominal discharge branch size Configuration see 3 1 above The typical nomenclature above is the general guide to the UB configuration description Identify the actual pump size and serial number from the pump nameplate Check that this agrees with the applicable certification provided
54. ors 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 A HAZARDOUS LIQUIDS When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by appropriate siting of the pump limiting personnel access and by operator training If the liquid is flammable and or explosive strict safety procedures must be applied Gland packing must not be used when pumping hazardous liquids PREVENT EXCESSIVE EXTERNAL PIPE LOAD Do not use pump as a support for piping Do not mount expansion joints unless allowed by Flowserve in writing so that their force due to internal pressure acts on the pump flange ENSURE CORRECT LUBRICATION See section 5 Commissioning startup operation and shutdown START THE PUMP WITH OUTLET VALVE PARTLY OPENED Unless otherwise instructed at a specific point in the User Instructions This is recommended to minimize the risk of overloading and damaging the pump motor at full or zero flow Pumps may be started with the valve further open only on installations where this situation cannot occur The pump outlet control valve may need to be adjusted to comply with the duty following the run up process See section 5 Commissioning start up operation and shutdown NEVER RUN THE PUMP DRY INLET VALVES TO BE FULLY OPEN WHEN PUMP IS RUNNING R
55. ot fastener is loosened While the pump is capable of operating with the maximum misalignment shown above maximum pump reliability is obtained by near perfect alignment of 0 05 to 0 10 mm 0 002 to 0 004 in TIR parallel and 0 05 mm 0 002 in per 100 mm 4 in of coupling flange diameter as TIR angular misalignment This covers the full series of couplings available UB USER INSTRUCTIONS ENGLISH 71569247 07 04 Pumps with thick flanged non spacer couplings can be aligned by using a straight edge across the outside diameters of the coupling hubs and measuring the gap between the machined faces using feeler gauges measuring wedge or callipers When the electric motor has sleeve bearings it is necessary to ensure that the motor is aligned to run on its magnetic centreline I Refer to the motor manual for details A button screwed into one of the shaft ends is normally fitted between the motor and pump shaft ends to fix the axial position m If the motor does not run in its magnetic centre the resultant additional axial force may overload the pump thrust bearing Complete piping as below and see sections 4 6 Final shaft alignment check up to and including section 5 Commissioning startup operation and shutdown before connecting driver and checking actual rotation 4 5 Piping per Protective covers are fitted to the pipe connections to prevent foreign bodies entering during transportation and installation Ensure t
56. pares should be stored in a clean dry area away from vibration Inspection and re treatment of metallic surfaces if necessary with preservative is recommended at 6 monthly intervals 6 4 Recommended spares and consumable items For start up purposes 1 complete set of gland packing 2 shaft sleeves 1 set of gaskets and seals optional 2 mechanical seals For 2 years operation 1 set of bearings line and thrust 2 sets of gland packing 2 shaft sleeves 2 sets of gaskets and seals 2 lantern rings 2 casing wear rings 1 diaphragm bush optional 2 mechanical seals 2 impeller wear rings For 4 years operation 1 set of bearings line and thrust 2 sets of gland packing 2 shaft sleeves 2 sets of gaskets and seals 2 lantern rings 2 casing wear rings Page 22 of 32 FLOWSERVE ERY 1 impeller 1 diaphragm bush optional 2 mechanical seals 2 impeller wear rings 6 5 Tools required A typical range of tools that will be required to maintain these pumps is listed below Readily available in standard tool kits and dependent on pump size e Open ended spanners wrenches to suit up to M 24 lz in screws nuts e Socket spanners wrenches up to M 24 s in screws e Allen keys up to 6 mm in A F e Range of screwdrivers e Soft mallet More specialized equipment Bearing pullers Bearing induction heater Dial test indicator C spanner wrench for
57. rformance curve to determine exact requirements particularly if flow has changed If in doubt please consult your nearest Flowserve office for advice and details of the minimum allowable margin for your application 5 9 5 Pumped flow Flow must not fall outside the minimum and maximum continuous safe flow shown on the pump performance curve and or data sheet 6 MAINTENANCE 6 1 General It is the plant operator s responsibility to ensure that all maintenance inspection and assembly work is carried out by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail See also section 1 6 2 Any work on the machine must be performed when it is at a standstill It is imperative that the procedure for shutting down the machine is followed as described in section 5 8 On completion of work all guards and safety devices must be re installed and made operative again Before restarting the machine the relevant instructions listed in section 5 Commissioning start up operation and shut down must be observed Oil and grease leaks may make the ground slippery Machine maintenance must always begin and finish by cleaning the ground and the exterior of the machine If platforms stairs and guard rails are required for maintenance they must be placed for easy access to areas where maintenance and inspection are to be carried out UB USER INSTRUCTIONS EN
58. rger than the pump inlet bore and pipe bends should be as large a radius as possible Pipework reducers should be conical and have a maximum total angle of divergence of 15 degrees On suction lift the piping should be inclined up towards the pump inlet with eccentric reducers incorporated to prevent air locks On positive suction the inlet piping must have a constant fall towards the pump Flow should enter the pump suction with uniform flow to minimize noise and wear This is particularly important on large or high speed pumps which should have a minimum of five diameters of straight pipe on the pump suction between the elbow and inlet flange See section 10 3 Reference 1 for more detail Inlet strainers when used should have a net free area of at least three times the inlet pipe area Do not install elbows at an angle other than perpendicular to the shaft axis Elbows parallel to the shaft axis will cause uneven flow Except in unusual circumstances strainers are not recommended in inlet piping If considerable foreign matter is expected a screen installed at the entrance to the wet well is preferable Fitting an isolation valve will allow easier maintenance Never throttle pump on suction side and never place a valve directly on the pump inlet nozzle Typical design flooded suction Discharge isolating valve Non return valve Concentric conical reducer Eccentric conical reducer UB USER INSTRUC
59. run at the actual operating temperature shut down and the alignment checked immediately Page 12 of 32 FLOWSERVE ERY 4 4 2 Alignment methods DANGER Ensure pump and driver are isolated electrically and the half couplings are disconnected fA canon 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 is achieved by adding or removing shims under the motor feet and also moving the motor horizontally as required In some cases where the alignment cannot be achieved it will be necessary to move the pump before recommencing the above procedure For couplings with narrow flanges use a dial indicator as shown below to check both parallel and angular alignment Parallel Maximum permissible misalignment at working temperature Parallel 0 2 mm 0 008 in TIR Angular 0 1 mm 0 004 in TIR When checking parallel alignment the total indicator read out TIR shown is twice the value of the actual shaft displacement Align in the vertical plane first then horizontally by moving motor When performing final alignment check for soft foot under the driver A TIR indicator placed on the coupling reading in the vertical direction should not indicate more than 0 05 mm 0 002 in movement when any driver fo
60. the work involved If the personnel in question do not already possess the necessary knowledge and skill appropriate training and instruction must be provided If required the operator may commission the manufacturer supplier to provide applicable training Always coordinate repair activity with operations and health and safety personnel and follow all plant safety requirements and applicable safety and health laws and regulations 1 6 3 Safety action This is a summary of conditions and actions to 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 UB USER INSTRUCTIONS ENGLISH 71569247 07 04 LA pancer NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER GUARDS MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL 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 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 k
61. two socket head screws securing each shaft sleeve nut Using C spanner remove shaft nuts Slide off shaft sleeves Page 23 of 32 FLOWSERVE ERY q Remove impellers casing rings diaphragm plate complete with its bush together with the impeller ke A If impellers prove difficult to remove the use of heat is permissible Refer to Section 1 6 Safety APPLYING HEAT TO REMOVE IMPELLER for more details r fit is required to remove the diaphragm plate bush then remove the 4 countersunk screws and push out the bush s If impeller rings are also fitted they are shrunk onto the impeller and fixed with locking screws between their diametric mating surfaces t Toremove the impeller rings remove the locking screws and heat up the ring until it slides off easily 6 9 Examination of parts Used parts must be inspected before assembly to ensure the pump will subsequently run properly In particular fault diagnosis is essential to enhance pump and plant reliability 6 9 1 Casing seal housing and impeller a Inspect for excessive wear pitting corrosion erosion or damage and any sealing surface irregularities b Replace as necessary 6 9 2 Shaft and sleeve if fitted Replace if grooved pitted or worn 6 9 3 Gaskets and O rings After dismantling discard and replace 6 9 4 Bearings It is recommended that bearings are not re used after any removal from the shaft 6 9 5 Bearing isolators labyrinths or lip s
62. unning the pump at zero flow or below the recommended minimum flow continuously will cause damage to the pump and mechanical seal UB USER INSTRUCTIONS ENGLISH 71569247 07 04 DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES Operating at a flow rate higher than normal or at a flow rate with no back pressure on the pump may overload the motor and cause cavitation Low flow rates may cause a reduction in pump bearing life overheating of the pump instability and cavitation vibration 1 6 4 Products used in potentially explosive atmospheres Measures are required to Avoid excess temperature Prevent build up of explosive mixtures Prevent the generation of sparks Prevent leakages Maintain the pump to avoid hazard The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection Both electrical and non electrical equipment must meet the requirements of European Directive 94 9 EC 1 6 4 1 Scope of compliance Use equipment only in the zone for which it is appropriate Always check that the driver drive coupling assembly seal and pump equipment are suitably rated and or certified for the classification of the specific atmosphere in which they are to be installed Where Flowserve has supplied only the bare shaft pump the Ex rating applies only to the pump The party responsible for assembling the pump set shall select the couplin
63. ure the inlet pipe and pump casing are completely full of liquid before starting continuous duty operation 5 5 1 Suction pressure above atmospheric pressure Horizontal pumps open vent connection 1 on top of the pump upper casing to allow the trapped air to escape Let liquid run out until free from air bubbles 1 Possible priming points x Ww VEN K Page 17 of 32 FLOWSERVE ERY 5 5 2 Suction lift with foot valve fitted Fill suction pipe and casing with liquid at a pressure of 1 to 2 bar from an external source Vent as described in section 5 5 1 5 5 3 Suction lift without foot valve Pump casing vents on the suction volute must be connected to an external vacuum pump priming system If in doubt please consult Flowserve Possible priming N oa lt p T oints o vacuum P a gt pump SE E 5 6 E the pump a Ensure flushing and or cooling heating liquid supplies are turned ON before starting the pump b CLOSE the outlet valve OPEN all inlet valves d Prime the pump e Ensure all vent connections are closed before starting f Start motor and check outlet pressure g Ifthe pressure is satisfactory slowly OPEN outlet control
64. valve h Do not run the pump with the outlet valve closed for a period longer than 30 seconds i If NO pressure or LOW pressure STOP the pump Refer to section 7 Faults causes and remedies for fault diagnosis 5 7 Running the pump 5 7 1 Venting the pump Vent the pump to enable all trapped air to escape taking due care with hot or hazardous liquids Under normal operating conditions after the pump has been fully primed and vented it should be unnecessary to re vent the pump UB USER INSTRUCTIONS ENGLISH 71569247 07 04 5 7 2 Pumps fitted with packed gland 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 pressurised The gland must be adjusted evenly to give visible leakage and concentric alignment of the gland to avoid excess temperature 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 re started When the pump is re started check to ensure leakage is taking place at the packed gland If hot liquids are being pumped it may be necessary to slacken the gland nuts to achieve leakage The pump should be run for 30 minutes with steady leakage and the gland nuts tightened by 10 degrees at a time until leakage is reduced to an acceptable level normally a minimum of 120 drops per minute is
65. wable rings and diaphragm plate are correctly located in the upper half bores and that dowel holes pick up the locating dowels in the lower half b Tap horizontal flange over locating dowels to accurately position the top half casing and torque up all horizontal flange bolts Check for free rotation d Using asharp flexible bladed knife cut off the exposed casing gasket in the stuffing box area flush with the stuffing box face e If mechanical seals are fitted apply a small amount of silicon rubber sealant along the horizontal joint line on the stuffing box face and fit seal cover complete with gasket or O ring Take care not to damage O ring if fitted and locate cover squarely on stuffing box face f Torque up seal cover bolts and check shaft sleeve does not rub on seal cover or stationary seal seat bore Ensure any spare holes in mechanical seal cover particularly on cartridge seals have sealing plugs fitted g If gland packing is fitted pack the gland ensuring that the cut ends in each ring are staggered by 120 degrees The glands are packed as shown on the relevant drawings in Sections 8 1 to 8 3 Finger tighten the gland nuts h Check coupling alignment fit coupling drive element s and fit guards i Pipe up any external auxiliary connections j Check for free rotation Page 26 of 32 FLOWSERVE ERY UB USER INSTRUCTIONS ENGLISH 71569247 07 04 7 FAULTS CAUSES AND REMEDIES FAULT SYMPTOM

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