backup di hwx 85392694 03-11 · 2018. 9. 4. · hwx user instructions english 85392694 - 03/11 page...

USER INSTRUCTIONS

HWX centrifugal pumps

Vertical single stage, single suction, radially split volute typecentrifugal pumps

PCN=85392694 – 03/11 (E) Original instructions

InstallationOperation

Maintenance

These instructions must be read prior to installing,operating, using and maintaining this equipment.

HWX USER INSTRUCTIONS ENGLISH 85392694 - 03/11

Page 2 of 56

CONTENTSPAGE

CONTENTS............................................................... 2

1 INTRODUCTION AND SAFETY ............................ 41.1 General ........................................................... 41.2 CE marking and approvals.............................. 41.3 Disclaimer ....................................................... 41.4 Copyright......................................................... 41.5 Duty conditions ............................................... 41.6 Safety .............................................................. 51.7 Nameplate and safety labels........................... 81.8 Specific machine performance........................ 81.9 Noise level....................................................... 9

2 TRANSPORT AND STORAGE ............................ 102.1 Consignment receipt and unpacking ............ 102.2 Handling ........................................................ 102.3 Lifting............................................................. 102.4 Storage.......................................................... 102.5 Recycling and end of product life.................. 12

3 PUMP DESCRIPTION......................................... 133.1 Configurations............................................... 133.2 Nomenclature................................................ 133.3 Design of major parts .................................... 133.4 Performance and operating limits ................. 14

4 INSTALLATION.................................................... 154.1 Location......................................................... 154.2 Part assemblies ............................................ 154.3 Foundation .................................................... 154.4 Grouting ........................................................ 174.5 Initial alignment ............................................. 174.6 Piping ............................................................ 194.7 Final shaft alignment check .......................... 214.8 Electrical connections ................................... 214.9 Protection systems........................................ 21

5 COMMISSIONING, START-UP, OPERATION ANDSHUTDOWN.................................................... 22

5.1 Pre-commissioning procedure ...................... 225.2 Pump Lubricants ............................................ 255.3 Direction of rotation....................................... 265.4 Guarding ....................................................... 275.5 Priming and auxiliary supplies ...................... 275.6 Starting the pump.......................................... 275.7 Operating checks .......................................... 285.8 Normal Start Up ............................................ 295.9 Stopping and shutdown ................................ 295.10 Hydraulic, mechanical and........................... 29electrical duty ....................................................... 29

6 MAINTENANCE.................................................... 306.1 General ......................................................... 306.2 Maintenance schedule .................................. 306.3 Spare parts ................................................... 31

PAGE

6.4 Recommended spares (according to API) ....326.5 Tools required................................................326.6 Fastener torques ...........................................326.7 Disassembly ..................................................336.8 Examination of parts.....................................356.9 Assembly .......................................................36

7 FAULTS; CAUSES AND REMEDIES....................43

8 PARTS LIST AND DRAWINGS............................45

9 CERTIFICATION..................................................52

10 OTHER RELEVANT DOCUMENTATION ANDMANUALS ........................................................52

10.1 Supplementary User Instruction manuals ...5210.2 Change notes ..............................................5210.3 Additional sources of information ................52


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INDEXPAGE

Additional sources (10.3)......................................... 52Alignment of shafting (see 4.5, 4.7 and 4.3)Assembly (6.9)......................................................... 36ATEX marking (1.6.4.2) ............................................. 7CE marking and approvals (1.2)................................ 4Certification (9) ........................................................ 52Change notes (10.2) ................................................ 52Clearances (see 6.9) ............................................... 36Commissioning and operation (see 5)..................... 22Compliance, ATEX (1.6.4.1)...................................... 6Configurations (3) .................................................... 13Copyright (1.4) ........................................................... 4Design of major parts (3.3) ...................................... 13Direction of rotation (5.3) ......................................... 26Disassembly (6.7) .................................................... 33Disclaimer (1.3).......................................................... 4Dismantling (see 6.7, Disassembly) ........................ 33Drawings (8) ............................................................ 45Duty conditions (1.5).................................................. 4Electrical connections (4.8) ..................................... 21End of product life (2.5) ........................................... 12Examination of parts (6.8) ....................................... 35Fastener torques (6.6) ............................................. 32Faults; causes and remedies (7) ............................. 43General assembly drawings (see 8.8) ..................... 52Grouting (4.4)........................................................... 17Guarding (5.4).......................................................... 27Handling (2.2) .......................................................... 10Hydraulic, mechanical and electrical duty (5.10)..... 29Impeller clearance (6.9)........................................... 36Inspection (6.2) ........................................................ 30Installation (4) .......................................................... 15Lifting (2.3)............................................................... 10Location (4.1)........................................................... 15Lubrication (see 5.1.1, 5.2 and 6.2.3)Lubrication schedule (see 5.2, Pump lubricants) .... 25Maintenance (6)....................................................... 30Maintenance schedule (6.2) .................................... 30Name nomenclature (3.2)........................................ 13Nameplate (1.7.1) ...................................................... 8Operating limits (3.4) ............................................... 14Ordering spare parts (6.3.1) .................................... 31Part assemblies (4.2)............................................... 15Parts lists (8)............................................................ 45Performance (3.4).................................................... 14Piping (4.6) .............................................................. 19Pre-commissioning (5.1).......................................... 22Protection systems (4.9).......................................... 21Priming and auxiliary supplies (5.5)......................... 27Reassembly (see 6.9, Assembly) ............................ 36Receipt and unpacking (2.1).................................... 10Recommended fill quantities (see 5.2.2) ................. 26Recommended oil lubricants (5.2.1)........................ 25

PAGE

Recommended spares (6.4).....................................32Recycling (2.5) .........................................................12Replacement parts (see 6.3 and 6.4)Running the pump (5.6) ...........................................27Safety action (1.6.3) ...................................................5Safety labels (1.7.2) ...................................................8Safety markings (1.6.1) ..............................................5Safety, protection systems (see 1.6 and 4.9)Sectional drawings (8)..............................................45Sound level (see 1.9, Noise level)..............................9Sources, additional information (10.3) .....................52Spare parts (6.3) ......................................................31Specific machine performance (1.8) ..........................8Starting the pump (5.6) ............................................27Stop/start frequency (5.7.5)......................................29Stopping and shutdown (5.9) ...................................29Storage, pump (2.4) .................................................10Storage, spare parts (6.3.2) .....................................32Supplementary manuals or information sources......52Tools required (6.5) ..................................................32Torques for fasteners (6.6).......................................32Trouble-shooting (see 7) ..........................................43Vibration (5.7.4)........................................................29


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1 INTRODUCTION AND SAFETY

1.1 General

These Instructions must always be keptclose to product's operating location or directlywith the product.Flowserve's products are designed, developed andmanufactured with state-of-the-art technologies inmodern facilities. The unit is produced with great careand commitment to continuous quality control, utilisingsophisticated quality techniques, and safetyrequirements.

Flowserve is committed to continuous qualityimprovement and being at service for any furtherinformation about the product in its installation andoperation or about its support products, repair anddiagnostic services.

These instructions are intended to facilitatefamiliarization with the product and its permitted use.Operating the product in compliance with theseinstructions is important to help ensure reliability inservice and avoid risks. The instructions may not takeinto account local regulations; ensure such regulationsare observed by all, including those installing theproduct. Always coordinate repair activity withoperations personnel, and follow all plant safetyrequirements and applicable safety and healthlaws/regulations.

These instructions must be read prior toinstalling, operating, using and maintaining theequipment in any region worldwide. Theequipment must not be put into service until all theconditions relating to safety, noted in theinstructions, have been met. Failure to follow andapply the present user instructions is consideredto be misuse. Personal injury, product damage,delay or failure caused by misuse are not coveredby the Flowserve warranty.

1.2 CE marking and approvalsIt is a legal requirement that machinery andequipment put into service within certain regions ofthe world shall conform with the applicable CEMarking Directives covering Machinery and, whereapplicable, Low Voltage Equipment, ElectromagneticCompatibility (EMC), Pressure Equipment Directive(PED) and Equipment for Potentially ExplosiveAtmospheres (ATEX).

Where applicable, the Directives and any additionalApprovals, cover important safety aspects relating to

machinery and equipment and the satisfactoryprovision of technical documents and safetyinstructions. Where applicable this documentincorporates information relevant to these Directivesand Approvals. To confirm the Approvals applyingand if the product is CE marked, check the serialnumber plate markings and the Certification, seesection 9, Certification.

1.3 DisclaimerInformation in these User Instructions is believedto be reliable. In spite of all the efforts ofFlowserve to provide sound and all necessaryinformation the content of this manual may appearinsufficient and is not guaranteed by Flowserve asto its completeness or accuracy.

Flowserve manufactures products to exactingInternational Quality Management System Standardsas certified and audited by external QualityAssurance organisations. Genuine parts andaccessories have been designed, tested andincorporated into the products to help ensurecontinued product quality and performance in use. AsFlowserve cannot test parts and accessories sourcedfrom other vendors the incorrect incorporation of suchparts and accessories may adversely affect theperformance and safety features of the products. Thefailure to properly select, install or use authorisedFlowserve parts and accessories is considered to bemisuse. Damage or failure caused by misuse is notcovered by Flowserve's warranty. In addition, anymodification of Flowserve products or removal oforiginal components may impair the safety of theseproducts in their use.

1.4 CopyrightAll rights reserved. No part of these instructions maybe reproduced, stored in a retrieval system ortransmitted in any form or by any means without priorpermission of Flowserve Corporation.

1.5 Duty conditionsThis product has been selected to meet thespecifications of your purchaser order. Theacknowledgement of these conditions has been sentseparately to the Purchaser. A copy should be keptwith these instructions.

The product must not be operated beyondthe parameters specified for the application. Ifthere is any doubt as to the suitability of theproduct for the application intended, contactFlowserve for advice, quoting the serial number.


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If the conditions of service on your purchase order aregoing to be changed (for example liquid pumped,temperature or duty) it is requested that the user seeksFlowserve’s written agreement before start up.

1.6 Safety

1.6.1 Summary of safety markingsThese User Instructions contain specific safetymarkings where non-observance of an instructionwould cause hazards. The specific safety markingsare:

This symbol indicates electrical safetyinstructions where non-compliance will involve a highrisk to personal safety or the loss of life.

This symbol indicates safety instructions wherenon-compliance would affect personal safety andcould result in loss of life.

This symbol indicates “hazardous and toxicfluid” safety instructions where non-compliance wouldaffect personal safety and could result in loss of life.

This symbol indicates safetyinstructions where non-compliance will involve somerisk to safe operation and personal safety and woulddamage the equipment or property.

This symbol indicates explosive atmospheremarking according to ATEX. It is used in safetyinstructions where non-compliance in the hazardousarea would cause the risk of an explosion.

This symbol is used in safety instructions toremind not to rub non-metallic surfaces with a drycloth; ensure the cloth is damp. It is used in safetyinstructions where non-compliance in the hazardousarea would cause the risk of an explosion.

This sign is not a safety symbol butindicates an important instruction in the assemblyprocess.

1.6.2 Personnel qualification and trainingAll personnel involved in the operation, installation,inspection and maintenance of the unit must bequalified to carry out the work involved. If thepersonnel in question do not already possess thenecessary knowledge and skill, appropriate trainingand instruction must be provided. If required theoperator may commission the manufacturer/supplierto provide applicable training.

Always coordinate repair activity with operations andhealth and safety personnel, and follow all plantsafety requirements and applicable safety and healthlaws and regulations.

1.6.3 Safety actionThis is a summary of conditions and actions tohelp prevent injury to personnel and damage tothe environment and to equipment. For productsused in potentially explosive atmospheres section1.6.4 also applies.

PREVENT EXCESSIVE EXTERNALPIPE LOADDo not use pump as a support for piping. Do notmount expansion joints, unless allowed by Flowservein writing, so that their force, due to internal pressure,acts on the pump flange.

ENSURE CORRECT LUBRICATION(See section 5, Commissioning, start-up, operationand shutdown.)

START THE PUMP WITH OUTLETVALVE PART OPENED(Unless otherwise instructed at a specific point in theuser instructions.)This is recommended to minimise the risk ofoverloading and damaging the pump and motor at fullor zero flow. Pumps may be started with the valvefurther open only on installations where this situationcannot occur. The pump outlet control valve mayneed to be adjusted to comply with the duty followingthe run-up process. (See section 5, Commissioningstart-up, operation and shutdown.)

NEVER RUN THE PUMP DRY

INLET VALVES TO BE FULLY OPENWHEN PUMP IS RUNNINGRunning the pump at zero flow or below therecommended minimum flow continuously will causedamage to the pump itself and to the seal.

DO NOT RUN THE PUMP ATABNORMALLY HIGH OR LOW FLOW RATESOperating at a flow rate higher than normal or at aflow rate with no back pressure on the pump mayoverload the motor and cause cavitation. Low flowrates may cause a reduction in pump/bearing life,overheating of the pump, instability and cavitation/vibration.

NEVER DO MAINTENANCE WORKWHEN THE UNIT IS CONNECTED TO POWER


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HAZARDOUS LIQUIDSWhen the pump is handling hazardous liquids caremust be taken to avoid exposure to the liquid byappropriate siting of the pump, limiting personnelaccess and by operator training. If the liquid isflammable and/or explosive, strict safety proceduresmust be applied.

Gland packing must not be used when pumpinghazardous liquids.

DRAIN THE PUMP AND ISOLATE PIPEWORKBEFORE DISMANTLING THE PUMPThe appropriate safety precautions should be takenwhere the pumped liquids are hazardous.

FLUORO-ELASTOMERS (When fitted.)When a pump has experienced temperatures over250 ºC (482 ºF), partial decomposition of fluoro-elastomers (eg Viton) will occur. In this conditionthese are extremely dangerous and skin contact mustbe avoided.

HANDLING COMPONENTSMany precision parts have sharp corners and thewearing of appropriate safety gloves and equipmentis required when handling these components. To liftheavy pieces above 25 kg (55 lb) use a craneappropriate for the mass and in accordance withcurrent local regulations.

GUARDS MUST NOT BE REMOVED WHILETHE PUMP IS OPERATIONALThe unit must not be operated unless coupling guardis in place. Failure to observe this warning couldresult in injury to operating personnel.

THERMAL SHOCKRapid changes in the temperature of the liquid withinthe pump can cause thermal shock, which can resultin damage or breakage of components and should beavoided.

NEVER APPLY HEAT TO REMOVE IMPELLERTrapped lubricant or vapour could cause anexplosion.

HOT (and cold) PARTSIf hot or freezing components or auxiliary heatingsupplies can present a danger to operators andpersons entering the immediate area action must betaken to avoid accidental contact. If completeprotection is not possible, the machine access mustbe limited to maintenance staff only, with clear visualwarnings and indicators to those entering the

immediate area. Note: bearing housings must not beinsulated and drive motors and bearings may be hot.If the temperature is greater than 80 °C (175 °F) orbelow -5 °C (20 °F) in a restricted zone, orexceeds local regulations, action as above shallbe taken.

1.6.4 Products used in potentially explosiveatmospheres

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 unitswhen installed in potentially explosive atmospheresmust be followed to help ensure explosion protection.Both electrical and non-electrical equipment mustmeet the requirements of European Directive94/9/EC.

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it isappropriate. Always check that the driver, drivecoupling assembly, seal and pump equipment aresuitably rated and/or certified for the classification ofthe specific atmosphere in which they are to beinstalled.

Where Flowserve has supplied only the bare shaftpump, the Ex rating applies only to the pump. Theparty responsible for assembling the pump set shallselect the coupling, driver and any additionalequipment, with the necessary CE Certificate/Declaration of Conformity establishing it is suitable forthe area in which it is to be installed.

The output from a variable frequency drive (VFD) cancause additional heating affects in the motor and so,for pumps sets with a VFD, the ATEX Certification forthe motor must state that it is covers the situationwhere electrical supply is from the VFD. Thisparticular requirement still applies even if the VFD isin a safe area.


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1.6.4.2 MarkingAn example of ATEX equipment marking is shownbelow. The actual classification of the pump will beengraved on the nameplate.

II 2 GD c IIC 135 ºC (T4)

Equipment GroupI = MiningII = Non-mining

Category2 or M2 = high level protection3 = normal level of protection

Gas and/or dustG = GasD = Dust

c = Constructional safety(in accordance with En13463-5)

Gas Group (Equipment Category 2 only)IIA – Propane (typical)IIB – Ethylene (typical)IIC – Hydrogen (typical)

Maximum surface temperature (Temperature Class)(see section 2.5)

1.6.4.3 Avoiding excessive surface temperatures

ENSURE THE EQUIPMENT TEMPERATURECLASS IS SUITABLE FOR THE HAZARD ZONEPumps have a temperature class as stated in theATEX Ex rating on the nameplate. These are basedon a maximum ambient of 40 °C (104 °F); refer toFlowserve for higher ambient temperatures.

The surface temperature on the pump is influencedby the temperature of the liquid handled. Themaximum permissible liquid temperature depends onthe temperature class and must not exceed thevalues in the table that follows.

The temperature rise at the seals and bearings anddue to the minimum permitted flow rate is taken intoaccount in the temperatures stated.

Temperatureclass to

EN 13463-1

Maximumsurface

temperaturepermitted

Temperature limit of liquidhandled (* depending onmaterial and construction

variant - check which is lower)T6T5T4T3T2T1

85 °C (185 °F)100 °C (212 °F)135 °C (275 °F)200 °C (392 °F)300 °C (572 °F)450 °C (842 °F)

Consult FlowserveConsult Flowserve115 °C (239 °F) *180 °C (356 °F) *275 °C (527 °F) *400 °C (752 °F) *

The responsibility for compliance with thespecified maximum liquid temperature is with theplant operator.

Temperature classification “Tx” is used when theliquid temperature varies and when the pump isrequired to be used in differently classified potentiallyexplosive atmospheres. In this case the user isresponsible for ensuring that the pump surfacetemperature does not exceed that permitted in itsactual installed location.

If an explosive atmosphere exists during theinstallation, do not attempt to check the direction ofrotation by starting the pump unfilled. Even a shortrun time may give a high temperature resulting fromcontact between rotating and stationary components.

Where there is any risk of the pump being run againsta closed valve generating high liquid and casingexternal surface temperatures it is recommended thatusers fit an external surface temperature protectiondevice.

Avoid mechanical, hydraulic or electrical overload byusing motor overload trips, temperature monitor or apower monitor and make routine vibration monitoringchecks.

In dirty or dusty environments, regular checks mustbe made and dirt removed from areas around closeclearances, bearing housings and motors.

1.6.4.4 Preventing the build up of explosivemixtures

ENSURE THE PUMP IS PROPERLY FILLEDAND VENTED AND DOES NOT RUN DRY

Ensure the pump and relevant suction and dischargepipeline system is totally filled with liquid at all timesduring the pump operation, so that an explosiveatmosphere is prevented. In addition it is essential tomake sure that seal chambers, auxiliary shaft sealsystems and any heating and cooling systems areproperly filled.

If the operation of the system cannot avoid thiscondition the fitting of an appropriate dry runprotection device is recommended (eg liquiddetection or a power monitor).

To avoid potential hazards from fugitive emissions ofvapour or gas to atmosphere the surrounding areamust be well ventilated.


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1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanicalcontact, the coupling guard must be non-sparking.

To avoid the potential hazard from random inducedcurrent generating a spark, the earth contact on thebaseplate must be used.

Avoid electrostatic charge. Do not rub non-metallic surfaces with a dry cloth; ensure the cloth isdamp.

The coupling must be selected to comply with94/9/EC and correct alignment must be maintained.

1.6.4.6 Preventing leakage

The pump must only be used to handle liquidsfor which it has been approved to have the correctcorrosion resistance.

Avoid entrapment of liquid in the pump andassociated piping due to closing of suction anddischarge valves, which could cause dangerousexcessive pressures to occur if there is heat input tothe liquid. This can occur if the pump is stationary orrunning.

Bursting of liquid containing parts due to freezingmust be avoided by draining or protecting the pumpand ancillary systems.

Where there is the potential hazard of a loss of a sealbarrier fluid or external flush, the fluid must bemonitored.

If leakage of liquid to atmosphere can result in ahazard, the installation of a liquid detection device isrecommended.

1.6.4.7 Maintenance to avoid the hazard

CORRECT MAINTENANCE IS REQUIRED TOAVOID POTENTIAL HAZARDS WHICH GIVE ARISK OF EXPLOSION

The responsibility for compliance withmaintenance instructions is with the plantoperator.

To avoid potential explosion hazards duringmaintenance, the tools, cleaning and paintingmaterials used must not give rise to sparking oradversely affect the ambient conditions. Where there

is a risk from such tools or materials, maintenancemust be conducted in a safe area.

It is recommended that a maintenance plan andschedule is adopted. (See section 6, Maintenance.)

1.7 Nameplate and safety labels

1.7.1 NameplateFor details of nameplate, see the Declaration ofConformity.

1.7.2 Safety labels

1.8 Specific machine performanceFor performance parameters see section 1.5, Dutyconditions. Pump performance data are summarisedon pump data sheet which is included in propersection of “Job User’s Instruction”.


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1.9 Noise levelWhen pump noise level exceeds 85 dBA attentionmust be given to prevailing Health and SafetyLegislation, to limit the exposure of plant operatingpersonnel to the noise. The usual approach is tocontrol exposure time to the noise or to enclose themachine to reduce emitted sound. You may havealready specified a limiting noise level when theequipment was ordered, however if no noiserequirements were defined then machines above acertain power level will exceed 85 dBA. In suchsituations consideration must be given to the fitting ofan acoustic enclosure to meet local regulations.

Pump noise level is dependent on a number offactors - the type of motor fitted, the operatingconditions, pipework design and acousticcharacteristics of the building. The levels specified inthe table 1.1 are estimated and not guaranteed.

The dBA values are based on the noisiest ungearedelectric motors that are likely to be encountered.They are Sound Pressure levels at 1 m (3.3 ft) fromthe directly driven pump, for "free field over areflecting plane".

If a pump unit only has been purchased, for fittingwith your own driver, then the "pump only" noiselevels should be combined with the level for the driverobtained from the supplier. If the motor is driven byan inverter, it may show an increase in noise level atsome speeds. Consult a Noise Specialist for thecombined calculation.

For units driven by equipment other thanelectric motors or units contained within enclosures,see the accompanying information sheets andmanuals.

Typical sound pressure level, dBA, LBpAB at 1 m reference 20 μPa (LBwAB sound power 1pW where LBpAB >85 dBA)3500 rpm 2900 rpm 1750 rpm 1450 rpmMotor size

and speed

kW (hp)

PumponlydBA

Pump &motordBA

PumponlydBA

Pump &motordBA

PumponlydBA

Pump &motordBA

PumponlydBA

Pump &motordBA


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2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpackingImmediately after receipt of the equipment it must bechecked against the delivery and shipping documentsfor its completeness and that there has been nodamage in transportation.

Any shortage and or damage must be reportedimmediately to Flowserve and received in writingwithin one month of receipt of the equipment. Laterclaims cannot be accepted.

Check any crates, boxes and wrappings for anyaccessories or spare parts which may be packedseparately with the equipment or attached to sidewalls of the box or equipment.Each product has a unique serial number. Checksthat this number corresponds with that advised andalways quote this number in correspondence as wellas when ordering spare parts or further accessories.

2.2 HandlingBoxes, crates, pallets or cartons may be unloadedusing fork-lift vehicles or slings dependent on theirsize and construction.

2.3 Lifting

Make sure that any equipment used to lift the pumpor any of its components is capable of supporting theweights encountered. Make sure that all parts arecorrectly rigged before attempting to lift.

A crane must be used for all pump sets inexcess of 25 kg (55 lb). Fully trained personnel mustcarry out lifting, in accordance with local regulations.The driver and pump weights are recorded ongeneral arrangement drawing included into the jobuser’s instruction.

2.3.1 To Lift unitTo lift the pump, driver, and mounting plate as a unit,rig the unit from the lifting lugs located on the supporthead. Also rig guide lines from the mounting plate toprevent the unit from tipping over. Rig using aspreader bar, as illustrated on figure 2.1 below, toprevent damage to the driver.

Spreader Bar

Driver

ControlLine

LiftingLugs

Pump

Figure 2.1

Do not lift pump, motor, baseplateunit by slinging from pump casing and/or eye bolton motor.

2.3.2 To lift driverRefer to Manufacturers Instructions.

2.3.3 To lift complete pump onlyLifting of the pump alone should be performed inaccordance with paragraph 2.3.1, to lift unit above.However, the use of a spreader bar is not required.

2.4 Storage

Store the pump in a clean, dry locationaway from vibration. Leave piping connection coversin place to keep dirt and other foreign material out ofpump casing. Turn pump at intervals to preventbrinelling of the bearings and the seal faces, if fitted,from sticking.Electric Motors (Pump Driver) should not be stored indamp places without special protection (Refer toMotor manufacturers instructions).

The pump may be stored as above for up to 6months.


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2.4.1 Long term storageDuring extended periods of storage prior toinstallation, precautions must be taken to protect thepump from deterioration. The various parts of thepump are protected prior to shipment by applyingvarying grades of preservative to the parts. However,during shipment and handling the preservatives aresubjected to conditions that can cause their removal.Also, during extended periods of time thepreservatives may deteriorate. The listed procedures(2.4.1.1 to 2.4.1.5) should be followed to preventdeterioration of the pump during the extendedstorage period. These procedures may also besupplemented by the experience of the person(s)performing the tasks.

2.4.1.1 Inspection upon arrivalWhen the pump is received it should be inspected fordamage or other signs of rough handling. If anydamage is found it should be reported to the carrierimmediately. Inspect the preservative coating onvarious parts. If necessary, renew preservative inareas where it has been rubbed or scraped.Inspect all painted surfaces. If necessary, touch upthe areas where paint has been chipped or scraped.Inspect all covers over pump openings and pipingconnections. If covers or seals for the covers aredamaged or loose, they are to be removed, and avisual inspection made of the accessible interiorareas for accumulation of foreign materials or water.If necessary, clean and preserve the interior parts asnoted above to restore the parts to the "as shipped"condition. Install or replace covers and fastensecurely.If the pump is configured for use with a pure mistlubrication system, then special precautions must betaken to prevent corrosion of the bearings. Removethe coupling guard, then place a bag of desiccantmaterial near each end of the bearing housing, thenwrap the entire bearing housing in an air-tight plasticcovering. This arrangement should only be disturbedfor periodic inspections.If the pump was shipped in a sealed plastic covering,then the covering should be reinstalled prior toplacing the pump in storage.

2.4.1.2 Storage

If at all possible, the pump and itscomponent parts should be stored indoors wherethey will be protected from the elements. In no caseshould any pump element be subjected to extendedperiods of submergence or wetting prior to start up. Ifit is not possible to store the pump and itscomponents indoors, precautions must be taken toprotect them from the elements. Regardless of

whether storage is indoors or outside, the storagearea should be vibration free. All boxes marked forindoor storage should be stored indoors. Whenstored outdoors the pump and its components shouldbe protected from dirt, dust, rain, snow, or otherunfavourable conditions by heavy plastic sheets,canvas, waterproof burlap or other suitable coverings.All equipment must be placed upon skids or blocks toprevent contact with the ground and surfacecontaminants. Equipment must be adequatelysupported to prevent distortion and bending.The pump shaft should be rotated, in the direction ofrotation, at least 1 and 1/4 turns each week duringthe storage period and any other periods of stand by.When selecting a storage area the following shouldbe taken intoconsideration.

a) The deterioration of the equipment will beproportionate to the class of storage provided.

b) The expenses involved in restoring theequipment at time of installation will beproportionate to the class of storage provided.

2.4.1.3 Inspection and maintenanceThe stored equipment has to be placed on a periodicinspection schedule by the purchaser.The responsibility for setting up an inspectionschedule rests with the purchaser and will bedependent upon the class of storage provided. Itwould be expected initially, inspection would occurweekly, then depending upon the inspection reportsbeing favourable or unfavourable, inspection wouldcontinue weekly, monthly, or quarterly, as may bedetermined.Each inspection should consist of a general surfaceinspection to assure that:

a) Pump supports are firmly in place.b) Pump covers over openings are firmly in place.c) Pump coverings, plastic or tarps are firmly in

place. Any holes or tears must be repaired toprevent entrance of dirt or water.

d) Pump covers are periodically removed fromopenings and interior accessible areas inspected.If surface rusting has occurred, clean or coat withpreservative.

e) If rusting occurs on exterior surfaces clean andrepaint or coat with preservative.

f) Check individually wrapped parts for signs ofdeterioration. If necessary, renew preservativeand wrapping.

Six months prior to the scheduled installation date, aFLOWSERVE representative is to be employed toconduct an inspection. This inspection may include,


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not necessarily in its entirety and not limited to thefollowing:

a) An inspection of all periodic inspection records askept on file by the purchaser, and all inspectionreports that have been compiled during thestorage period.

b) An inspection of the storage area to determinethe "as stored" condition of the equipment prior toany protection covers being removed.

c) An inspection of the equipment with protectivecovers and flange covers removed.

d) Depending upon the length of time the equipmentwas stored, the type of storage provided (i.e.Indoor: heated, unheated, ground floor, concretefloor. Outdoors: under roof, no roof, waterproofcoverings, on concrete, on ground) and as aresult of the inspection of (a),(b) & (c) above theFLOWSERVE representative may require apartial or complete dismantling of the equipment.

e) Dismantling may necessitate restoration ofpainted or preserved surfaces, and, orreplacement of gaskets, "O" rings, packing andbearings.

f) All costs involved during inspection, dismantling,restoration, replacement of parts and reassemblywill have to the accounted to the purchaser. Allnecessary labour, tools and cranes will besupplied by the purchaser.

Upon completion of the inspection the FLOWSERVErepresentative shall submit a report to the purchaser,and to the Manager of Customer Service, stating indetail the results of the inspection.One month prior to installation of the equipment, aFLOWSERVE representative is to be employed toconduct a final inspection. This inspection will bemade to assure that the requirements of the sixmonths inspection report were satisfactorilycompleted and that the equipment is ready forinstallation.Upon completion of this inspection the FLOWSERVErepresentative shall submit a final report to thepurchaser, and to the Manager of Customer Service,advising the results of the final inspection.All costs involved in conducting the final inspectionwill have to the accounted to the purchaser.Prior to and during start up, any requirements for theservices of an FLOWSERVE representative willrevert back to the original contract agreement forequipment purchased, with revised costing.

2.4.1.4 Painting and preservationPaints and preservatives used are eitherFLOWSERVE standard or 'special' as required by thecontract specification. Refer to FLOWSERVE for thedescription of paints and preservatives used on thisorder if needed

2.4.1.5 Associated equipmentMotors, Turbines, Gears, etc., being supplied byFLOWSERVE.Generally rotors of associated equipment should beblocked to relieve bearing loads. Storage should beindoors and dry. See the specific manufacturersstorage requirements.

2.5 Recycling and end of product lifeAt the end of the service life of the product or itsparts, the relevant materials and parts should berecycled or disposed of using an environmentallyacceptable method and local regulations. If theproduct contains substances which are harmful to theenvironment, these should be removed and disposedof in accordance with current regulations. This alsoincludes the liquids and or gases in the "seal system"or other utilities.

Make sure that hazardous substances ortoxic fluids are disposed of safely and that the correctpersonal protective equipment is used. The safetyspecifications must be in accordance with the currentregulations at all times.


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3 PUMP DESCRIPTION

3.1 ConfigurationsThe HWX pump is a vertical, single-stage, singlesuction, radially split centrifugal process pump. Thepump conforms to the specifications outlined in API610/682 and is intended for continuous duty servicein all process and industrial applications withinspecified pressure and temperature limitations.Maintenance of the pump is facilitated by the in-lineconfiguration, use of cartridge mechanical seals, anda spacer coupling designed to allow a back pull-outdisassembly of the internal pump parts.

3.2 NomenclatureThe pump size will be engraved on the nameplatetypically as below: 3x4x7 A-HWX

Nominal discharge branch size

Nominal suction branch size

Nominal full size impeller diameter

Casing pattern type

Pump type

The typical nomenclature above is the general guideto the HWX description. Identify the actual pump sizeand serial number from the pump nameplate. Checkthat this agrees with the applicable certificationprovided.

3.3 Design of major parts

3.3.1 Pump casingThe casing is of single or dual volute design thatreduces forces on the rotating element therebyminimizing vibration and shaft deflection.

Dual volute is standard on many 3 inch dischargepumps and on all pumps above 3 inch discharge.

Single volute is standard on some 3 inch dischargepumps and on all smaller sizes.

The fluid passages are designed to preventturbulence and emphasize streamline flow.

Motor support heads are mounted directly on thecasing for a true back-pull-out of the pump rotorwithout disturbing the driver electrical connections,nor casing.

3.3.2 ImpellerThe HWX impeller is a fully shrouded, radial flow,single suction design. All sizes are precision cast toassure the highest attainable efficiency. All impellersare dynamically balanced keyed to the shaft andsecured by locknut and lockscrew. Renewable wearrings are press fit onto the impeller hubs (front andback) and positively secured with axial screws or tackwelding.

3.3.3 Casing coverThe casing cover is either fabricated from plate orcast, depending on the material of construction.Designed to the dimensional standards within the API682 specification, the seal chamber canaccommodate a wide variety of single or dual sealarrangements as standard.

3.3.4 ShaftThe shaft is of ample strength and rigidity. It isprecision machined over its entire length and hasgenerous fillet radii at each change of section toreduce stress concentrations. Shaft deflections at theseal chamber are minimal and fall within theguidelines stated in API 610 8th - 9th Edition.

3.3.5 Bearing housingThere are three types of bearing housing, dependingon the desired lubrication: grease, pure oil mist, andOil Cascade sump. To maximise partsinterchangeability, there are only two sizes of bearinghousings and bearings used for all pump sizes. Forgrease and pure oil mist lubrication, a fabricated steelbearing housing is used; a cast housing is used forOil Cascade sump design. Operating speeds arefrom 900 to 3600 r.p.m. TRICO constant level oiler issupplied as standard for Oil Cascade sump and noconstant level oiler is supplied for pure oil mist.Fan cooling is supplied always as a standard forgrease and Oil Cascade sump. No cooling is requiredfor pure oil mist application.

3.3.6 Pump bearings and lubricationThe standard bearing arrangement for all HWXpumps is angular contact deep groove ball thrustbearings arranged back to back and a deep grooveball radial bearing able to ensure long life under themost severe operating conditions.

Thrust Bearings are brass cage design and linebearing is metal cage design in accordance withnormal oil industry preferences and API 9th ed.requirement. Bearing manufacturers must be FPDapproved suppliers.Lubrication of the bearings is provided by oil cascade,pure oil mist or grease.


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3.3.7 Shaft sealThe mechanical seal is a cartridge type design forsingle, tandem, and double seals to control theleakage of liquid to the environment. The cartridgedesign provides for proper axial alignment of the sealfaces and minimises the contamination of sensitiveseal faces during installation.Lubrication of the mechanical seal is provided by thepumped liquid or by an auxiliary seal-flush system. Avent connection is provided to eliminate the possibilityof the seal becoming vapour bound.

3.3.8 DriverThe driver is normally an electric motor mounted on asupport head and coupled to the pump by a flexiblespacer coupling.

3.3.9 Coupling/Coupling guardsFlexible spacer couplings are provided in variousmakes and models to suit customer preference.(Aluminium non- hinged guards are provided)

3.3.10 Mounting Plate and Motor Support HeadHWX pumps are supplied with a mounting plate as astandard, already suitable for levelling screwsinstallation.

Extended dimension mounting plates are available onrequest for applications where coolers or seal potsare required and need to be contained within themounting plate.

The motor support head is a heavy duty, register-fitmotor mount with generous openings allowing easyaccessibility for field maintenance. The opencompartments allow easy access to all bolting andremoval of the entire rotor with the bearing housingfrom either side.

3.3.11 AccessoriesAccessories may be fitted when specified by thecustomer.

3.4 Performance and operating limitsThis product has been selected to meet thespecifications of your purchase order see section 1.5.

These pumps are furnished for a particular servicecondition. Changes in the hydraulic system mayaffect the pump's performance adversely. This isespecially true if the changes reduce the pressure atthe suction flange or if the liquid temperature isincreased. In case of doubt, contact the nearestFLOWSERVE office.

3.4.1 Effect of specific gravityPump capacity and total head in metres (feet) do notchange with SG, however pressure displayed on apressure gauge is directly proportional to SG. Powerabsorbed is also directly proportional to SG.It is therefore important to check that any change inSG will not overload the pump driver or over-pressurise the pump.

3.4.2 Effects of viscosityThe pump is designed to deliver rated capacity andrated head for a liquid with a particular viscosity.For a given flow rate the total head reduces withincreased viscosity and increases with reducedviscosity. Also for a given flow rate the powerabsorbed increases with increased viscosity, andreduces with reduced viscosity.When contemplating operation at some viscosityother than the one for which the pump was originallydesigned and/or applied, the changed conditionsshould be referred to FLOWSERVE forrecommendations.

When pump is handling heavyviscous liquid, the temperature of the liquid mustallow it to be pumped easily. Liquid may have tobe heated prior to pump start-up.

3.4.3 Changing the pump speedChanging pump speed effects flow, total head, powerabsorbed, NPSHR, noise and vibration. Flow variesin direct proportion to pump speed. Head varies asspeed ratio squared. Power varies as speed ratiocubed. If increasing speed it is important therefore toensure the maximum pump working pressure is notexceeded, the driver is not overloaded,NPSHA>NPSHR, and that noise and vibration arewithin local requirements and regulations.

3.4.4 Net Positive Suction Head (NPSH)Any liquid, hot or cold, must be pushed into theimpeller of the pump by absolute pressure, such asthe atmospheric or vessel pressure from which thepump takes its suction.The head in feet of liquid necessary to push therequired flow into the pump is called Net PositiveSuction Head. This value, more commonly calledNPSH, is measured above the vapour pressure of theliquid at the pumping temperature.There are two kinds of NPSH: the NPSHR is the headrequired by the pump to cover the losses in the pumpsuction - that is shown on the pump characteristiccurve. The second, NPSHA, is the head available inthe system, taking into account friction loss in suctionpiping, valves, fittings etc. In all cases the NPSHA,


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measured above vapour pressure, must exceed theNPSHR in order to push the liquid into the pump.Failure to have this will result in both badperformance and mechanical damage to the pump,and in certain cases actual pump failure.If any change in NPSHA is proposed, ensure itsmargin over NPSHR is not significantly eroded. Referto the pump performance curve to determine exactrequirements particularly if flow has changed. If indoubt please consult your nearest Flowserve officefor advice and details of the minimum allowablemargin for your application.

3.4.5 Minimum Continuous Stable FlowThe Minimum Continuous Stable Flow for the pump isstated on the Data sheet.

3.4.6 Minimum flow controlIn all cases, it is the customer's responsibility tosupply a system and/or control which assures thatany pump within a system is not operated below itsminimum flow condition.In many cases, this is not a problem because thesystem is operating within its own flow range toassure product delivery. A simple high pressurealarm, shut down and/or bypass control can be used.However, in systems where product demand has highswings or where more than 100% capacity units aredesired to support a product system, additional caremust be taken.

3.4.7 Thermal controlA thermal control of the unit can be provided bythermal sensors which read direct or "related to" fluidtemperatures and respond accordingly by openingadditional flow paths until the given unit re-establishes the acceptable temperature rise, and setsoff alarms if not achieved within reasonable/normaltime periods. (High limit could actually shut downunit).

3.4.8 Pressure and/or Flow ControlPressure and/or flow sensors can be used to hold theunit at higher flows by opening additional flow pathsonce a "high pressure limit" or " low flow limit" wasindicated. Upon system reaching increased flow a"low pressure limit" or "high flow limit" setting wouldclose the bypass flow path. Care must be taken toallow for signal spread to avoid cyclic conditions.

3.4.9 Operating at Reduced Capacity

Damage to pump may result fromprolonged operations at capacities less than MCSFas stated in Data Sheet.

4 INSTALLATION

Equipment operated in hazardous locationsmust comply with the relevant explosion protectionregulations. See section 1.6.4, Products used inpotentially explosive atmospheres.

4.1 LocationThe HWX pump is designed to be installed directly inthe pipeline. The driver must be located above thepump and the piping must be supported. The pumpmust be supported by a support pad which will allowthe pump to move freely with the piping toaccommodate thermal growth.Make certain that the space above the pump issufficient to provide clearance for lifting the pumpassembly from the casing, and that the space aroundthe unit provides room for general accessibility andventilation. Be sure to allow adequate space formaintenance operations involving dismantling andinspection of parts. The certified general arrangementdrawing gives the overall dimensions, mountingdetails, clearance required, etc.Location of the unit should be in an area whereambient temperatures are not detrimental to theoperation of the driver (see driver instructions).When selecting a location, be sure to makeprovisions for draining and venting of the pump sealand seal-flush system. Refer to the GeneralArrangement and Seal Piping drawings for locationand size of pipe taps for the seal-flush system.

When pump is fitted with manifoldvent and drain lines, each line must be equipped withan individual valve to prevent any liquid from a highpressure line flowing into a low pressure line. Thesevalves must be closed during pump operation.

4.2 Part assembliesIf motor is supplied loose. It is the responsibility ofthe installer to ensure that the motor is assembled tothe pump and lined up as detailed in section 4.5.2.

4.3 Foundation

There are many methods of installingpump units to their foundations. The correct methoddepends on the size of the pump unit, its location andnoise vibration limitations. Non-compliance with theprovision of correct foundation and installation maylead to failure of the pump and, as such, would beoutside the terms of the warranty.The foundation should be sufficiently rigid andsubstantial to prevent any pump vibration and topermanently support the mounting plate at all points.


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The most satisfactory foundations are made ofreinforced concrete. These should be poured well inadvance of the installation to allow sufficient time fordrying and curing.The General Arrangement Drawing (In Job’s UserInstruction) will furnish overall outline of pumpmounting plate, anchor bolt locations, size of bolts,etc in order to provide proper shape to the primaryconcrete. Anchor bolts can be positioned or by aspecial template (not supplied by FLOWSERVE seefigure 4.2) or by the mounting plate itself if properpockets have been provided in primary concrete.

Figure 4.1Template for Hanging Foundation Bolts

Figure 4.3 below illustrates an alternative foundationbolt arrangement which can be used in lieu ofstandard foundation bolts. Notice the large washerwith lugs at the bottom. It should be welded to thebolt and pipe sleeve to prevent turning.Allow a little more than the specified threaded boltlength above the rail of the mounting plate. Theexcess can always be cut off if it is not needed.A rough finish top surface is best when applyinggrout.

Figure 4.2

4.3.1 Baseplate levellingBefore putting the unit on the foundation, thoroughlyclean the top of the foundation. Break off any loosepieces of cement and roughen the top with a chisel toafford a good hold for grout.

Coupling bolting and spacer piece mustbe removed from between the pump and driver halfcouplings before lifting the pump assembly.

When lifting pump assembly use all liftinglugs provided. Refer to Section 2.3.1

Prepare sufficient steel plates to be placed beloweach mounting plate jacking screw furnished with themounting plate. The purpose of the plate is to spreadthe load of the screw without crushing the concretebelow.

4.3.2 Method of levelling mounting plate usingwedges or shimsa) Level the mounting plate by using a machinist's

level on the machined surfaces of the pump anddriver pads. Levelling is best achieved byadjusting the shim pack thickness under eachholding bolt. Carefully raise the mounting plate byusing either the mounting plate jacking screwsprovided or by levering with a suitable pinch baror by installing a low level hydraulic jack.

b) Adjust the shim pack thickness and lower themounting plate.


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c) Repeat this procedure in a logical manner ateach bolt position until the mounting plate is bothstraight and levelled. A degree of 0.25 mm permetre (0.0035 inch per foot) length is achievableon most units with a maximum of 0.40 mm permetre length (0.005 inch per foot).

d) When the mounting plate is level, pull down thefoundation bolts so they are snug. This may havedisturbed the mounting plate, so re-check thelevels.

e) Ensure that shaft alignment per Section 4.5 canbe achieved prior to grouting the mounting plate.

4.4 GroutingIt is a matter of personal preference whether thelevelling wedges under the mounting plate should beremoved after grouting. If you do not want to removethe wedges, carefully mark their locations beforepouring grout.

Before grouting perform a roughshaft/coupling alignment. Alignment after grouthas set will not be possible if above is notsatisfactorily completed.

Use a good, high strength, non shrink grout mix andinstall as per manufacturer's instructions.

4.5 Initial alignment

4.5.1 Thermal expansion

The pump and motor will normallyhave to be aligned at ambient temperature andshould be corrected to allow for thermal expansion atoperating temperature.

4.5.2 Alignment methods

Ensure pump and driver are isolatedelectrically and the half couplings are disconnected.

The alignment MUST be checked.Although the pump will have been aligned at thefactory it is most likely that this alignment will havebeen disturbed during transportation or handling. Ifnecessary, align the motor to the pump, not the pumpto the motor.

4.5.2.1 Shaft/Coupling alignment

Shaft alignment must be correct forsuccessful operation. Rapid wear, noise, vibrationand actual damage to the equipment may becaused by shaft misalignment. The shafts must

be aligned within the limits given within thissection.

Adjustment to correct the alignment in onedirection may alter the alignment in another direction.Always check in all directions after making anyadjustment.Coupled equipment must be aligned to minimiseunnecessary stresses in shafts, bearings andcoupling. Flexible couplings will not compensate forappreciable misalignment. Foundation settling,thermal expansion or nozzle loads resulting inbaseplate/foundation deflection and vibration duringoperation may require the full coupling misalignmentcapability.

4.5.2.1.1 Types of misalignmentThere are two types of shaft misalignment: angularand offset. Therefore, two sets of measurements andcorrections are required. Both types of misalignmentcan occur in horizontal and vertical planes and arepresent in most applications.

A) Angular misalignmentIn angular misalignment, the centre line of the shaftsintersect, but are not on the same axis.

Figure 4.3B) Offset misalignmentIn offset misalignment, the shaft centre lines areparallel but do not intersect.


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Figure 4.4

4.5.2.2 Alignment using the Reverse AlignmentMethod

The following practices are recommended whenusing the reverse method of alignment. These shouldbe carried out prior to main alignment.

Ensure pump and driver are isolatedelectrically and the half couplings are disconnected.

The alignment MUST be checked.Although the pump will have been aligned at thefactory it is most likely that this alignment will havebeen disturbed during transportation or handling. Ifnecessary, align the motor to the pump, not the pumpto the motor.

To prevent deflection of dial indicator, thebracket must be rigid in construction and securelyfixed in position.

a) Attach lifting equipment to driver and set it onsupport head.

b) Check hubs for run out or possible bent shaftconditions and correct, if necessary, beforeproceeding with alignment.

c) Attach a bracket to the pump coupling hub orshaft. Set dial indicator to read the periphery orrim of the driver coupling hub. (See figure 4.5)

Parallel

Angular

Figure 4.5

d) Set the dial indicator to zero.e) Rotate pump shaft 360° and record indicator

reading. If reading is less than 0.05mm TIR(0.002 in.), proceed to step (f).The Maximum permissible misalignment atworking temperature is:

Parallel 0.05 mm (0.002 in.) TIRAngular 0.025 mm (0.001 in.) TIR

f) Tighten motor hold down bolts. Re-check offsetmisalignment by rotating the pump shaft 360°and verifying indicator reading is less than 0.05mm (0.002 in) TIR.

g) If misalignment exceeds maximum allowed:• Release driver hold down bolts.• Using jackscrews, make necessary horizontal

corrections while monitoring indicator.• repeat steps (d) and (e) above to verify

alignment setting.h) Repeat step (f).i) Remove dial indicator and bracket.j) Briefly operate driver in accordance with

manufacturer's instructions and observe rotationof shaft; its rotation must correspond to thedirection in which the pump is designed to turn.

k) Secure coupling spacer between half-couplings,if not previously done.

l) Secure coupling spacer between half-couplings,if not previously done.

m) Install coupling guard.

Complete piping as below and see sections 4.7,“Final shaft alignment check” up to and includingsection 5, “Commissioning, start-up, operation andshutdown” before connecting driver and checkingactual rotation.


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4.5.4 Hot alignmentThe factory alignment of driver and pump would beperformed at an average temperature of 75°F (24°C).Since operation of a pump at less than, or greater,than this temperature would cause alignmentchanges due to thermal effects on the pump'spedestal position, final alignment must be made withthe pump and driver at their actual operatingtemperature; else there can be no assurance thatpump and driver are in alignment while operating.Driver temperature change from ambient to operationtemperature will also affect alignment.A hot check can only be made after the unit has beenin operation a sufficient length of time to assume itsNORMAL operating temperature and conditions. Ifthe unit has been correctly cold set, parallelmisalignment will be within 0.05 mm (0.002 in.) TIRand the angular misalignment will be within 0.025 mm(0.001 in.) when in operation. If not makeadjustments.

Do not attempt any maintenance,inspection, repair or cleaning in the vicinity ofrotating equipment. Such action could result ininjury to operating personnel.

Before attempting any inspection or repairon the pump the driver controls must be in the"off" position, locked and tagged to preventrestarting equipment and injury to personnelperforming service on the pump.4.5.5 Assemble couplinga) Assemble coupling as per the manufacturer's

instructions included in Appendix of this manual.b) Install coupling guard

4.5.6 Installation check lista) Level Mounting Plate?b) Check Foundation Bolts?c) Alignment Shaft/Coupling?d) Piping Installed - Correct Vent, Gauge, Valve,

Suction Strainer Locations?e) All Flange Bolting Correctly Torqued with

appropriate gaskets in place?f) Check Shaft/Coupling Alignment again.g) Coupling guard correctly installed?

4.6 Piping

Never use the pump as a support forpiping

4.6.1 GeneralThese units are furnished for a particular servicecondition. Changes in the hydraulic system mayaffect performance adversely. This is especially true ifthe changes reduce the pressure at the suction or ifthe liquid temperature is increased. In case of doubtcontact FLOWSERVESuction and discharge piping should be of amplesize, be installed in direct runs, and have a minimumof bends. Double bends must be avoided in suctionline and a straight run of pipe, equal 5 times the pipediameter is desired directly upstream of the suctionnozzle.In order to minimise friction losses and hydraulicnoise in the pipework it is good practice to choosepipework that is one or two sizes larger than thepump suction and discharge. Typically mainpipework velocities should not exceed 2 m/s (6 ft/sec)suction and 3 m/s (9 ft/sec) on the discharge. Typicalsuction and discharge piping arrangement isaccording to Figure.4.6.

Provision must be made to support pipingexternal to the pump to prevent excessive nozzleloads, maintain pump/driver alignment and avoid pipeinduced vibrations.

Take into account the available NPSH which must behigher than the required NPSH of the pump.

Maximum forces and moments allowed on the pumpflanges vary with the pump size and type. Tominimise these forces and moments that may, ifexcessive, cause misalignment, hot bearings, worncouplings, vibration and the possible failure of thepump casing, the following points should be strictlyfollowed:• 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

Ensure piping and fittings are flushedbefore use.

Ensure piping for hazardous liquids is arrangedto allow pump flushing before removal of the pump.


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Reducer andStrainer

Suction Lift

Flooded Suction

Long RadiusElbow

Foot ValveReducer

andStrainer

Gate Valve**

Location of In-LineStrainer***

Pipe*

HW PumpPriming Plug

(Optional)

Gate Valve(Optional)

Support

Drain Line Support Pad

CheckValve

NOTES

* - The length of this pipe should be equal to at least five times the diameter of the suction pipe.

** - The installation of this gate valve is recommended for flooded suction. If a multiple suction isused, install a two-way valve at this point

*** - The in-line suction strainer, when used, should be located a minimum of five times thediameter of the suction pipe away from the pump suction flange.

Support

Figure 4.6

4.6.2 Suction pipinga) The inlet pipe should be one or two sizes larger

than the pump inlet bore and pipe bends shouldbe as large radius as possible.

b) Keep the suction pipe free of all air pockets.(Vent is required).

c) Pipework reducers should have a maximum totalangle of divergence of 15 degrees.

d) The piping should be inclined up towards thepump inlet with eccentric reducers incorporatedto prevent air locks.

e) Flow should enter the pump suction with uniformflow, to minimise noise and wear.

f) Except if considerable foreign matter is expectedstrainers are not recommended in inlet piping.Inlet strainers, when used, should have a net“free area” (see section 4.6.2.1)

4.6.2.1 Suction strainerIn a new installation, great care should be taken toprevent dirt, scale, welding beads and other itemsfrom entering the pump, as it is particularly importantto protect the numerous close running fits fromabrasive matter present in new piping

The suction system should be thoroughly flushedbefore installing the suction strainer and making upsuction piping to the pump.The suction strainer should be installed between 5 to20 pipe diameters upstream from the pump suctionflange.

The open area of the strainer shouldhave a minimum of a 3 to 1 ratio to the area of thepump suction.

Preferred Directionof Flow

Cone Type Strainer

Figure 4.7Cone Type Strainer

The FLOWSERVE recommendation for suctionstrainers consists of a conical shaped steel plate. Theplate has 1.6 mm (1/16 in.) perforations and is ofsufficient size and thickness for the required flow. Thestrainer should be fitted with a screen to filter theincoming flow: 100-mesh screen is typical for start-upoperation at limited flow rates; 20-mesh screen istypical for final operation. See Figure.4.11.

Other type of strainers may be used as long as theyconform to the requirements stated above.

Pressure gauges should be installed on both sides ofthe screen so that the pressure drop across thescreen can be measured.When the unit is being started, the gauges on eachside of the screen should be carefully watched. Anincrease in the differential pressure between the twogauges indicates that the screen is becoming cloggedwith dirt and scale. At this point, the pump should beshut down, and the screen cleaned and/or replaced.Differential pressure should be monitored on aregular basis.

A spool piece should be installed insuction line so that the suction strainer may beinstalled and removed with a pressure gaugebetween the strainer and pump.

The pressure drop across thestrainer is a direct reduction in the NPSHavailable to the pump. NPSH available mustalways exceed the NPSH required by the pump.This requirement may limit pump flow rate,particularly during startup.


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4.6.2.2 Bypass Line

Operation at low flows results inpump horsepower heating the liquid. A bypassmay be required to prevent vaporisation andsubsequent pump damage. Refer to localFLOWSERVE branch to determine if a bypass isrequired. Mechanical damage may result fromcontinuous operation at flows less than specified.

4.6.3 Discharge pipinga) Install a check valve and a gate valve in the

discharge pipe of the pump. When the pump isstopped, the check valve will protect the pumpagainst excessive pressure and will prevent thepump from running backward. The check valveshould be installed between the gate valve andthe pump nozzle in order to permit its inspection.Never throttle pump on suction side and neverplace a valve directly on the pump inlet nozzle.

b) Pipework reducers should have a maximum totalangle of divergence of 15 degrees.

4.6.4 DrainsPipe pump casing drains and gland leakage to aconvenient disposal point.

4.6.5 Pumps fitted with mechanical sealsCartridge mechanical seals are provided, to seal theshaft against leakage. The seals used on the "HWX"pump have internal design differences for sealingagainst specific liquids and conditions.

Long seal life with minimal leakage can only beobtained if the seals are provided with clean, coolliquid. Even tiny solids that may be suspended in theliquid being pumped can damage the seal faces andcause the seal to leak, making an external flush or adifferent seal arrangement necessary. The sealbalancing and flushing arrangement provided foreach pump is designed and fitted for the specificorder requirements.The "HWX" pump can be arranged with either asingle, dual mechanical pump seal. Refer to theGeneral Arrangement for piping connections to beused with your pump.Mechanical seal replacement or servicing requiresthat the pull out element be removed from the casing.For removal of cartridge element refer toManufacturer’s instructions.

4.6.6 Final checksCheck the tightness of all bolts in the suction anddischarge pipework. Check also the tightness of allfoundation bolts and auxiliary lines.

4.7 Final shaft alignment checkAfter connecting piping to the pump, rotate the shaftseveral times by hand to ensure there is no bindingand all parts are free.

Recheck the coupling alignment, as previouslydescribed, to ensure no strain on coupling is due topipe. If pipe strain exists, correct piping.

4.8 Electrical connections

Electrical connections must be made bya qualified Electrician in accordance with relevantlocal national and international regulations.

It is important to be aware of the EUROPEANDIRECTIVE on potentially explosive areas wherecompliance with IEC60079-14 is an additionalrequirement for making electrical connections.

It is important to be aware of the EUROPEANDIRECTIVE on electromagnetic compatibility whenwiring up and installing equipment on site. Attentionmust be paid to ensure that the techniques usedduring wiring/installation do not increaseelectromagnetic emissions or decrease theelectromagnetic immunity of the equipment, wiring orany connected devices. If in any doubt contactFlowserve for advice.

The motor must be wired up inaccordance with the motor manufacturer'sinstructions (normally supplied within the terminalbox) including any temperature, earth leakage,current and other protective devices as appropriate.The identification nameplate should be checked toensure the power supply is appropriate.

A device to provide emergency stopping mustbe fitted.

If not supplied pre-wired to the pump unit, thecontroller/starter electrical details will also be suppliedwithin the controller/starter.

For electrical details on pump sets with controllerssee the separate wiring diagram.

See section 5.3, Direction of rotationbefore connecting the motor to the electrical supply.

4.9 Protection systems

The following protection systems arerecommended particularly if the pump is installed in a


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potentially explosive area or is handling a hazardousliquid. If in doubt consult Flowserve.

If there is any possibility of the system allowing thepump to run against a closed valve or belowminimum continuous safe flow a protection deviceshould be installed to ensure the temperature of theliquid does not rise to an unsafe level.

If there are any circumstances in which the systemcan allow the pump to run dry, or start up empty, apower monitor should be fitted to stop the pump orprevent it from being started. This is particularlyrelevant if the pump is handling a flammable liquid.

If leakage of product from the pump or its associatedsealing system can cause a hazard it isrecommended that an appropriate leakage detectionsystem is installed.

To prevent excessive surface temperatures atbearings it is recommended that temperature orvibration monitoring are carried out. See sections5.7.4 and 5.7.5.

5 COMMISSIONING, START-UP,OPERATION AND SHUTDOWN

These operations must be carriedout by fully qualified personnel.

5.1 Pre-commissioning procedureThe following steps should be followed at initial startup and after the equipment has been overhauled:a) Prior to installing the pump, flush the suction side

of the system to remove all deposit (slag, boltsetc).

b) Ensure the pump and piping is clean. Beforeputting the pump into operation, the piping shouldbe thoroughly back flushed to remove any foreignmatter which may have accumulated duringinstallation. Take all possible care not tocontaminate your system.

c) Install suction strainer if required. (See Section4.6.2.1).

d) Fill the bearing housing with the appropriate oil tothe correct level (if applicable). Bearing mustreceive a small amount of oil prior to starting toensure adequate lubrication at start up. (Refer toSection 5.1.1).

e) Grease the thrust bearings with the propergreaser fitted on the bearing (if applicable).Bearing must receive a small amount of greaseprior to starting to ensure adequate lubrication atstart up. (Refer to Section 5.1.1).

f) Turn pump rotor by hand or with a strap wrenchto make sure it turns smoothly.

g) Assure that correct seal piping has been installedand has not been damaged.

h) Prior to coupling installation, bump start motor tocheck for correct rotation. If rotation is not correctrefer to motor manual for appropriate connectionsto change rotation (Shut down all power prior tochange).

i) Ensure coupling is correctly aligned andlubricated. (Refer to Section 4.5).

j) Ensure coupling guard is correctly installed.

The unit must not be operated unlesscoupling guard is securely and completelybolted in place. Failure to observe thewarning could result in injury to operatingpersonnel.

a) Check torque of all bolting and the plugs fortightness.

5.1.1 LubricationLubrication of bearing is by grease, by oil mist or byoil cascade into the bearing housing.

5.1.1.1 Grease Lubricated Ball-BearingsBefore a pump with greased ball bearings is placedinto operation, it must have grease supplied to thethrust bearings, the line bearing is life greased.Unplug the grease outlet plug located opposite thezirc fitting in the bearing housing outer cover. Pumpgrease into the zirc fitting in the bearing housing outercover until grease just begins to extrude from thegrease outlet. Replug the grease outlet and turn theshaft several times by hand to distribute the grease inthe bearings. Thereafter, re-grease thrust bearings at3000 hour intervals of operation. Refer to Section5.2.1 for proper grease type.

BREATHE PLUG

OVERFILL GREASENIPPLE

Figure 5.1


Page 23 of 56

5.1.1.2 Pure Oil Mist Lubricated Ball-BearingsFor bearings lubricated by pure oil mist system,ensure that the pure oil mist system is installed on thepump bearing housing, and is operating inaccordance with the manufacturer’s instructions. Nofurther preparation is necessary.

OIL MISTVENT

OIL MISTDRAIN

OIL MISTINLET

OIL MISTVENT

Figure 5.2

5.1.1.3 Oil Cascade Lubricated Ball-Bearings

Preparing bearing housingBefore filling the bearing housing reservoir, flush outthe housing thoroughly with safety solvent and aleading grade of flushing oil, compatible with thelubricating oil that will be used. The reservoir is to befilled to appropriate level as illustrated in figures 5.3,5.4 and 5.5

The oil level must be maintained at the correct level:oil lack may cause overheating and failure of thebearings, while exceeding the correct level can resultin leakage. The constant level oiler can be adjustedby changing the height of the cross arms whichsupport the glass reservoir, as illustrated for TRICOoiler in figure 5.5

OIL LEVEL

Figure 5.3

The oil circulation is ensured by a pumping ring andan oil thrower (see figure 5.4) according to thedescription as follow:

OIL LEVEL

OIL FILLING

OIL THROWER

BREATHE PLUG

PUMPING RING

CONSTANT LEVEL OILER

OVERFLOW PLUG

Figure 5.4

thrust bearings lubrication• By a pumping ring fitted on the shaft the oil reach

the top of the bearing housing towards the oilchannel.

• Once at the top the oil flows into the thrustbearings and falls directly over the oil thrower.

• The oil thrower, fitted on the pump shaft, splashthe oil to the bearing housing walls.

line bearing lubrication• Once the oil flow on bearing housing wall it

reaches the line bearing by three radial oil


Page 24 of 56

collectors and then once it flows into the linebearing it returns into the oil sump.

• The oil that misses the three radial oil collectorsflows directly on the oil sump.

Trico oiler setting (standard)a) Initial fill via top of housing, using overflow plug to

establish correct level (see Figure 5.4).b) Release thumb screw and remove bottle.

Establish a measurement from the centre line ofthe oiler connection in bearing housing to theupper cross arm of 6 mm (0.24 in.); this can beobtained by completely screwing down the lowerarm as illustrated on figure 5.5.

c) Fill bottle with recommended oil and install onholder. Remove and fill bottle as many times as isrequired to fill the bearing housing up to the crossarm level and no air bubbles appear in the bottle.

d) Remove bottle and ascertain that the oil level is 6mm (0.24 in.) from the centre line of oilerconnection. Adjust upper cross arm as requiredand lock in place with lower arm.

UPPERARM

LOWERARM

Figure 5.5

InspectionInspect the oil level in the bearing housing and thecondition of the oil at least weekly. Oil is alwayssubject to gradual deterioration from use andcontamination from dirt and moisture which is thecause of premature bearing wear.

For oil lubricated pumps, fill thebearing housing with correct grade of oil to thecorrect level, i.e. constant level oiler bottle (standardconfiguration) and sight glass (when fitted onrequest).

Figure 5.6Sight glass

ReplenishmentReplenish the oil in the oiler as required. Morefrequent replenishment at high temperatures may berequired.

Oil changeFrequency of oil change is dependent on pumpservice and environmental conditions. As a generalguide, oil in the bearing housing should be changedevery 4000 operating hours, after the initial change.

Lubrication SpecificationThe ideal bearing lubricant is a straight well refined,neutral mineral, preferably of the turbine type. Itshould not contain free acid, chlorine sulphur or morethan a trace of free alkali. It is suggested that the oilconform to the following physical characteristics.


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5.2 Pump Lubricants5.2.1 Recommended oil lubricants

Oil Oil Ring or Slinger Lubrication Pure Oil MistLubrication

Lubrication service Ball BearingType Mineral Oil

(Petroleum Based)Mineral Oil

(Petroleum Based)Viscosity

mm ²/s 40 ºC [cSt] 32 46 68 100

Oil temperature range *ºC (ºF)

-5 to 65(-23 to 149)

up to 75(up to 167)

up to 85(up to 185)

-30 and above(59 and above)

Approx. Consumptioncontinuous operation

0.12 litres / month ¼ pint per month

0.12 litres / month¼ pint per month

0.12 litres / month¼ pint per month

0.12 litres¼ pint per month

Running in Period 500 hours 500 hours 500 hours 500 hoursFirst Oil Charge 500 hours 500 hours 500 hours 500 hours

Further Oil Changes 4000 hours 4000 hours 4000 hours 4000 hoursOne Year Consumption 1.44 litres approx. max 1.44 litres approx. max 1.44 litres approx. max 1.44 litres approx. max

Cen

trifu

gal P

ump

Lubr

icat

ion

Designation according toDIN51502 ISO VG 32 46 68 100

BP BP Energol HL32BP Energol HLP32BP Energol HL46

BP Energol HLP46BP Energol HL68

BP Energol HLP68 -

CASTROL Perfecto T32 Perfecto T46 Perfecto T68 -DEA Anstron HL32

Anstron HLP32Anstron HL46

Anstron HLP46Anstron HL68

Anstron HLP68 -

Elf OLNA 32HYDRELEF 32TURBELF 32

ELFOLNA DS32

TURBELF SA46

ELFOLNA DS46

TURBELF SA68

ELFOLNA DS68

-

Esso TERESSO 32NUTO H32

TERESSO 46NUTO H46

TERESSO 68NUTO H68 -

LSC(for oil mist)

LSO 32Synthetic oil

LSO 46Synthetic oil

LSO 68Synthetic oil

LSO 100Synthetic oil

Mobil Mobil DTE oil lightMobil DTE13M

MobilDTE24

Mobil DTE oil mediumMobil DTE15MMobil DTE25

Mobil DTE oil heavymedium

Mobil DTE26-

Q8 Q8 Verdi 32Q8 Haydn 32

Q8 Verdi 46Q8 Haydn 46

Q8 Verdi 68Q8 Haydn 68 -

Shell Shell Tellus 32Shell Tellus 37

Shell Turbo T32

Shell Tellus 01 C 46Shell Tellus 01 46Shell Turbo T46

Shell Tellus 01 C68Shell Tellus 01 68Shell Turbo T68

-

Texaco Rando Oil HD 32Rando Oil HD-AZ-32

Rando Oil 46Rando Oil HD B-46

Rando Oil 68Rando Oil HD C-68 -

Total Azolla ZS32 Azolla ZS46 Azolla ZS68 -

Oil

Com

pani

es a

nd L

ubric

ants

Wintershall(BASF Group)

Wiolan HN32Wiolan HS32

Wiolan HN46Wiolan HS46

Wiolan HN68Wiolan HS68 -

(*) Note that it normally takes 2 hours for bearing temperature stabilize and the final temperature will depend on the ambient, r/min,pumpage temperature and pump size. Also some oils have a greater Viscosity Index than the minimum acceptable of 95 (e.g. MobilDTE13M) which may extend the minimum temperature capability of the oil. Always check the grade capability where the ambient is lessthan -5 ºC (-23 ºF).


Page 26 of 56

If a synthetic lubricant (fire resistant fluid) is to beused instead of the normal type oil for the lubricationof bearings, gears etc., the material of all gaskets and"O" rings in contact with the lubricant must becompatible with the lubricant. Normal gasketmaterials will usually swell and deteriorate whenimmersed in synthetic lubricants: also normal paintswill peel from internal walls of reservoirs and bearingchambers.

Grease nipples on Thrust Bearing SideGrease

NLGI 2 NLGI 3Temp. range ºC

(ºF) -30 to +120(-22 to +266)-30 to +120

(-22 to +266)

Designationaccording to DIN

K2K-30 K2K-30

SKF LGMT2 LGMT3NILS NILENA SSO -

Line BearingGreaseNLGI 3

Temp. range ºC (ºF)

-30 to +120(-22 to +266)

SKF MT33Different greases can’t be mixed !

5.2.2 Recommended fill quantities

CapacitiesBearing HousingSize (*) BearingDesignation Oil Cascadelitres (US pint)

Greasecm3 (inch3)

#1 7311 0.86 (1.82) 115 (7.02)#2 7313 1.52 (3.22) 165 (10.07)

* The bearing housing size can be identified from thethrust bearing size indicated by nameplate.

5.2.3 Bearing housing oil and grease limitations

Recommended Oil Temperature At Start Up 60 °F15.6 °C

Desirable Operating Temperature 140-160 °F60-71 °C

Oil Level Above Oil Connection Centre line 6 mm

When the starting temperature is below -10 °C (14°F) for long time it’s suggested to use synthetic oil.Other drivers and gearboxes, if appropriate, shouldbe lubricated in accordance with their manuals.

Recommended Grease Temperature AtStart Up

15.6 °C60 °F

Desirable Operating Temperature 60-71 °C140-160 °F

In the case of product lubricatedbearings the source of product supply should bechecked against the order. There may berequirements for an external clean supply, particularsupply pressure or the commencement of lubricationsupply before pump start-up.

5.2.4 Lubrication schedule

5.2.4.1 Oil lubricated bearingsNormal oil change intervals are 4000 operating hoursor at least every 6 months. For pumps on hot serviceor in severely damp or corrosive atmosphere, the oilwill require changing more frequently. Lubricant andbearing temperature analysis can be useful inoptimising lubricant change intervals.The lubricating oil should be a high quality mineral oilhaving foam inhibitors. Synthetic oils may also beused if checks show that the rubber oil seals will not beadversely affected.

5.2.4.2 Grease lubricated bearingsWhen grease nipples are fitted, one charge betweengrease changes is advisable for most operatingconditions, i.e. 2 000 hours interval.

Normal intervals between grease changes are 4 000hours or at least every 6 months.

The characteristics of the installation and severity ofservice will determine the frequency of lubrication.Lubricant and bearing temperature analysis can beuseful in optimising lubricant change intervals.

Never mix greases containing differentbases, thickeners or additives.

For both lubrication type a continuously risingtemperature, or an abrupt rise, indicate a fault.Based on the specified operating conditions and anambient temperature of 43°C (110°F) oil sumptemperature below 82°C (180°F) is expected.

5.3 Direction of rotation

Ensure the pump is given the samerotation as the pump direction arrow fit on bearinghousing. In any case the direction of rotation must bechecked with the pump disconnected.


Page 27 of 56

To avoid dry running the pump must either be filledwith liquid or have the flexible coupling disconnectedbefore driver is switched on.

If maintenance work has been carriedout to the site's electricity supply, the direction ofrotation should be re-checked as above in case thesupply phasing has been altered.

5.4 Guarding

Guarding is supplied fitted to the pump set. Ifthis has been removed or disturbed ensure that all theprotective guards around the pump coupling andexposed parts of the shaft are securely fixed.

5.5 Priming and auxiliary supplies

Ensure all electrical, hydraulic,pneumatic, sealant and lubrication systems (asapplicable) are connected and operational.

Ensure the inlet pipe and pump casingare completely full of liquid before starting continuousduty operation.

Before starting or while operating thepump, the casing and suction line must be completelyfilled with the liquid being pumped. The rotating partsdepend on this liquid for lubrication and the pumpmay seize if operated without liquid.

Before starting or while operating thepump, ensure that mechanical seal is properl

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