I.O.M.Installation,Operation andMaintenance

Durco Mark IIIAlloy Pumps

ANSI Standard Sealmatic Unitized Self-Priming Recessed Impeller Lo-Flo

Bulletin P-10-502e (E)

Pump Division

Pump Division

TABLE OF CONTENTS1.0 Introduction .....................................................................1

2.0 Safety considerations .....................................................2

3.0 Overview3.1 Warranty statement................................................43.2 Nameplate ..............................................................43.3 Storage

Short term..............................................................4Long term ..............................................................5

3.4 Lifting pumps and assemblies................................5

4.0 Mark III ANSI Standard Pump4.1 General description of pump ..................................74.2 Installation

Protection of openings and threads .......................8Rigid baseplates overview...................................8Installation and Alignment

Factory AlignmentProcedure........................................................8Recommended Procedure forBaseplate Installation and Final Field Alignment .......................................9

New Grouted Baseplates ..........................9Existing Grouted Baseplates...................10Stilt Mounted Baseplates........................10

Zirconium Components........................................11Piping connection Suction/discharge ................11Mechanical Seal ...................................................12Packing ................................................................13Piping connection Seal/packing

support system .............................................13Piping connection Bearing housing

cooling system ..............................................13Piping connection Support leg cooling

for centerline mounting option ......................13Piping connection Heating/cooling fluid

for jacketed cover/casing ...............................14Piping connection Oil mist lubrication

system...........................................................14Coupling...............................................................15

Coupling guard maintenance.........................15C-flange motor adapter

Special considerations..............................154.3 Operation

Rotation check .....................................................16Pre start-up checks ..............................................16

(See Maintenance Section for details)Impeller setting .............................................16Shaft seal ......................................................16Seal/packing support system ........................16Bearing lubrication ........................................16Bearing housing cooling system ...................16

Support leg cooling for centerlinemounting option .......................................16

Heating/cooling fluid for jacketedcover/casing .............................................16

4.4 Start-up considerationsEnsuring proper NPSHA.......................................17Minimum flow......................................................17Starting the pump and adjusting flow ..................17Operation in sub-freezing conditions....................18Shutdown considerations.....................................18Troubleshooting ...................................................18

4.5 MaintenancePreventive maintenance .......................................22Need for maintenance records .............................22Need for cleanliness .............................................22Disassembly.........................................................22Cleaning/inspection..............................................25Critical measurements and tolerances..................25Assembly .............................................................26Power end assembly

Bearing installation........................................27Lip seals 29Labyrinth seals ..............................................29Magnetic seals ..............................................29Bearing carrier/power end

assembly ..................................................29Wet end assembly

Cartridge mechanical sealsSeal installation ........................................30Rear cover plate installation .....................30Impeller installation and

clearance setting..................................30Component-type mechanical seal

Determination of seal location ..................30Gland installation......................................30Seal installation ........................................30Rear cover plate installation .....................31Impeller installation and

clearance setting..................................31Packing with split gland

Rear cover plate installation .....................31Impeller installation and

clearance setting..................................31Packing/gland installation.........................31

Packing with one-piece glandGland installation......................................31Impeller installation and

clearance setting..................................32Packing installation...................................32

Bearing lubricationOil bath ........................................................32

Pump Division

GreaseRegreaseable bearings .............................33Shielded bearings .....................................33Sealed bearings ........................................33

Oil mist ........................................................33Reinstallation .......................................................33

4.6 Spare parts ........................................................34How to order spare parts .....................................34

5.0 Mark III Sealmatic Pump 5.1 General description of pump ................................385.2 Overview

Repeller function ..................................................39Design difference .................................................39Seal options

Packing - Option A ........................................40Checkmatic - Option B...................................40Dry Running Seals - Option C........................41

5.3 OperationGeneral information..............................................41Start-Up ...............................................................41

5.4 MaintenanceDisassembly of Group 2 Pumps...........................42Disassembly of Group 3 Pumps...........................42Reassembly - Sealmatic

with Packing..................................................42Reassembly - Sealmatic with

Checkmatic Seal ............................................42Reassembly - Sealmatic with

Dry Running Seal ..........................................425.5 Miscellaneous information ...................................43

Repeller selection instructions .............................435.6 Spare parts...........................................................44

6.0 Mark III Unitized Self-Priming Pump 6.1 General description of pump ................................456.2 Pump installation and operation...........................466.3 Spare parts...........................................................48

7.0 Mark III Recessed Impeller Pump 7.1 General description of pump ................................497.2 Setting the impeller ..............................................507.3 Spare parts...........................................................50

8.0 Mark III Lo-Flo Pump 8.1 General description of pump ................................518.2 Setting the impeller ..............................................518.3 Spare parts...........................................................52

Appendix A. IOM for C-flange motors adaptersAppendix B. Assembly of stilt and spring mounted

baseplatesAppendix C. Critical measurements and tolerancesAppendix D. Installation/clearance setting of reverse vane

impellerAppendix E. Installation/clearance setting of front vane

open impellerAppendix F. Removal/installation of seals with

SealSentry FMI seal chamberAppendix G. Bearing isolation maintenance instructionsAppendix H. Installation of repeller cover, repeller, cover,

impeller for Sealmatic PumpAppendix I. Allowable nozzle loadsAppendix J. ClearGuard Trimming and Assembly

InstructionsAppendix K. Sources of additional information

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Pump Division

Section 1.0

Section 1.0 INTRODUCTIONThis bulletin contains instructions and guidelines for theinstallation, operation, and maintenance of the Durco Mark IIIANSI Standard Pump, the Mark III Sealmatic Pump, the Mark IIIUnitized Self-Priming Pump, the Mark III Recessed ImpellerPump and the Mark III Lo-Flo Pump.

These pumps all use the Mark IIIA standard power end, or theANSI 3A upgraded power end. The A designation signifiesthat both of these power ends are the new improved design thatwas released in 1995. Information concerning the older Mark IIIand ANSI 3 power ends is also available in the IOM.

There are many factors affecting the successful installation,operation, and maintenance of a pump. From one pump to thenext there is typically significant variation in these factors. Thismakes it impossible to create a bulletin that covers all situations.Therefore, the information contained herein is meant to serveonly as a general guideline. If detailed questions or problemsarise, contact the nearest Flowserve Regional Sales Office orDistributor/Representative.

It is extremely important that this entire bulletin be read priorto installation or start-up of the pump. This is important forsafety, for proper performance of the pump, and for maximumMean Time Between Planned Maintenance (MTBPM).

THE COMPANYAmong Flowserve Corporations brands, Durco has long beenrecognized as the leading name in chemical process pumps.Durco pumps are manufactured at Flowserves modernfacilities, utilizing state-of-the-art equipment and sophisticatedquality control techniques. Flowserve provides technicalsupport and special services specific to the needs of itscustomers. Flowserve is proud of earning preferred supplierstatus with many of the world's leading processing companies.Engineered and manufactured, sold and serviced to ISO 9001quality certification, Durco process pumps are truly world classproducts. And with more than 120 years of experience inserving the needs of the worldwide process industries,Flowserve has become the unchallenged leader in hydraulicdesign engineering, materials expertise, and application know-how. Committed to continuous quality improvement, Flowservecontrols the complete product life cycle from melting andcasting, to cellular manufacturing to assembly and testing, tosupply of aftermarket products, repair and diagnostic services.

The advanced design and precision manufacture of the rugged,heavy-duty Mark III chemical service pump significantlyenhance bearing and seal life, thereby extending mean timebetween planned maintenance (MTBPM). Its exclusive featuresprovide significant performance benefits for chemical pumpusers. Most notable among these are:1. The exclusive reverse vane impeller offers important

performance-enhancing, maintenance-reducing advantages. 2. The exclusive external micrometer shaft adjustment provides

dead accurate setting of impeller clearance in seconds.3. The ANSI 3A power end, SealSentry family of seal

chambers, Ultralign pump/motor shaft alignment systemand the BaseLine family of baseplates are building blocksfor improved MTBPM.

A Flowserve Sales Engineer, Representative or Distributor willbe happy to review the advanced product features that make theMark III the leader in chemical pumping technology.

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Pump Division

Section 2.0

The Durco Mark III process pump has been designed andmanufactured for safe operation. In order to ensure safeoperation, it is very important that this manual be read in itsentirety prior to installing or operating the pump. Flowserveshall not be liable for physical injury, damage or delays causedby a failure to observe the instructions for installation, operationand maintenance contained in this manual.

Remember that every pump has the potential to be dangerous,because of the following factors: parts are rotating at high speeds high pressures may be present high temperatures may be present highly corrosive and/or toxic chemicals may be present

Paying constant attention to safety is always extremelyimportant. However, there are often situations that requirespecial attention. These situations are indicated throughout thisbook by the following symbols:

DANGER Immediate hazards which WILL result in severepersonal injury or death.

WARNING Hazards or unsafe practices which COULD result insevere personal injury or death.

CAUTION Hazards or unsafe practices which COULD result inminor personal injury or product or property damage.

Several important general precautions are listed below:

1. DO NOT RUN EQUIPMENT DRY OR START THE PUMPWITHOUT THE PROPER PRIME (Casing Flooded).

2. DO NOT EXCEED THE MAXIMUM DESIGN PRESSURE(MDP) AT THE TEMPERATURE SHOWN ON PUMPNAMEPLATE. See Figure 1 for general pressure versustemperature ratings of common alloys.

3. ALWAYS LOCK OUT POWER TO THE DRIVER BEFOREPERFORMING PUMP MAINTENANCE.

4. NEVER OPERATE THE PUMP WITHOUT COUPLING GUARDAND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED.

5. DO NOT APPLY HEAT TO DISASSEMBLE THE PUMP OR TOREMOVE THE IMPELLER. Entrapped liquid could cause anexplosion.

6. NEVER OPERATE THE PUMP FOR MORE THAN A SHORTINTERVAL WITH THE DISCHARGE VALVE CLOSED. The lengthof the interval depends on several factors including the natureof the fluid pumped and its temperature. This interval must bedetermined by the customers Engineering personnel.

7. NEVER OPERATE THE PUMP WITH THE SUCTION VALVECLOSED.

8. EXCESSIVE PUMP NOISE OR VIBRATION may indicate adangerous condition. The pump must be shut downimmediately.

9. DO NOT OPERATE THE PUMP FOR AN EXTENDED PERIODBELOW THE RECOMMENDED MINIMUM FLOW (Figure 20).

10. THE PUMP SHAFT MUST TURN CLOCKWISE WHENVIEWED FROM THE MOTOR END. It is absolutely essential thatthe rotation of the motor be checked before installation of thecoupling spacer and starting the pump. Incorrect rotation of thepump for even a short period of time can unscrew the impeller,which can cause severe damage.

Section 2.0 SAFETY CONSIDERATIONS

NOTE: ALWAYS COORDINATE REPAIR ACTIVITY WITH OPERATIONS PERSONNEL, AND FOLLOW ALL PLANT SAFETYREQUIREMENTS AND APPLICABLE SAFETY AND HEALTH LAWS/REGULATIONS.

CAUTION

WARNING

DANGER

Pump Division

Section 2.0

300

250

200

150

100

50

2000

1750

1500

1250

1000

750

500

250

-50 0 50 100 150 200 250 300 350

-100 0 100 200 300 400 500 600 700

-50 0 50 100 150 200 250 300 350

-100 0 100 200 300 400 500 600 700

350

300

250

200

150

100

2250

2000

1750

1500

1250

1000

750

500

DNI

CD4MDS

DC2 TIDC3 TIP ZR

D4D4L

D2D2L

DCI

DINC

D20

DNI

DM

CR29

DINCDC2DC3

DM

CD4M DS

D4D2 D4D2L D4LD20

TITIPZR

FIGURE 1 Pressure-Temperature Limits By Alloy

FIGURE 2 Alloy Cross-Reference ChartDesignation Symbol ACI Designation Equivalent Wrought Designation ASTM Specifications

Ductile Iron DCI None None A395High Chrome Iron CR28 None None A532 class IIIHigh Chrome Iron CR29 None None NoneHigh Chrome Iron CR35 None None NoneCarbon Steel DS None Carbon Steel A216 Gr. WCBDurco CF8 D2 CF8 304 A744, Gr. CF8Durco CF3 D2L CF3 304L A744, Gr. CF3Durco CF8M D4 CF8M 316 A744, Gr. CF8MDurco CF3M D4L CF3M 316L A744, Gr. CF3MDurcomet 100 CD4M CD4MCu Ferralium A744, Gr. CD4MCuDurimet 20 D20 CN7M Alloy 20 A744, Gr. CN7MDurcomet 5 DV None None NoneDurco CY40 DIN CY40 Inconel 600 A744, Gr. CY40Durco M35 DM M351 Monel 400 A744, Gr. M351Nickel DNI CZ100 Nickel 200 A744, Gr. CZ100Chlorimet 2 DC2 N7M Hastelloy B A494, Gr. N7MChlorimet 3 DC3 CW6M Hastelloy C A494, Gr. CW6MDuriron D None None A518Durichlor 51 D51 None None A518Superchlor SD51 None None A518Durco DC8 DC8 None None NoneTitanium Ti None Titanium B367, Gr. C3Titanium-Pd Ti-Pd None Titanium-Pd B367, Gr. C8AZirconium Zr None Zirconium B752, Gr. 702C

Duriron, Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation Ferralium is a registered trademark of Langley Alloys Hastelloy is a registered trademark of Haynes International, Inc. Inconel and Monel are registered trademarks of International Nickel Co. Inc.

TEMPERATURES C

TEMPERATURES F

TEMPERATURES C

TEMPERATURES F

MAX

DIS

CHAR

GE P

RESS

URE

- lb f

/in2

MAX

DIS

CHAR

GE P

RESS

URE

- kPa

MAX

DIS

CHAR

GE P

RESS

URE

- lb f

/in2

MAX

DIS

CHAR

GE P

RESS

URE

- kPa

CLASS 150FLANGES

CLASS 300FLANGES

GROUP I & IICLASS 300 MARK III PUMPSBASED ON ANSI B16.5GROUP IIICLASS 300 MARK III PUMPSLIMITED TO CLASS 150 RATINGS

CLASS 150 MARK III PUMPSBASED ON ANSI B16.5

DSDCI LOW TEMPERATURELIMIT CD4M

UPPER LIMIT

DCIUPPER LIMIT

CD4MUPPER LIMIT

DSLOWTEMPERATURELIMIT

CURVE NO. 2505-7 CURVE NO. 2505-7

3

4

Pump Division

Section 3.0

Section 3.0 OVERVIEW3.1 WARRANTY STATEMENTThe warranty on a Durco pump is provided in a statement whichwas sent with the Order Acknowledgement. Please call theFlowserve Regional Sales Office or Distributor/Representative for a copy of this warranty statement.

3.2 NAMEPLATEAn example of the nameplate used on the Mark III pump isshown below. This nameplate, which is always mounted on theMark III bearing housing, is shown in Figure 3.

FIGURE 3How To Identify Durco Mark III Process Pump

Flowserves pump size code is used to indicate the size of the pump.For example, consider the following:

3.3 STORAGESHORT TERM STORAGENormal packaging is designed to protect the pump duringshipment and for dry, indoor storage for up to two months orless. The procedure followed for this short term storage issummarized below:

Standard Protection for Shipment :a. Loose unmounted items, including, but not limited to,

oilers, packing, coupling spacers, stilts, and mechanicalseals are packaged in a water proof plastic bag andplaced under the coupling guard. Larger items arecartoned and metal banded to the baseplate. For pumpsnot mounted on a baseplate, the bag and/or carton isplaced inside the shipping carton. All parts bags andcartons are identified with the Flowserve order number,the customer purchase order number, and the pump itemnumber (if applicable).

b. Inner surfaces of the bearing housing, shaft (areathrough bearing housing), and bearings are coated withCortec VCI-329 rust inhibitor, or equal.Note: Bearing housings are not filled with oil prior toshipment.

c. Regreasable bearings are packed with grease (ChevronSRI #2).

d. After a performance test, if required, the pump is tippedon the suction flange for drainage (some residual watermay remain in the casing). Then, internal surfaces offerrous casings, covers, flange faces, and the impellersurface are sprayed with Calgon Vestal Labs RP-743m,or equal. Exposed shafts are taped with Polywrap.

e. Flange faces are protected with plastic covers securedwith plastic drive bolts. 3/16 in (7.8 mm) steel, or 1/4 in(6.3 mm) wood covers with rubber gaskets, steel bolts,and nuts are available at extra cost.

f. All assemblies are bolted to a wood skid which confinesthe assembly within the perimeter of the skid.

g. Assemblies with special paint are protected with a plasticwrap.

h. Group 1 and Group 2 bare pumps, when not mounted onbaseplates, are packed in hard paper cartons mounted onwood skids.

i. Group 3 bare pumps, when not mounted on baseplates,are bolted to wood skids.

j. All pump assemblies utilizing polycrete baseplates aremounted on wood skids.

k. All assemblies having external piping (seal flush andcooling water plans), etcare packaged and braced towithstand normal handling during shipment. In somecases components may be disassembled for shipment.

The pump must be stored in a covered, dry location.

Pump Division

2K6X4M-13A/124RV

2 K 6 X 4 M 1 3 A / 1 2 4 R V2 indicates a medium size pumpframe - in this example, a Group 2

1=Group 1 (small frame)2=Group 2 (medium frame)3=Group 3 (large frame)

K = Mark 3 style power endJ = Mark 3 style PE arranged for

Mark 2 wet endNo letter and no preceding number

indicates a Mark 2 power endNominal suction port sizeNominal discharge port sizeModifier for specialty pumps

blank or no letter = Standard pumpM = Sealmatic L = Non-metallic wet endR = Recessed impeller H = High silicon ironUS = Unitized self-priming S = Old style self-primingV = Vertical in-line T = Teflon lined wet endLF = Lo-Flo E = Durcon wet end

Nominal maximum impeller diameter13 = 13 inch

Pump design variationA = This pump has been redesigned from an earlier

version. The impeller and casing are no longerinterchangeable with the earlier version.

H = This pump is designed for a higher flow capacity thananother pump with the same basic designation.Examples: 4X3-10 and 4X3-10H; 6X4-10 and 6X4-10H;10X8-16 and 10X8-16H. In each case the pump withthe H is designed for a higher flow capacity.

HH = This pump is designed for a higher head than anotherpump with the same basic designation. Example: 4X3-13 and 4X3-13HH

Actual impeller size124 = 124/8 or 121/2 in diameter; 83 = 83/8 in; 106 = 106/8 or 103/4 in

Impeller styleRV = Reverse vane impeller; OP = Open impeller

Serial No.

Equipment No.

Purchase Order

Model

Size

MDP

Material

Date, DD/MMM/YY

5

Pump Division

Section 3.4

LONG TERM STORAGELong term storage is defined as more than two months, butless than 12 months. The procedure Flowserve follows for longterm storage of pumps is given below. These procedures are inaddition to the short term procedure.

Solid wood skids are utilized. Holes are drilled in the skid toaccommodate the anchor bolt holes in the baseplate, or thecasing and bearing housing feet holes on assemblies lessbaseplate. Tackwrap sheeting is then placed on top of the skidand the pump assembly is placed on top of the Tackwrap. Metalbolts with washers and rubber bushings are inserted throughthe skid, the Tackwrap, and the assembly from the bottom ofthe skid and are then secured with hex nuts. When the nuts aresnugged down to the top of the baseplate or casing andbearing housing feet, the rubber bushing is expanded, sealingthe hole from the atmosphere. Desiccant bags are placed on the Tackwrap. The Tackwrap is drawn up around the assemblyand hermetically (heat) sealed across the top. The assembly iscompletely sealed from the atmosphere and the desiccant willabsorb any entrapped moisture. A solid wood box is then usedto cover the assembly to provide protection from the elementsand handling. This packaging will provide protection up totwelve months without damage to mechanical seals, bearings,lip seals, etc. due to humidity, salt laden air, dust, etc.

After unpacking, protection will be the responsibility of the user.Addition of oil to the bearing housing will remove the inhibitor.If units are to be idle for extended periods after addition oflubricants, inhibitor oils and greases should be used.

Every three months, the shaft should be rotatedapproximately 10 revolutions.

3.4 LIFTING PUMPS AND PUMPASSEMBLIES

Lifting should only be done by trained personnel. Pumps andmotors often have integral lifting eyes or eye bolts. These areintended for use in lifting the individual piece of equipment.

Do not use eye bolts or cast-in lifting lugs to lift pump, motor,and baseplate assemblies.

Before lifting the equipment refer to the pump data sheet for thecomplete assembly weight.

LIFTINGThe following describes how to lift pump components,assembled pumps, or pump, motor and baseplate assemblies.Do not attempt to lift a pump mounted on a baseplate by itself.Only a pump-motor assembly may be lifted once installed on abaseplate.

Pump Components:Casing (#100): Use a choker hitch pulled tight around the

discharge nozzle.Rear cover (#106): Insert an eye hook in the drilled and

tapped hole at the top of the cover. Use either a sling orhook through the eye bolt.

Bearing housing (#119): Group I. Insert a sling between theupper and lower support ribs between the housing barreland the casing attachment flange. Use a choker hitchwhen slinging. Caution, make sure there are no sharpedges on the bottom side of the ribs which could cutthe sling.Group 2 and 3. Insert either a sling or hook through thelifting lug located on the top of the housing.

Power end: Same as bearing housing.

Bare Pump: Sling around the pump discharge nozzle, andaround the outboard end of the bearing housing withseparate slings. Choker hitches must be used at bothattachment points and pulled tight. Make sure thecompletion of the choker hitch on the discharge nozzle istoward the coupling end of the pump shaft as shown inFigure 4. The sling lengths should be adjusted to balancethe load before attaching the lifting hook.

Pump, motor and baseplate assembly: If the baseplate haslifting holes cut in the sides at the end, (Type A Group 3,Type D, and Type E bases) insert lifting S hooks at thefour corners and use slings or chains to connect to thelifting eye as shown in Figure 5. Do not use slingsthrough the lifting holes.

For other baseplates sling around the pump dischargenozzle, and around the outboard end of the motor frameusing choker hitches pulled tight (Figure 6). The slingshould be positioned so the weight is not carried throughthe motor fan housing. Make sure the completion of thechoker hitch on the discharge nozzle is toward thecoupling end of the pump shaft as shown in Figure 6.

CAUTION

6

Pump Division

Section 3.4

FIGURE 4

FIGURE 5

FIGURE 6

7

Pump Division

Section 4.0

Section 4.0 MARK III ANSI STANDARD PUMPNote: Throughout this book all references to pump parts arefollowed by an item number in parentheses. These itemnumbers are listed and shown pictorially in the Spare Partssection.

4.1 GENERAL DESCRIPTION OF PUMPThe Durco Mark III chemical process pump is a horizontal, endsuction, single stage, centerline discharge, centrifugal pump. Itis an ANSI standard pump, which means it conforms to theASME B73.1M ANSI standard.

8

Pump Division

Section 4.2

we supply our standard baseplate. Some users may desirean even flatter surface which can facilitate installation andalignment. Flowserve will supply flatter baseplates uponrequest at extra cost. For example, mounting surfaceflatness of 0.002 in/ft (0.17 mm/m) is offered on Durco TypeE Ten Point baseplate shown in Figure 7.

3. The baseplate must be designed to allow the user to finalfield align the pump and driver to within their own particularstandards and to compensate for any pump or drivermovement that occurred during handling. Normal industrypractice is to achieve final alignment by moving the motor tomatch the pump. Flowserves practice is to confirm in ourshop that the pump assembly can be accurately aligned.Before shipment, the factory verifies that there is enoughhorizontal movement capability at the motor to obtain aperfect final alignment when the installer puts the base-plate assembly into its original, top leveled, unstressedcondition.

INSTALLATION AND ALIGNMENTFactory Preliminary Alignment ProcedureThe purpose of factory alignment is to ensure that the user willhave full utilization of the clearance in the motor holes for finaljob-site alignment. To achieve this, the factory alignmentprocedure specifies that the pump be aligned in the horizontalplane to the motor, with the motor foot bolts centered in themotor holes. This procedure ensures that there is sufficientclearance in the motor holes for the customer to field align themotor to the pump, to zero tolerance. This philosophy requiresthat the customer be able to place the base in the samecondition as the factory. Thus the factory alignment will bedone with the base sitting in an unrestrained condition on a flatand level surface. This standard also emphasizes the need toensure the shaft spacing is adequate to accept the specifiedcoupling spacer.

The factory alignment procedure is summarized below:1. The baseplate is placed on a flat and level work bench in a

free and unstressed position.2. The baseplate is leveled as necessary. Leveling is accom-

plished by placing shims under the rails (or, feet) of the baseat the appropriate anchor bolt hole locations. Levelness ischecked in both the longitudinal and lateral directions.

3. The motor and appropriate motor mounting hardware isplaced on the baseplate and the motor is checked for anyplanar soft-foot condition. If any is present it is eliminatedby shimming.

4. The motor feet holes are centered around the motor mount-ing fasteners. This is done by using a centering nut asshown in Figure 9.

4.2 INSTALLATIONPROTECTION OF OPENINGS AND THREADSWhen the pump is shipped all threads and all openings arecovered. This protection/covering should not be removed untilinstallation. If, for any reason, the pump is removed fromservice, this protection should be reinstalled.

RIGID BASEPLATES OVERVIEWThe function of a baseplate is to provide a rigid foundationunder a pump and its driver that maintains alignment betweenthe two. Baseplates may be, generally, classified into two types:

Foundation-mounted, grouted design (Figure 7) Stilt mounted, or free-standing (Figure 8)

FIGURE 7

FIGURE 8

Baseplates intended for grouted installation are designed to usethe grout as a stiffening member. Stilt mounted baseplates, onthe other hand, are designed to provide their own rigidity. There-fore, the designs of the two baseplates are usually different.

Regardless of the type of baseplate used, it must providecertain functions that ensure a reliable installation. Three ofthese requirements are:1. The baseplate must provide sufficient rigidity to assure the

assembly can be transported and installed, given reasonablecare in handling, without damage. It must also be rigidenough when properly installed to resist operating loads.

2. The baseplate must provide a reasonably flat mountingsurface for the pump and driver. Uneven surfaces will resultin a soft-foot condition that may make alignment difficult, orimpossible. Flowserves experience indicates that a base-plate that has a top surface flatness of 1/16 in (1.6 mm)across the diagonal corners of the baseplate provides such amounting surface. Therefore, this is the tolerance to which

9

Pump Division

Section 4.2

FIGURE 9

5. The motor is fastened in place by tightening the nuts ontwo diagonal motor mounting studs.

6. The pump is put onto the baseplate and leveled. The footpiece under the bearing housing is adjustable. It is used tolevel the pump, if necessary.Mark IIIA designIf an adjustment is necessary, we add or delete shims(#109A) between the foot piece and the bearing housing.Old style Mark III designIf an adjustment is necessary, the adjuster nut (#136B) isused to adjust the footpiece up or down.

7. The spacer coupling gap is verified.8. The parallel and angular vertical alignment is made by

shimming under the motor.9. The motor feet holes are again centered around the motor

mounting studs using the centering nut. At this point thecentering nut is removed and replaced with a standard nut.This gives maximum potential mobility for the motor to behorizontally moved during final, field alignment. All fourmotor feet are tightened down.

10. The pump and motor shafts are then aligned horizontally,both parallel and angular, by moving the pump to the fixedmotor. The pump feet are tightened down.

11. Both horizontal and vertical alignment are again finalchecked as is the coupling spacer gap.

Recommended Procedure for BaseplateInstallation and Final Field AlignmentNew Grouted Baseplates1. The pump foundation should be located as close to the

source of the fluid to be pumped as practical. There shouldbe adequate space for workers to install, operate, andmaintain the pump. The foundation should be sufficient toabsorb any vibration and should provide a rigid support forthe pump and motor. Recommended mass of a concretefoundation should be three times that of the pump, motorand base. Refer to Figure 10. Note that foundation bolts areimbedded in the concrete inside a sleeve to allow somemovement of the bolt.

2. Level the pump baseplate assembly. If the baseplate hasmachined coplanar mounting surfaces, these machinedsurfaces are to be referenced when leveling the baseplate.

This may require that the pump and motor be removedfrom the baseplate in order to reference the machinedfaces. If the baseplate is without machined coplanarmounting surfaces, the pump and motor are to be left onthe baseplate. The proper surfaces to reference whenleveling the pump baseplate assembly are the pumpsuction and discharge flanges. DO NOT stress thebaseplate. Do not bolt the suction or discharge flanges ofthe pump to the piping until the baseplate foundation iscompletely installed. If equipped, use leveling jackscrews tolevel the baseplate. If jackscrews are not provided, shimsand wedges should be used (see Figure 10). Check forlevelness in both the longitudinal and lateral directions.Shims should be placed at all base anchor bolt locations,and in the middle edge of the base if the base is more thanfive feet long. Do not rely on the bottom of the baseplate tobe flat. Standard baseplate bottoms are not machined, andit is not likely that the field mounting surface is flat.

Figure 10Baseplate Foundation

3. After leveling the baseplate, tighten the anchor bolts. Ifshims were used, make sure that the baseplate wasshimmed near each anchor bolt before tightening. Failure todo this may result in a twist of the baseplate, which couldmake it impossible to obtain final alignment. Check thelevel of the baseplate to make sure that tightening theanchor bolts did not disturb the level of the baseplate. If theanchor bolts did change the level, adjust the jackscrews orshims as needed to level the baseplate. Continue adjustingthe jackscrews or shims and tightening the anchor boltsuntil the baseplate is level.

4. Check initial alignment. If the pump and motor wereremoved from the baseplate proceed with step 5 first, thenthe pump and motor should be reinstalled onto the base-plate using Flowserves Factory Preliminary AlignmentProcedure, and then continue with the following. Asdescribed above, pumps are given a preliminary alignmentat the factory. This preliminary alignment is done in a waythat ensures that, if the installer duplicates the factoryconditions, there will be sufficient clearance between the

Shims(For VerticalAlignment)

Plastic TubingAround Bolt

Dam

Wedge

Packing

Sleeve

Locking TabWelded to Bolt

AnchorBolt

Washer

Concrete Foundation

Grout

Baseplate

10

Pump Division

Section 4.2

Old style Mark III designUse the adjuster nut (#136B) to adjust the footpiece up ordown.

3. Check initial alignment. (Step 4 above)4. Run piping to the suction and discharge flanges of the

pump. (Step 6 above)5. Perform final alignment. (Step 7 above)6. Recheck alignment after pump is hot. (Step 8 above)

Stilt Mounted BaseplatesRefer to Appendix B for instructions for assembling stilt orspring mounted baseplates. The low vibration levels of Durcopumps allows the use of these baseplates provided they areof a rigid design. The baseplate is set on a flat surface with notie down bolts or other means of anchoring it to the floor. Theprocedure for motor alignment on stilt or spring mountedbaseplates is similar to grouted baseplates. The difference isprimarily in the way the baseplate is levelled.

1. Level the baseplate by using the stilt adjusters. (Shims arenot needed as with grouted baseplates.) After the base islevel, it is locked in place by locking the stilt adjusters.

2. Next the initial pump alignment must be checked. Thevertical height adjustment provided by the stilts allows thepossibility of slightly twisting the baseplate. If there hasbeen no transit damage or twisting of the baseplate duringstilt height adjustment, the pump and driver should bewithin 0.015 in (0.38 mm) parallel, and 0.0025 in/in(0.0025 mm/mm) angular alignment. If this is not the case,check to see if the driver mounting fasteners are centeredin the driver feet holes.

3. If the fasteners are not centered there was likely shippingdamage. Recenter the fasteners and perform a preliminaryalignment to the above tolerances by shimming under themotor for vertical alignment, and by moving the pump forhorizontal alignment.

4. If the fasteners are centered, then the baseplate may betwisted. Slightly adjust (one turn of the adjusting nut) thestilts at the driver end of the baseplate and check foralignment to the above tolerances. Repeat as necessarywhile maintaining a level condition as measured from thepump discharge flange. Lock the stilt adjusters.

The remaining steps are as listed for new grouted baseplates(Steps 6, 7 and 8).

ZIRCONIUM 702 OR HIGH CHROME IRON COMPONENTSIf any of the components of the pump have been made ofzirconium or high chrome iron, the following precautionarymeasures should be followed: Use hand wrenches rather than impact wrenches. This equipment should not be subjected to sudden changes

in temperature or pressure. Avoid striking this equipment with any sharp blows.

motor hold down bolts and motor foot holes to move themotor into final alignment. If the pump and motor wereproperly reinstalled to the baseplate or if they were notremoved from the baseplate and there has been no transitdamage, and also if the above steps where done properly,the pump and driver should be within 0.015 in (0.38 mm)FIM (Full Indicator Movement) parallel, and 0.0025 in/in(0.0025 mm/mm) FIM angular. If this is not the case firstcheck to see if the driver mounting fasteners are centeredin the driver feet holes. If not, recenter the fasteners andperform a preliminary alignment to the above tolerances byshimming under the motor for vertical alignment, and bymoving the pump for horizontal alignment.

5. Grout the baseplate. A non-shrinking grout should beused. Make sure that the grout fills the area under thebaseplate. After the grout has cured, check for voids andrepair them. Jackscrews, shims and wedges should beremoved from under the baseplate at this time. If they wereto be left in place, they could rust, swell, and causedistortion in the baseplate.

6. Run piping to the suction and discharge of the pump. Thereshould be no piping loads transmitted to the pump afterconnection is made. Recheck the alignment to verify thatthere are no significant loads.

7. Perform final alignment. Check for soft-foot under thedriver. An indicator placed on the coupling, reading in thevertical direction, should not indicate more than 0.002 in(0.05 mm) movement when any driver fastener isloosened. Align the driver first in the vertical direction byshimming underneath its feet. When satisfactory alignmentis obtained the number of shims in the pack should beminimized. It is recommended that no more than fiveshims be used under any foot. Final horizontal alignment ismade by moving the driver. Maximum pump reliability isobtained by having near perfect alignment. Flowserverecommends no more than 0.002 in (0.05mm) parallel, and0.0005 in/in (0.0005 mm/mm) angular misalignment.

8. Operate the pump for at least an hour, or until it reachesfinal operating temperature. Shut the pump down andrecheck alignment while the pump is hot. Piping thermalexpansion may change the alignment. Realign pump asnecessary.

Existing Grouted BaseplatesWhen a pump is being installed on an existing groutedbaseplate, the procedure is somewhat different from theprevious section New Grouted Baseplates.

1. Mount the pump on the existing baseplate.2. Level the pump by putting a level on the discharge flange. If

not level, adjust the footpiece as follows:Mark IIIA designAdd or delete shims (#109A) between the footpiece and thebearing housing.

11

Pump Division

Section 4.2

Zirconium 702 and high chrome iron have relatively low impactstrengths. These materials could crack if subjected to excessivetemperature changes, pressure changes or impacts.

ZIRCONIUM 705 AND HIGH CHROME IRON COMPONENTSAvoid any repair or fabrication welds on Zirconium 705 andhigh chrome iron components.

PIPING CONNECTION SUCTION/DISCHARGEAll piping must be independently supported, accurately alignedand preferably connected to the pump by a short length offlexible piping. The pump should not have to support the weightof the pipe or compensate for misalignment. It should bepossible to install suction and discharge bolts through matingflanges without pulling or prying either of the flanges. All pipingmust be tight. Pumps may air-bind if air is allowed to leak intothe piping. If the pump flange(s) have tapped holes, selectflange fasteners with thread engagement at least equal to thefastener diameter but that do not bottom out in the tappedholes before the joint is tight.

Piping Forces: Take care during installation and operation tominimize pipe forces and/or moments on the pump casing.Forces and moments must be kept within the limits given inAppendix I.

Many bellows type joints have an effective area larger than thepipe area. The force resulting from application of systempressure over the effective area when combined with other liveand dead loads must not exceed the values given in Appendix I.If the combined forces and moments are greater than thevalues from Appendix I, a piping system as shown in Figure 11must be used.

FIGURE 11Mark III Pump Installation Using Expansion Joints

Suction PipingTo avoid NPSH and suction problems, suction pipe sizes mustbe at least as large as the pump suction connection. Never usepipe or fittings on the suction that are smaller in diameter thanthe pump suction size.

Figure 12 illustrates the ideal piping configuration with aminimum of 10 pipe diameters between the source and thepump suction. In most cases, horizontal reducers should beeccentric and mounted with the flat side up as shown in Figure13 with a maximum of one pipe size reduction. Never mounteccentric reducers with the flat side down. Horizontallymounted concentric reducers should not be used if there is any possibility of entrained air in the process fluid. Verticallymounted concentric reducers are acceptable. In applicationswhere the fluid is completely deaerated and free of any vapor orsuspended solids, concentric reducers are preferable toeccentric reducers.

FIGURE 12Good Piping Practice

FIGURE 13Good Piping Practice

WARNING

WARNING Fixed axial supports mustbe designed to resist thecollapsing forces of theexpansion joint selectedand to permit adjustmentto pump flanges withoutloading or creating forces on flanges.

Short spools foraxial supports

Expansion joint

DIAMETERS

SUCTION

12

Pump Division

Section 4.2

Avoid the use of throttling valves and strainers in the suctionline. Start up strainers must be removed shortly after start up.When the pump is installed below the source of supply, a valveshould be installed in the suction line to isolate the pump and topermit pump inspection and maintenance. However, neverplace a valve directly on the suction nozzle of the pump.

Refer to the Durco Pump Engineering Manual and the Centrifugal Pump IOM Section of the Hydraulic InstituteStandards for additional recommendations on suction piping.(See Appendix K)

Suction pressure limits for Mark III pumps with reverse vaneimpellers are given in Figure 14. The curves show maximumallowable suction pressure at various specific gravities. Notethat Class 300 flanges may be necessary. Note also that forfront vane open impellers the suction pressure is limited onlyby the pressure/ temperature curves shown in Figure 1.

The pressure temperature ratings shown in Figure 1 must notbe exceeded. Suction pressure is limited only by the pressuretemperature ratings, for pump sizes 10 x 8-14, 8 x 6-16A, 10x 8-16 and 10 x 8-16H up through 2.0 specific gravity. Consultfactory for specific gravity greater than 2.0.

Discharge PipingInstall a valve in the discharge line. This valve is required forregulating flow and/or to isolate the pump for inspection andmaintenance.

When fluid velocity in the pipe is high, for example, 10 f/s (3 m/s) or higher, a rapidly closing discharge valve can cause adamaging pressure surge. A dampening arrangement should beprovided in the piping.

Pump and Shaft Alignment CheckAfter connecting piping, rotate the pump drive shaft clockwise(view from motor end) by hand several complete revolutions tobe sure there is no binding and that all parts are free. Recheckshaft alignment. If piping caused unit to be out of alignment,correct piping to relieve strain on the pump.

FIGURE 14Suction pressure limits

MECHANICAL SEALWhen the pump is intended to be equipped with a mechanicalseal, it is Flowserves standard practice to install the mechanicalseal in the pump prior to shipment. Specific order requirementsmay specify that the seal be shipped separately, or none besupplied. It is the pump installers responsibility to determine ifa seal was installed. If a seal was supplied but not installed, theseal and installation instructions will be shipped with the pump.

Failure to ensure that a seal is installed may result in seriousleakage of the pumped fluid.

Seal and seal support system must be installed and operationalas specified by the seal manufacturer.

MAXIMUM ALLOWABLE SUCTION PRESSURE kPa

SPEC

IFIC

GRA

VITY

SPEC

IFIC

GRA

VITY

MAXIMUM ALLOWABLE SUCTION PRESSURE kPa

MAXIMUM ALLOWABLE SUCTION PRESSURE lbf / in2

SUCTION PRESSURE IS LIMITED ONLY BY THE PRESSURETEMPERATURE RATINGS FOR ALL OPEN IMPELLER PUMPSIZES AT ALL SPECIFIC GRAVITIES AND FOR SEMI-OPENIMPELLER PUMP SIZES 10X8-14, 8X6-16A, 10X8-16 AND 10X8-16H THROUGH 2.0SPECIFIC GRAVITY. CONSULT DURCO SALES ENGINEERS FORSPECIFIC GRAVITIES ABOVE 2.0

Mark IIIREVERSE VANE IMPELLERMAXIMUM ALLOWABLESUCTION PRESURE1750 RPM

Mark III GROUP I & IIREVERSE VANE IMPELLER MAX.SUCTION PRESSURE3500 RPM

FOR ALL OPEN IMPELLER PUMPS SUCTION PRESSURE IS LIMITED ONLY BY THE PRESSURE TEMPERATURE RATINGS

MAXIMUM ALLOWABLE SUCTION PRESSURE lbf / in2

WARNING

WARNING

WARNING

13

Pump Division

Section 4.2

Abrasive Packing Arrangement The installation proceduresare the same as the standard packing with some exceptions. Aspecial lip seal is installed first, followed by two seal cageassemblies, then two of the packing rings provided (Figure 16).A flush line from a clean external source should be connectedvia Tap V, in the top of the stuffing box.

FIGURE 16

PIPING CONNECTION BEARING HOUSING COOLING SYSTEMMake connections as shown below. Liquid at less than 90F(32C) should be supplied at a regulated flow rate of at least 1 gpm (0.06 l/s).

PIPING CONNECTION SUPPORT LEG COOLING FOR CENTERLINE MOUNTING OPTIONIf the casing is centerline mounted, and the processtemperature is over 350F (178C), then the casing supportlegs may need to be cooled. Cool water (less than 90F (32C) )should be run through the legs at a flow rate of at least 1 gpm(0.06 l/s) as shown below.

The stuffing box/seal chamber/gland may have ports that havebeen temporarily plugged at the factory to keep out foreignmatter. It is the installers responsibility to determine if theseplugs should be removed and external piping connected. Referto the seal drawings and/or the local Flowserve representativefor the proper connections.

PACKINGWhen the pump is intended to be equipped with shaft packing,it is not Flowserves standard practice to install the packing inthe stuffing box prior to shipment. The packing is shipped withthe pump. It is the pump installers responsibility to install thepacking in the stuffing box.

Failure to ensure that packing is installed may result in seriousleakage of the pumped fluid.

PIPING CONNECTION SEAL/PACKING SUPPORT SYSTEM

If the pump has a seal support system, it is mandatory that thissystem be fully installed and operational before the pump isstarted.

If packing is used:Packing Lubrication Water, when compatible with the pump-age, should be introduced into Tap V (Figure 15) at pressure 10to 15 lbf/in2 (69 to 103 kPa) above the stuffing box pressure.The gland should be adjusted to give a flow rate of 20 to 30drops per minute for clean fluid. For abrasive applications, theregulated flow rate should be 1-2 gpm (0.06-0.13 l/s).

FIGURE 15

Grease lubrication, when compatible with the pumpage, may beused. Again, introduced into Tap V.

In non-abrasive applications the pumpage itself may besufficient to lubricate the packing without need for externallines. Tap V should be plugged.

Tap V

PackingSeal Cage

Lip Seal

1/2 in O.D. Tubing

Outlet Outlet

Inlet Inlet

WARNING

WARNING

Tap V

14

Pump Division

Section 4.2

PIPING CONNECTION HEATING/COOLING FLUID FOR JACKETED COVER/CASINGThe piping connections for jacketed covers and casings areshown below. The flow rate of the cooling water (less than90F (32C) ) should be at least 2 gpm (0.13 l/s).

PIPING CONNECTION OIL MIST LUBRICATION SYSTEMThe piping connections for an oil mist lubrication system areshown below.

Inlet for Steam or SelfVenting Outlet for Liquid

Inlet for Liquid or SelfDraining Outlet for SteamCondensate

DrainPlug

Valve

DischargeOutlet

3/4 NPT Inlet/Vent/Outlet

3/4 NPT Inlet/Vent/Outlet

Suct

ion

Inle

t

Suggested Plumbing toObtain Drain WhenUsing Liquid

OIL MIST READY HOUSING WET SUMP

Locate Vent FittingAbove Horizontal CL AtAssy

Locate Pipe PlugBelow Horizontal CL AtAssy

1/4 NPTOpp Side

1/4 NPTOpp Side

1 NPT

1/2 NPT

Locate Vent FittingAbove Horizontal CL AtAssy

Locate Pipe PlugBelow Horizontal CL AtAssy

1/2 NPT

OIL MIST READY HOUSING DRY SUMP

Notes:1. When circulating steam, use top hole for inlet. Both

bottom holes must be plumbed together for outlet, toensure draining both sides of jacket.

2. When circulating liquid, use both bottom holes as inlets.Use top hole as outlet.

Coupling Guard Maintenance

Power must never be applied to the driver when the couplingguard is not installed.

The Durco coupling guard is of the clam shell design and isshown in Figure 19. It is hinged at the top. It can be removed byloosening one of the foot bolts and sliding the support leg outfrom under the cap screw (note that the foot is slotted). The legcan then be rotated upward and half of the guard can be dis-engaged (unhinged) from the other. Note that only one side ofthe guard needs to be removed. To reassemble simply reversethe above procedure.

Refer to Appendix J for trimming and assembly instructions forthe ClearGuard coupling guard.

Flowserve coupling guards are safety devices intended toprotect workers from inherent dangers of the rotating pumpshaft, motor shaft and coupling. It is intended to prevent entryof hands, fingers or other body parts into a point of hazard byreaching through, over, under or around the guard. No standardcoupling guard provides complete protection from a disinte-grating coupling. Flowserve cannot guarantee their guards willcompletely contain an exploding coupling.

The Durco coupling guard shown in Figure 19 conforms to theU.S.A. standard ASME B15.1, Safety Standard for MechanicalPower Transmission Apparatus. Flowserve manufacturingfacilities worldwide conform to local coupling guardregulations.

FIGURE 19

C-flange motor adapter special considerationsIf the pump is equipped with a C-flange motor adapter, refer toAppendix A for guidelines on installation, operation, andmaintenance.

15

Pump Division

Section 4.2

COUPLING

A direction arrow is cast on the front of the Casing (SeeFigure 17) and on the Bearing Housing. Make sure the motorrotates in the same direction before coupling the motor to thePump. It is absolutely essential that the rotation of the motorbe checked before connecting the shaft coupling. Incorrectrotation of the pump, for even a short time, can dislodge theimpeller which may cause serious damage to the pump. AllDurco pumps turn clockwise as viewed from the motor end or,conversely, counterclockwise when viewed from the suctionend as shown in Figure 17.

FIGURE 17

The coupling (Figure 18) should be installed as advised by thecoupling manufacturer. Pumps are shipped without the spacerinstalled. If the spacer has been installed to facilitate alignment,then it must be removed prior to checking rotation. Removeprotective material from the coupling and any exposed portionsof the shaft before installing the coupling.

FIGURE 18 Typical SpacerCoupling

Typical Non-Spacer Coupling

CAUTION WARNING

16

Pump Division

Section 4.3

4.3 OPERATIONROTATION CHECK

It is absolutely essential that the rotation of the motor bechecked before connecting the shaft coupling. Incorrectrotation of the pump, for even a short time, can dislodge anddamage the impeller, casing, shaft and shaft seal. All Durcopumps turn clockwise as viewed from the motor end. Adirection arrow is cast on the front of the casing as shown inFigure 17. Make sure the motor rotates in the same direction.

PRE START-UP CHECKS Prior to starting the pump it is essential that the followingchecks are made. These checks are all described in detail in theMaintenance Section of this booklet. Pump and Motor properly secured to the baseplate All fasteners tightened to the correct torques Coupling guard in place and not rubbing Rotation check, see above, section 4.3

THIS IS ABSOLUTELY ESSENTIAL. Impeller clearance setting Shaft seal properly installed Seal support system operational Bearing lubrication Bearing housing cooling system operational Support leg cooling for centerline mounting option operational Heating/cooling for jacketed casing/cover operational Pump instrumentation is operational Pump is primed Rotation of shaft by hand

As a final step in preparation for operation, it is important torotate the shaft by hand to be certain that all rotating parts movefreely, and that there are no foreign objects in the pump casing.

CAUTION

17

Pump Division

Section 4.4

FIGURE 2060 Hz 50 Hz

Minimum Minimumflow flow

Pump Size RPM (% of BEP) RPM (% of BEP)

1K3X2-6 3500 25% 2900 21%2K3X2-8 3500 25% 2900 21%2K4X3-8 3500 25% 2900 21%2K3X2-10 3500 33% 2900 28%2K4X3-10 3500 33% 2900 28%2K6X4-10 3500 50% 2900 42%2K3X2-13 3500 50% 2900 42%2K4X3-13 3500 50% 2900 42%2K6X4-13 1750 50% 1450 42%ALL GROUP 3 PUMPS* 1750 50% 1450 42%ALL OTHER SIZES ANY 10% ANY 10%

*In some cases, the 3K6X4-16 can be used at lower than 50% of BEP, by making amodification. Contact Flowserve Engineering if this pump is to be used at a lower flow.

Note: Minimum intermittent flow value of 50% of the minimumcontinuous flow as long as that flow is greater than theminimum thermal flow.Note: The Lo-Flo pump is not covered by this table. See Section8.0 for a discussion of the Lo-Flo pump.

All Mark III pumps also have a Minimum Thermal Flow. Thisis defined as the minimum flow that will not cause an excessivetemperature rise. Minimum Thermal Flow is applicationdependent.

Do not operate the pump at below Minimum Thermal Flow, asthis could cause an excessive temperature rise. Contact aFlowserve Sales Engineer for determination of MinimumThermal flow.

STARTING THE PUMP AND ADJUSTING FLOW1. Open the suction valve to full open position. It is very

important to leave the suction valve open while the pump isoperating. Any throttling or adjusting of flow must be donethrough the discharge valve. Partially closing the suction valvecan create serious NPSH and pump performance problems.

Never operate pump with both the suction and discharge valvesclosed. This could cause an explosion.

2. A standard centrifugal pump will not move liquid unless thepump is primed. A pump is said to be primed when thecasing and the suction piping are completely filled withliquid. Open discharge valve a slight amount. This will allowany entrapped air to escape and will normally allow the

4.4 START-UP CONSIDERATIONSENSURING PROPER NPSHANet Positive Suction Head Available (NPSHA) is the measureof the energy in a liquid above the vapor pressure. It is used todetermine the likelihood that a fluid will vaporize in the pump. Itis critical because a centrifugal pump is designed to pump aliquid, not a vapor. Vaporization in a pump will result in damageto the pump, deterioration of the Total Differential Head (TDH),and possibly a complete stopping of pumping.

Net Positive Suction Head Required (NPSHR) is the decreaseof fluid energy between the inlet of the pump, and the point oflowest pressure in the pump. This decrease occurs because offriction losses and fluid accelerations in the inlet region of thepump, and particularly accelerations as the fluid enters theimpeller vanes. The value for NPSHR for the specific pumppurchased is given in the pump data sheet, and on the pumpperformance curve.

For a pump to operate properly the NPSHA must be greater thanthe NPSHR. Good practice dictates that this margin should be atleast 5 ft (1.5 m) or 20%, whichever is greater.

Ensuring that NPSHA is larger than NPSHR by the suggestedmargin will greatly enhance pump performance and reliability.It will also reduce the likelihood of cavitation, which canseverely damage the pump.

MINIMUM FLOWMinimum continuous stable flow is the lowest flow at which thepump can operate and still conform to the bearing life, shaftdeflection and bearing housing vibration limits of ANSI/ASMEB73.1M-1991. Pumps may be operated at lower flows, but itmust be recognized that the pump may not conform to one ormore of these limits. For example, vibration may exceed thelimit set by the ASME standard. The size of the pump, theenergy absorbed, and the liquid pumped are some of theconsiderations in determining the minimum flow.

Typically, limitations of 10% of the capacity at the bestefficiency point (BEP) should be specified as the minimum flow.However, Flowserve has determined that several pumps mustbe limited to higher minimum flows to provide optimumservice. The following are the recommended minimum flows for these specific pumps:

CAUTION

WARNING

DANGER

Pump Division

Section 4.4

pump to prime, if the suction source is above the pump.(See Section 6.0 for special information regarding DurcoUnitized Self Priming pumps.) When a condition existswhere the suction pressure may drop below the pumpscapability, it is advisable to add a low pressure controldevice to shut the pump down when the pressure dropsbelow a predetermined minimum.

3. All cooling, heating, and flush lines must be started andregulated.

4. Start the driver (typically, the electric motor).5. Slowly open the discharge valve until the desired flow is

reached, keeping in mind the minimum flow restrictionslisted above.

It is important that the discharge valve be opened within a shortinterval after starting the driver. Failure to do this could cause adangerous build up of heat, and possibly an explosion.

6. Reduced capacityAvoid running a centrifugal pump at drastically reducedcapacities or with discharge valve closed for extendedperiods of time. This can cause severe temperature rise andthe liquid in the pump may reach its boiling point. If thisoccurs, the mechanical seal will be exposed to vapor, withno lubrication, and may score or seize to the stationaryparts. Continued running under these conditions when thesuction valve is also closed, can create an explosive con-dition due to the confined vapor at high pressure andtemperature.

Thermostats may be used to safeguard against over heatingby shutting down the pump at a predetermined temperature.

TROUBLESHOOTINGThe following is a guide to troubleshooting problems with Durco pumps. Common problems are analyzed and solutions are offered.Obviously, it is impossible to cover every possible scenario. If a problem exists that is not covered by one of the examples, then referto one of the books listed in the Sources of Additional Information section or contact a local Flowserve Sales Engineer orDistributor/Representative for assistance.

PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY

Problem #1 1.1 Recalculate NPSH available. It must be greater Pump not reaching design Insufficient NPSH. (Noise may than the NPSH required by pump at desired flow.flow rate not be present.) If not, redesign suction piping, holding number of elbows and

number of planes to a minimum to avoid adverse flow rotationas it approaches the impeller.

1.2 Reduce system head by increasing pipe size and/System head greater than or reducing number of fittings. Increase impelleranticipated. diameter.

NOTE: Increasing impeller diameter may require use of a largermotor.

Safeguards should also be taken against possible operationwith a closed discharge valve, such as installing a bypassback to the suction source. The size of the bypass line andthe required bypass flow rate is a function of the inputhorsepower and the allowable temperature rise.

7. Reduced HeadNote that when discharge head drops, the pumps flow rateusually increases rapidly. Check motor for temperature riseas this may cause overload. If overloading occurs, throttlethe discharge.

8. Surging ConditionA rapidly closing discharge valve can cause a damagingpressure surge. A dampening arrangement should beprovided in the piping.

OPERATION IN SUB-FREEZING CONDITIONSWhen using the pump in sub-freezing conditions where thepump is periodically idle, the pump should be properly drainedor protected with thermal devices which will keep the liquid inthe pump from freezing. High chrome iron pumps are notrecommended for applications below 0F (-18C).

SHUTDOWN CONSIDERATIONSWhen the pump is being shutdown, the procedure should bethe reverse of the start-up procedure. First, slowly close thedischarge valve, shutdown the driver, then close the suctionvalve. Remember, closing the suction valve while the pump isrunning is a safety hazard and could seriously damage thepump and other equipment.

DANGER

18

19

Pump Division

Section 4.4

PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY

Cont: Problem #1.0 1.3 1. Check suction line gaskets and threads for tightness.Pump not reaching design Entrained air. Air leak from 2. If vortex formation is observed in suction tank, installflow rate. atmosphere on suction side. vortex breaker.

3. Check for minimum submergence.

1.4 Process generated gases may require larger pumps.Entrained gas from process.

1.5 Check motor speed against design speed.Speed too low.

1.6 After confirming wrong rotation, reverse any two of threeDirection of rotation wrong. leads on a three phase motor.

The pump should be disassembled and inspected before it isrestarted.

1.7 Replace with proper diameter impeller.Impeller too small. NOTE: Increasing impeller diameter may require use of a larger

motor.

1.8 Reset impeller clearance.Impeller clearance too large.

1.9 1. Reduce length of fiber when possible.Plugged impeller, suction line or casing 2. Reduce solids in the process fluid when possible.which may be due to a product or large 3. Consider larger pump.solids.

1.10 Replace part or parts.Wet end parts (casing cover, impeller)worn, corroded or missing.

Problem #2.0 2.1 Refer to remedies listed under Problem #1.0 and #3.0.Pump not reaching design Refer to possible causes underhead (TDH). Problem #1.0.

Problem #3.0 3.1 Repeat priming operation, recheck instructions. If pump hasNo discharge or flow with Not properly primed. run dry, disassemble and inspect the pump before operation.

3.2 After confirming wrong rotation, reverse any two of threeDirection of rotation wrong. leads on a three phase motor.

The pump should be disassembled and inspected beforeoperation.

3.3 Refer to recommended remedy under Problem #1.0,Entrained air. Air leak from Item #1.3.atmosphere on suction side.

3.4 Refer to recommended remedy under Problem #1.0,Plugged impeller, suction line or Item #1.9.casing which may be due to afibrous product or large solids.

3.5 Replace damaged parts.Damaged pump shaft, impeller.

Problem #4.0 4.1 Refer to recommended remedy under Problem #1.0,Pump operates for short Insufficient NPSH. Item #1.1.period, then loses prime.

4.2 Refer to recommended remedy under Problem #1.0,Entrained air. Air leak from Item #1.3.atmosphere on suction side.

20

Pump Division

Section 4.4

PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY

Problem #5.0 5.1 Refer to recommended remedy under Problem #1.0,Excessive noise from Cavitation - insufficient NPSH available. Item #1.1.wet end.

5.2 Redesign suction piping, holder number of elbows andAbnormal fluid rotation due to number of planes to a minimum to avoid adverse fluidcomplex suction piping. rotation as it approaches the impeller.

5.3 1. Check and reset impeller clearance.Impeller rubbing. 2. Check outboard bearing assembly for axial end play.

Problem #6.0 6.1 1. Work with clean tools in clean surroundings.Excessive noise from Bearing contamination appearing 2. Remove all outside dirt from housing beforepower end. on the raceways as scoring, pitting, exposing bearings.

scratching, or rusting caused by 3. Handle with clean dry hands.adverse environment and 4. Treat a used bearing as carefully as a new one.entrance of abrasive contaminants 5. Use clean solvent and flushing oil.from atmosphere. 6. Protect disassembled bearing from dirt and moisture.

7. Keep bearings wrapped in paper or clean cloth whilenot in use.

8. Clean inside of housing before replacing bearings.9. Check oil seals and replace as required.

10. Check all plugs and tapped openings to make sure that theyare tight.

6.2 When mounting the bearing on the drive shaft use aBrinelling of bearing identified by proper size ring and apply the pressure against theindentation on the ball races, usually inner ring only. Be sure when mounting a bearing to caused by incorrectly applied forces in apply the mounting pressure slowly and evenly.assembling the bearing or by shockloading such as hitting the bearing ordrive shaft with a hammer.

6.3 1. Correct the source of vibration.False brinelling of bearing identified 2. Where bearings are oil lubricated and employed inagain by either axial or circumferential units that may be out of service for extended periods,indentations usually caused by the drive shaft should be turned over periodically tovibration of the balls between the races relubricate all bearing surfaces at intervals of one-to-in a stationary bearing. three months.

6.4 1. Follow correct mounting procedures for bearings.Thrust overload on bearing identified byflaking ball path on one side of the outerrace or in the case of maximum capacitybearings, may appear as a spalling of theraces in the vicinity of the loading slot.(Please note: maximum capacity bearingsare not recommended in Mark IIIpumps.) These thrust failures are causedby improper mounting of the bearing orexcessive thrust loads.

6.5 Handle parts carefully and follow recommended mountingMisalignment identified by fracture of procedures. Check all parts for proper fit and alignment.ball retainer or a wide ball path on theinner race and a narrower cocked ballpath on the outer race. Misalignment iscaused by poor mounting practices ordefective drive shaft. For example,bearing not square with the centerline orpossibly a bent shaft due to improperhandling.

21

Pump Division

Section 4.4

PROBLEM POSSIBLE CAUSE RECOMMENDED REMEDY

Cont.: Problem #6.0 6.6 1. Where current shunting through the bearing cannot beExcessive noise from Bearing damaged by electric corrected, a shunt in the form of a slip ring assemblypower end. arcing identified as electro- should be incorporated.

etching of both inner and outer 2. Check all wiring, insulation and rotor windings to bering as a pitting or cratering. sure that they are sound and all connections areElectrical arcing is caused by a properly made.static electrical charge eminat- 3. Where pumps are belt driven, consider the eliminationing from belt drives, electrical of static charges by proper grounding or consider beltleakage or short circuiting. material that is less generative.

6.7 1. Be sure the lubricant is clean.Bearing damage due to improper 2. Be sure proper amount of lubricant is used.lubrication, identified by one or The constant level oiler supplied with Durco pumps willmore of the following: maintain the proper oil level if it is installed and operating1. Abnormal bearing temperature properly. In the case of greased lubricated bearings, berise. sure that there is space adjacent to the bearing into which2. A stiff cracked grease it can rid itself of excessive lubricant, otherwise the bear-appearance. ing may overheat and fail prematurely.3. A brown or bluish discoloration 3. Be sure the proper grade of lubricant is used.of the bearing races.

22

Pump Division

Section 4.5

DISASSEMBLYRefer to the parts list shown in Figure 52 for item numberreferences used throughout this section.1. Before performing any maintenance, disconnect the driver

from its power supply and lock it off line.

Lock out power to driver to prevent personal injury.

2. Close the discharge and suction valves, and drain all liquidfrom the pump.

3. Close all valves on auxiliary equipment and piping, thendisconnect all auxiliary piping.

4. Decontaminate the pump as necessary.

If Durco pumps contain dangerous chemicals, it is important tofollow plant safety guidelines to avoid personal injury or death.

5. Remove the coupling guard. (See page 15 on CouplingGuards.)

6. Remove the spacer from the coupling.7. Remove casing fasteners (#115A).8. Remove the fasteners holding the bearing housing foot to

the baseplate.9. Move the power end, rear cover, and seal chamber

assembly away from the casing. Discard the casing/ covergasket (#107).

The power end and rear cover assembly is heavy. It isimportant to follow plant safety guidelines when lifting it.

10. Transport the assembly to the maintenance shop.11. Remove the coupling hub from the pump shaft (#105).12. Using the shaft key (#130), mount the impeller wrench

from the Durco Tool Kit (Figure 21) to the end of theshaft. With the wrench handle pointing to the left whenviewed from the impeller end, grasp the impeller (#103)firmly with both hands (wear heavy gloves), by turning theimpeller in the clockwise direction move the wrench handleto the 11:00 oclock position and then spin the impellerquickly in a counterclockwise direction so that the wrenchmakes a sudden impact with a hard surface on the bench.After several sharp raps, the impeller should be free.

4.5 MAINTENANCEPREVENTIVE MAINTENANCEThe following sections of this manual give instructions on howto perform a complete maintenance overhaul. However, it isalso important to periodically repeat the Pre start-up checkslisted on page 16. These checks will help extend pump life aswell as the length of time between major overhauls.

NEED FOR MAINTENANCE RECORDSA procedure for keeping accurate maintenance records is acritical part of any program to improve pump reliability. Thereare many variables that can contribute to pump failures. Oftenlong term and repetitive problems can only be solved byanalyzing these variables through pump maintenance records.

NEED FOR CLEANLINESSOne of the major causes of pump failure is the presence ofcontaminants in the bearing housing. This contamination canbe in the form of moisture, dust, dirt and other solid particlessuch as metal chips. Contamination can also be harmful to themechanical seal (especially the seal faces) as well as other partsof the pumps. For example, dirt in the impeller threads couldcause the impeller to not be seated properly against the shaft.This, in turn, could cause a series of other problems. For thesereasons, it is very important that proper cleanliness bemaintained. Some guidelines are listed below.

After draining the oil from the bearing housing, periodicallysend it out for analysis. If it is contaminated, determine thecause and correct. The work area should be clean and free fromdust, dirt, oil, grease, etc. Hands and gloves should be clean.Only clean towels, rags, and tools should be used. To simplifymaintenance, it is recommended that the Durco Tool Kit,shown in Figure 21, to used. This tool kit includes a handyimpeller wrench, which simplifies installation and removal ofthe impeller. It also contains nose cones which protect shaftthreads and O-rings during maintenance.

FIGURE 21Durco Tool Kit

CAUTION

DANGER

DANGER

23

Pump Division

Section 4.5

Unscrew the impeller and remove from the shaft. Discardthe impeller gasket (#104).

Do not apply heat to the impeller. If liquid is entrapped in thehub, an explosion could occur.

Refer to Appendix F for instructions on removing the seal,sleeve, and rear cover plate if pump is equipped with aSealSentry FMI seal chamber. This is the Durco sealchamber that does not have a separate gland. The gland isintegral to the seal chamber.

13. Remove the seal or packing gland nuts (#111A).14. Remove the two cap screws (#140) which attach the rear

cover plate to the adapter. Carefully remove the rear coverplate (#106).

FIGURE 22

15. If a cartridge type mechanical seal (#153) is used (Figure22), loosen the set screws which lock the unit to the shaftand remove the complete seal assembly. If the seal is bebe reused, the spacing clips or tabs should be reinstalledprior to loosening the set screws. This will ensure that theproper seal compression is maintained.

16. If a component type inside mechanical seal (#153) is used,loosen the set screws on the rotating unit and remove itfrom the shaft, see Figure 23. Then pull the gland (#190)and stationary seat off the shaft. Remove the stationaryseat from the gland. Discard all O-rings and gaskets.

17. If a component type outside mechanical seal is used,remove the gland and the stationary seat. Remove thestationary seat from the gland. Loosen the set screws inthe rotating unit and remove it. Discard all O-rings andgaskets.

FIGURE 23

18. If packing (#113) is used, remove it and the seal cage(lantern ring)(#112). Remove the gland (#110).

19. If the pump has a hook type sleeve (#177) it can now beremoved. Unit now appears as shown in Figure 24.

FIGURE 24

20. If the power end is oil lubricated, remove the drain plug(#134) and drain the oil from the bearing housing (#119).

21. If the pump has lip seals, a deflector (#114) will bepresent. Remove it.

22. Loosen the three set screws (#201A) on the bearing carrier(#201). The bearing carrier must be completely unscrewedfrom the bearing housing. Note: Do not pry against theshaft. Mark IIIA designThe face of the bearing carrier has three square lugs thatprotrude from the surface. The bearing carrier is turned byusing an open end wrench on one of the square lugs asshown in Figure 25.

DANGER

24

Pump Division

Section 4.5

FIGURE 25

Old style Mark III designOn Group 1 and 2 pumps the bearing carrier is turned byusing a strap wrench, with the strap located around theO.D. of the carrier face. On Group 3 pumps, the bearingcarrier is turned by using a spanner wrench to engage thecogs on the O.D. of the bearing carrier.

23. Because the O-rings (#201B) will cause some resistance inremoving the bearing carrier assembly from the housing,hold the bearing carrier flange firmly and with slight rota-tion, pull it out of the bearing housing. The bearing carrierassembly with the shaft and bearings should come free.This unit will appear as shown in Figure 25A. Furtherdisassembly is not required unless the bearings are to

be replaced.

FIGURE 25A

24. Remove the snap ring (#201C) (Figure 26) on Group 1and 2 pumps, or the bearing retainer (#201D) on Group 3pumps.

FIGURE 26

Note: Group 1 and 2 pumps equipped with duplex angularcontact bearings use a bearing retainer (#201D) instead ofthe snap ring. Remove the carrier from the bearing.

25. The bearing locknut (#124) and lockwasher (#125) maynow be removed from the shaft (#105). Discard thelockwasher.

26. An arbor or hydraulic press may be used to remove thebearings (#120 and #121) from the shaft. It is extremelyimportant to apply even pressure to the inner bearing raceonly. Never apply pressure to the outer race as this exertsexcess load on the balls and causes damage.

Applying pressure to the outer race could permanently damagethe bearings.

27. The Mark IIIA design has an optional oil slinger (#122)located between the bearings. If present, inspect it fordamage or looseness. Remove if it needs to be replaced.

28. On Group 2 and 3 pumps, the bearing housing (#119)must be separated from the bearing housing adapter(#108).Mark IIIA designThis is accomplished by removing the capscrews (#139)which thread into the bearing housing.Old style Mark III designThis is accomplished by removing the hexnuts (#139A)and the capscrews (#139). The adapter O-ring (#131)should be discarded.

29. If lip seals (#118) and (#129) (Figure 27) are used, theyshould be removed from the bearing housing and adapterand discarded.

CAUTION

25

Pump Division

Section 4.5

FIGURE 30

CLEANING/INSPECTIONAll parts should now be thoroughly cleaned and inspected. Newbearings, O-rings, gaskets, and lip seals should be used. Anyparts that show wear or corrosion should be replaced with newgenuine Flowserve parts.

It is important that only non-flammable, non-contaminatedcleaning fluids are used. These fluids must comply with plantsafety and environmental guidelines.

CRITICAL MEASUREMENT AND TOLERANCESTo maximize reliability of pumps, it is important that certainparameters and dimensions are measured and maintainedwithin specified tolerances. Please refer to Appendix C for asummary of these various physical parameters and theassociated tolerances which are vital for maximizing pumpreliability. It is very important that all parts be checked asspecified in Appendix C. Any parts that do not conform to thespecifications should be replaced with new Flowserve parts.

FIGURE 27

30. If bearing isolators are used, refer to Appendix G.31. If magnetic seals are used, maintain the seals as specified

by the manufacturer.32. If present, the Trico oiler (#133) (Figure 28) should be

removed from the bearing housing.

FIGURE 28

33. The sight gage (#200) (Figure 29) should be removed fromthe bearing housing. The Mark IIIA design will have the tagshown in Figure 30 attached to the sight gage. Removethis tag and save it to be re-installed later.

FIGURE 29

WARNING

26

Pump Division

Section 4.5

ASSEMBLY

Note: Refer to Figure 31 for all bolt torque information.

It is very important that all pipe threads be sealed properly.PTFE tape provides a very reliable seal over a wide range offluids, but it has a serious shortcoming if not used properly. If,during application to the threads, the tape is wrapped over theend of the male thread, strings of the tape will be formed offwhen threaded into the female fitting. This string can then tearaway and lodge in the piping system. If this occurs in the sealflush system, small orifices can become blocked effectivelyshutting off flow. For this reason, Flowserve does notrecommend the use of PTFE tape as a thread sealant.

Flowserve has investigated and tested alternate sealants andhas identified two that provide an effective seal, have the samechemical resistance as the tape, and will not plug flushsystems. These are La-co Slic-Tite and Bakerseal. Bothproducts contain finely ground PTFE particles in an oil basedcarrier. They are supplied in a paste form which is brushed onthe male pipe threads. Flowserve recommends using one ofthese paste sealants.

Full thread length engagement is required for all fasteners.

Recommended Bolt Torques (US Customary Units)

Item Description Group 1 Group 2 Group 3Non-lubricated Non-lubricated Non-lubricated

201E Bearing retainer capscrews - standard bearings N/A N/A 5/16 in - 6 ftlbf201E Bearing retainer capscrews - duplex bearings 3/16 in - 2 ftlbf 3/16 in - 2 ftlbf 5/16 in - 6 ftlbf139 Bearing housing/adapter capscrews and nuts N/A 1/2 in - 27 ftlbf 5/8 in - 53 ftlbf111 Mechanical seal gland studs/nuts, with gasket 3/8 in - 10 ftlbf 3/8 in - 10 ftlbf 1/2 in - 25 ftlbf111 Mechanical seal gland studs/nuts, with O-ring 3/8 in - 40 ftlbf 3/8 in - 40 ftlbf 1/2 in - 97 ftlbf115 Casing studs/nuts 1/2 in - 25 ftlbf 1/2 in - 25 ftlbf 3/4 in - 75 ftlbf

5/8 in - 45 ftlbf140 Capscrew cover/adapter (token bolts) 3/8 in - 11 ftlbf 3/8 in - 11 ftlbf 1/2 in - 27 ftlbf201A Bearing carrier set screws 3/8 in - 11 ftlbf 1/2 in - 27 ftlbf 1/2 in - 27 ftlbf136 Capscrew foot 1/2 in - 27 ftlbf 3/4 in - 94 ftlbf 1 in - 228 ftlbf195 Capscrews - repeller cover to cover N/A 3/8 in - 10 ftlbf 1/2 in - 25 ftlbf

Note: For lubricated or PTFE-coated threads, use 75% of the values given.

FIGURE 31

Recommended Bolt Torques (Metric)

Item Description Group 1 Group 2 Group 3Non-lubricated Non-lubricated Non-lubricated

201E Bearing retainer capscrews - standard bearings N/A N/A 5/16 in - 8 Nm201E Bearing retainer capscrews - duplex bearings 3/16 in - 3 Nm 3/16 in - 3 Nm 5/16 in - 8 Nm139 Bearing housing/adapter capscrews and nuts N/A 1/2 in - 37 Nm 5/8 in - 72 Nm111 Mechanical seal gland studs/nuts, with gasket 3/8 in - 13 Nm 3/8 in - 13 Nm 1/2 in - 34 Nm111 Mechanical seal gland studs/nuts, with O-ring 3/8 in - 54 Nm 3/8 in - 54 Nm 1/2 in - 130 Nm115 Casing studs/nuts 1/2 in - 34 Nm 1/2 in - 34 Nm 3/4 in - 102 Nm

5/8 in - 61 Nm140 Capscrew cover/adapter (token bolts) 3/8 in - 15 Nm 3/8 in - 15 Nm 1/2 in - 37 Nm201A Bearing carrier set screws 3/8 in - 15 Nm 1/2 in - 37 Nm 1/2 in - 37 Nm136 Capscrew foot 1/2 in - 37 Nm 3/4 in - 130 Nm 1 in - 300 Nm195 Capscrews - repeller cover to cover N/A 3/8 in - 13 Nm 1/2 in - 34 Nm

Note: For lubricated or PTFE-coated threads, use 75% of the values given.

27

Pump Division

Section 4.5

bearing refers to the bearing nearest to the casing. Outboardbearing refers to the bearing nearest to the motor.

1. Install the inboard bearing (#120) on the shaft (#105).Mark IIIA designThe inboard bearing must be positioned against the shoulderas shown in Figure 36.Old style Mark III designThe correct position for the inboard bearing is given inFigure 34. It is important to note that on Group 1 and 2pumps, the inboard bearing is not located against ashoulder. The position must be determined from the chart.On Group 3 shafts the inboard bearing is positioned againsta shoulder.

If the power end is equipped with single shield regreaseablebearings, the shields should be oriented as shown inFigure 32A.

FIGURE 32A

POWER END ASSEMBLYThe Mark IIIA design has an optional oil slinger. If the slingerwas removed during disassembly, install a new slinger (#122).

FIGURE 32

Bearing installationMounting of bearings on shafts must be done in a cleanenvironment. Bearing and power end life can be drasticallyreduced if even very small foreign particles work their way intothe bearings.

Bearings should be removed from their protective packagingonly immediately before assembly to limit exposure to possiblecontamination. After removing the packaging they should onlycome in contact with clean hands, fixtures, tools and worksurfaces.

The chart shown in Figure 33 gives the SKF part numbers forbearings in Durco Mark III pumps. Note that the term inboard

FIGURE 33Durco Mark III Bearings

Inboard Outboard Double Row, Optional OutboardSingle Row, Angular Contact, Duplex Angular

Group Type of Bearings Deep Groove5 Deep Groove5 Contact5

1 Oil bath/mist Open1 6207-C3 5306-AC3 7306-BECBYRegreasable Single Shielded2 6207-ZC3 5306-AZC3 NA6Greased for life Double Shielded3 6207-2ZC3 5306-A2ZC3 NA7Sealed for life Double Sealed4 6207-2RSIC3 5306-A2RSC3 NA7

2 Oil bath/mist Open1 6310-C3 5310-AHC3 7310-BECBYRegreasable Single Shielded2 6310-ZC3 5310-AZC3 NA6Greased for life Double Shielded3 6310-2ZC3 5310-A2ZC3 NA7Sealed for life Double Sealed4 6310-2RSIC3 5310-A2RSC3 NA7

3 Oil bath/mist Open1 6314-C3 5314-AC3 7314-BECBYRegreasable Single Shielded2 6314-ZC3 5314-AZC3 NA6Greased for life Double Shielded3 6314-2ZC3 5314-A2ZC3 NA7Sealed for life Double Sealed4 6314-2RSIC3 5314-A2RSC3 NA7

1 These bearings are open on both sides. They are lubricated by oil bath or oil mist.2 These bearings are pre-greased by Flowserve. Replacement bearings will generally not be pre-greased, so grease must be applied by the user. They

have a single shield, which is located on the side next to the grease buffer, or reservoir. The bearings draw grease from the reservoir as it is needed.The shield protects the bearing from getting too much grease, which would generate heat. The grease reservoir is initially filled with grease byFlowserve. Lubrication fittings are provided, to allow the customer to periodically replenish the grease, as recommended by the bearing and/orgrease manufacturer.

3 These bearings are shielded on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease these bearings.The shields do not actually contact the bearing race, so no heat is generated.

4 These bearings are sealed on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease these bearings.The seals physically contact and rub against the bearing race, which generates heat. These bearings are not recommended at speeds above 1750RPM.

5 The codes shown are SKF codes. Inboard and outboard bearings have the C3, greater than Normal clearance. These clearances are recommendedby SKF to maximize bearing life.

6 Regreasable Single Shielded bearings are not available in the duplex configuration; however, open oil bath-type bearings can be used for theregreasable configuration. These bearings must be pre-greased during assembly. Lubrication fittings are provided, to allow the user to periodicallyreplenish the grease, as recommended by the bearing and/or grease manufacturer.

7 Not available.

OutboardBearing

InboardBearing

OutboardBearing

InboardBearing

Shield

Slinger

28

Pump Division

Section 4.5

2. Place the snap ring (#201C) or the bearing retainer (#201D)onto the outboard end of the shaft and slide down to theinboard bearing. Note the proper orientation of the bearingretainer or snap ring must be assured in this step. The flatside of the snap ring and the small side of