VINTAGE PARTS MARKETING PRODUCT LINE: DVS HERITAGE COMPANY: BWIP - FLS CONFIGURATION: Horizontal split case, single

stage, double suction TYPICAL APPLICATION: Pipeline, Condensate,

Boiler feed booster VINTAGE: 1992 - current PRODUCT LIFESPAN: API compliant 8th edition -

current SUBJECT: Installation and Operations

Manual (IOM) This product is the integration of the BJ and UCP model DVS. It was specifically designed to take the best features and hydraulics and make it 8th edition compliant. Many more hydraulics than the published curves exist. NOTE: This information is intended for the use of Flowserve Employees. The information provided is based on standard catalogue / price book information. Details for specific units or serial numbers may be different as a result of non-standard construction, and parts, repairs and upgrades provided by Flowserve or third parties.

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DVS PUMP INSTALLATION OPERATION & MAINTENANCE

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FOREWORD

This manual provides installation, operation, and maintenance instructions

for the pump described herein.

Outlined within are the general procedures that must be observed to ensure

long, trouble free service. It is assumed that site personnel are familiar with

the basic principles and tools involved in the installation, care and service of

pumps. Successful operation is dependent on careful study of the manual

and a well-planned maintenance program.

Should questions arise which are not specifically answered, please contact

the nearest FLOWSERVE CORPORATION, FPD sales office or the

dealer through whom the unit was purchased for additional information. All

inquiries should identify the applicable pump by type, size and serial

number as shown on the pump nameplate.

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TABLE OF CONTENTS

PARAGRAPH

NUMBER

SECTION ONE DESIGN DATA

DESIGN DATA 1.1

SECTION TWO DESCRIPTION

PUMP 2.1

Case 2.1.1

Rotating Element 2.1.2

Bearings and Housings 2.1.3

Shaft Seals 2.1. 4

SECTION THREE INSTALLATION

GENERAL 3.1

SHIPMENT CONFIGURATION 3.2

SITE EQUIPMENT REQUIRED 3.3

HANDLING PRECAUTIONS 3.4

UNLOADING AND CHECKING 3.5

FOUNDATION PREPARATION 3.6

BASEPLATE LEVELING AND GROUTING 3.7

BEARING HOUSING CLEANING AND LUBRICATION 3.8

DRIVE COUPLING INSTALLATION AND ALIGNMENT 3.9

MAIN PIPING CONNECTION 3.10

AUXILIARY EQUIPMENT CONNECTION 3.11

DOWELING 3.12

SITE STORAGE 3.13

SECTION FOUR OPERATION

OPERATING PRECAUTIONS 4.1

PRELIMINARY CHECK 4.2

OPERATING CHECK 4.3

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SECTION FIVE MAINTENANCE

GENERAL 5.1

PREVENTATIVE MAINTENANCE 5.2

TROUBLE-SHOOTING 5.3

SITE EQUIPMENT REQUIRED (CUSTOMER SUPPLIED) 5.4

HANDLING INSTRUCTIONS 5.5

Handling Precautions 5.5.1

Lifting Methods 5.5.2

PUMP DISASSEMBLY 5.6

Preparation For Disassembly 5.6.1

Coupling Removal 5.6.2

Thrust Bearing and Housing Removal 5.6.3

Radial Bearing and Housing Removal 5.6.4

Shaft Seal Removal 5.6.5

Pump Case Removal 5.6.6

Rotating Element Disassembly 5.6.7

PARTS CLEANING AND INSPECTION 5.7

PUMP REASSEMBLY 5.8

Preparation for Reassembly 5.8.1

Rotating Element Reassembly 5.8.2

Pump Case Reassembly 5.8.3

Shaft Setting Check 5.8.4

Shaft Seal Installation 5.8.5

Thrust Bearing and Housing Installation 5.8.6

Radial Bearing and Housing Installation 5.8.7

FINAL ASSEMBLY 5.9

SECTION SIX SPARE PARTS

RECOMMENDED 6.1

ORDERING 6.2

STORAGE 6.3

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This material is the property of FLOWSERVE CORPORATION, FPD and is furnished only for

the purpose indicated, any and all confidential, proprietary, patent and other rights, in the

subject matter being retained including any exclusive rights of use and/or manufacture and/or

sale. Possession of this material does not convey any permission to reproduce this material, in

whole or in part, or manufacture the subject matter shown therein, or use the confidential or

proprietary information thereon. Such permission to be granted only by specific authorization

in writing signed by an officer or other authorized agent of FLOWSERVE CORPORATION,

FPD.

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SECTION TWO - DESCRIPTION

2.1 PUMP

The model DVS centrifugal pump is horizontally mounted, single-stage double suction,

with sleeve radial bearings and a duplex ball thrust bearing. It has an axial split case,

a rotating element assembly, shaft seals, and bearing housings. The pump is pedestal

mounted on a baseplate.

For descriptions of other components supplied by FLOWSERVE CORPORATION, FPD

refer to pump outline drawing and other manufacturers material in Section Seven.

NOTE

Refer to pump sectional drawing and mechanical seal drawing in Section Seven for location of pans described in manual text

2.1.1 Case

The axial split pump case is a double volute design with the joints of the halves sealed by a

gasket and secured by studs and cap nuts. The suction and discharge nozzles, and bearing

housing brackets, are integral with the case bottom half. This permits removing the top half case

and the rotating element without disturbing the main piping.

2.1.2 Rotating Element

NOTE

All of the component parts for the rotating element described below may not be found in the purchased pump. See the Pump Sectional Drawing, Section Seven for parts applicability

The rotating element assembly consists of the pump shaft, impeller and its wear rings

(when furnished), the case wear rings, shaft sleeves, and throat bushings. The key

driven impeller is installed on the pump shaft with a shrink fit and positioned by shaft

sleeve/impeller nut.

The case wear rings are positioned by tongue and groove fit with both halves of the

case, each of their tongues having an anti-rotation pin that engages a slot in the bottom

half case at the parting line.

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2.1.3 Bearings and Housings

The horizontally split bearing housings contain the radial and thrust bearings components and are

secured to the bearing housing brackets by cap screws, with dowels used to maintain alignment.

The pump has sleeve radial bearings and an angular contact duplex pair of ball bearings at the

thrust end. A locating pin in the top half of each bearing housing prevents rotation of the sleeve

bearing. The bearing housings contain oil for lubricating the bearings. Distribution of the oil to each

bearing is accomplished by oil rings that ride in a groove on an oil ring retainer. Leakage of oil

from the bearing housing is prevented by shaft mounted deflectors.

2.1.4 Shaft Seals

Sealing of the pump shaft where it exits each end of the pump case is accomplished by the use of

shaft sealing device. For a description and operation of the sealing device, see Section Seven.

SECTION THREE - INSTALLATION

3.1 GENERAL

Installation of the pump is performed in the sequence described in paragraphs 3.5 through 3.10.

Final alignment (paragraph 3.9) and doweling (paragraph 3.12) are performed after the pump has

operated for at least twenty-four hours.

3.2 SHIPMENT CONFIGURATION

The pump is shipped to the job site assembled, and may be either mounted on its baseplate or

shipped separately. If shipped separately, the pump will be suitably wrapped and mounted on

skids or crated with all openings closed off and protected. Some small items may be packaged in

separate containers.

3.3. SITE EQUIPMENT REQUIRED

In addition to common tools used in this type of work, the following should be available at the job

site when installing or removing the pump, baseplate, and/or driver:

Lifting equipment of sufficient capacity to handle the equipment safely (see Section Five,

paragraph 5.4). The approximate weight of the pump and other equipment supplied is normally

given on the Pump Outline Drawing, Section Seven.

Steel blocks and wedges (one each per foundation bolt) of 2” (50.8 mm) minimum thickness, for

leveling baseplate. Blocks and wedges should be free of burrs. Shim packs can substitute for the

wedges.

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Grouting materials, such as non-shrink grout, sufficient lumber for building a wooden trough to

contain grout, and risers or funnels for guiding grout, normally provided by grouting contractor. A

good oil paint is recommended for grout protective coating.

One dial indicator and suitably stiff bracket having an arm of sufficient length to extend from the

driver coupling hub to the pump coupling hub for performing coupling alignment.

3.4 HANDLING PRECAUTIONS

When handling the pump or its components, always work safely to prevent accidents. The unit can

be handled and installed using equipment normally found at the job site; no special tools are

required. Be sure lifting devices used are in good condition and are capable of safely carrying the

weights being lifted. Observe the following precautions :

0 When handling the unit as shipped, use lifting Iugs provided on each corner of

baseplate or, as an alternate method, use chains or slings passed under the

baseplate. Crated assemblies may be handled with a forklift of suitable capacity.

0 When lifting the pump or driver separately, use lifting lugs when provided;

otherwise, use padded slings around the pump or driver outer case. DO NOT use eyebolts on

top of pump or bearing housing for lifting the assembled pump. DO NOT place lifting slings

around bearing housings or shafts.

0 Adjust lifting equipment so that the load is balanced and supported adequately, and watch for

overhead obstructions. Use care to prevent bumping, pushing or scraping of pump parts,

especially the shafts and other machined surfaces and fits.

0 Take care to prevent foreign materials or dirt from entering the working parts of the pump or

driver.

3.5 UNLOADING AND CHECKING

1. Before handling the equipment, review the procedures of paragraph 3.4. Work safely to prevent

accidents.

2. After unloading, uncrate and unwrap all parts and inspect carefully to be certain nothing was

damaged during shipment. Check driver carefully to be certain there are no signs of oil leakage.

3. Check shipment against packing list or manifest for possible shortages.

4. If damage or shortage has occurred, immediately advise the carriers claim department and the

nearest FLOWSERVE CORPORATION, FPD office or the dealer through whom the unit was

purchased.

5. If pump or auxiliary equipment is to be stored for short or long term (over 6 months) periods,

refer to paragraph 3.13 for procedures used in preparing equipment for shipment and site

storage.

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3.6 FOUNDATION PREPARATION

1. Choose a solid ground location for foundation.

2. Build foundation approximately three inches larger overall than the pump baseplate, to provide

ample anchorage for the foundation bolts. The foundation should be at least several times the

mass (weight) of pump, baseplate and driver. The final mass (weight) of the foundation must be

determined by the customer.

3. Locate foundation bolts accurately, according to the Pump Outline Drawing, Section Seven.

4. Choose foundation bolts of specified size. Provide pipe enclosures for the foundation bolts three

or four diameters larger than the bolts and stuff waste around bolts while pouring the concrete.

5. Leave top foundation surface rough, to provide a good base for grout.

6. Allow foundation to cure before installing equipment.

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3.7 BASEPLATE LEVELING AND GROUTING (See Figure 3-1)

1. Place the steel blocks and wedges (or shim packs) as closely as possible to the foundation

bolts.

2. Disconnect all piping and wiring as required.

3. Attach chain fall hooks at each corner of baseplate. Lift and guide baseplate to center above

foundation bolts, then lower onto bolts.

4. Using a precision level across baseplate pads at A-B, C-D, E-F and G-H, adjust wedges (or

shim packs) as necessary to insure that baseplate is level in all directions to within the

recommended tolerance of 0.002 inch (.051 mm) per linear foot. Wedges or shim packs should

feel solid when tapped lightly with a hammer.

5. When baseplate is level and held firmly with foundation bolt nuts, it is ready for grouting.

6. To contain grout, provide wooden trough about 2-1/2 inches (63.5 mm) deep around outside of

baseplate. Also provide riser or funnels over grout holes to insure correct placement of grout.

7. Stir or vibrate the grout while pouring grout into all open spaces. Tap baseplate to eliminate air

pockets.

8. Allow grout to settle, then dress surplus grout on outside of baseplate.

9. When grout is thoroughly hardened, remove wedges, fill the wedge holes with grout, and

completely tighten the foundation bolts.

10. Apply oil paint to protect grout from moisture.

11. Observing the precautions of paragraph 3.4, reinstall the pump and driver. Position them on the

baseplate with their shafts located to the between shafts dimension as shown on Pump Outline

Drawing, Section Seven. With a plumb line or other suitable means, establish approximate

alignment of shaft centerlines.

FIGURE 3-1. BASEPLATE LEVELING

12. Install and temporarily tighten the cap screws securing equipment to baseplate, but do not

tighten driver cap screws until required during coupling alignment, paragraph 3.9.

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13. Reconnect all piping and wiring disconnected in Step 2. Connect required auxiliary equipment

as applicable.

14. Check driver for correct rotation by momentarily operating it as per manufacturers instructions,

(Section Seven). Correct as required. Also check for proper magnetic alignment of driver shaft.

3.8 BEARING HOUSING CLEANING AND LUBRICATION

The inside of the bearing housing is cleaned and sprayed with rust inhibitor before the pump is

shipped. However, dirt or moisture may have entered the housing during shipment, storage, or

installation. If it is suspected that bearings have been exposed to dirt or moisture disassemble and

thoroughly clean the bearings and housings with a solvent and air-dry the parts. When clean, coat

machined and unpainted inside surfaces of housing and parts above the oil level with a thin layer of

petroleum and reassemble the bearing housing.

3.9 DRIVE COUPLING INSTALLATION AND ALIGNMENT (See Figure 3-2)

Pump-to-driver alignment assures that the pump and driver shaft centerlines are parallel and in line

with each other. The coupling alignment consists of angular and offset alignment procedures.

Alignments should be checked at least three times:

0 Preliminary: With foundation bolts and pump hold down bolts pulled tight, but prior to

tightening driver hold down bolts.

FIGURE 3-2. COUPLING ALIGNMENT

0 Secondary: After the pump and driver are bolted down tightly and the suction and discharge

pipes are connected (paragraph 3.10).

0 Final (hot alignment check prior to doweling): After pump has operated for at least twenty-four

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(24) hours and is still at operating temperature and pressure. When final alignment is

completed, recheck the tightness of the pump and driver hold down bolts.

Alignment of pump and driver coupling is performed as follows:

Angular Alignment

1. Fasten or clamp a dial indicator to one hub with indicator stem contacting face of the

opposite hub, location (A).

2. Rotate one shaft and take indicator readings at a minimum of four places 90°

apart. Shim under driver feet as necessary to attain parallel hub faces with 0.001” to

0.002” (.025 mm to .050 mm) total indicator reading (T.I.R.)

Offset Alignment

1. Fasten or clamp a dial indicator to one hub with indicator stem contacting

circumference of the opposite hub, location (B).

2. Rotate one shaft and take indicator readings at a minimum of four places 90°

apart. Shim under driver feet as necessary to attain parallel alignment of shaft centerlines

within 0.002 to 0.004 inch (.50mm to .10 mm) T.I.R.

3. Repeat step 1 with indicator clamped to the opposite hub.

NOTE: After establishing the offset alignment, recheck that angular alignment has not

changed and that pump and driver anchor bolts are secure.

3.10 MAIN PIPING CONNECTION

With the pump baseplate grouted and firmly fastened to the foundation, the pump and

driver installed, the main piping should then be connected to the pump proper. Piping-to-pump

flange faces must mate flush and parallel without use of excessive force. The piping forces

supported by the pump must not displace the pump out of alignment. DO NOT use drifts or

flange bolts to force alignment of piping. Provide piping supports close to the pump flanges to

avoid vibration and strain on pump casing. To prevent possible damage, be certain that piping

and suction and discharge cavities are thoroughly clean before connecting pump to piping.

Observe the following:

0 Use pipe of ample size for the length of line and the pressures involved. Allow

absolute minimum of bends and fittings.

0 Suction piping should be as short and direct as possible, never smaller in diameter

than the suction entrance to the pump. Where a long suction pipe is necessary, its

Diameter should be at least one size, preferable two, larger than the pump suction

port. Any bends or elbows used in suction piping should be of a long radius type.

0 DO NOT use a straight tapered reducer on a horizontal suction line (use offset

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Reducer with offset down).

0 Install check valve, followed by gate valve, in discharge line. Check valve prevents

back flow in event of power failure, and protects pump from excessive pressure.

0 Reducer, if used in discharge line, should be fined to discharge flange preceding

check valve and gate valve.

0 Provide strainers or screens where required to prevent entry of solids into the

pump. Strainers or screens, if used, must not deprive the pump of adequate intake

flow.

NOTE

Use of gages or other measuring devices are recommended to monitor the pressure drop across each strainer or screen that may be used. Strainers and screens must be removed and cleaned when the pressure drop increases, indicating a flow restriction.

3.11 AUXILIARY EQUIPMENT CONNECTION

Install and connect required auxiliary instruments, wiring and piping as shown on the

Pump Outline Drawing in Section Seven.

3.12 DOWELING

Doweling of the pump and driver prevents movement, simplifies realignment if alignment is

disturbed, and temporarily holds unit should mounting bolts loosen. It is performed after the

final alignment check of paragraph 3.9. Dowel pump and driver as follows:

1. Using the existing pilot holes in the feet on the driven end of the pump, drill new pilot holes

into the mounting pedestals to a minimum depth of 1-1/2 times the diameter of the dowel

pin. The drilled holes should be of a diameter 1/64” (.40 mm) less than the diameter of

the dowel pins to be installed. Clean out the chips.

2. Ream the holes in the feet and mounting pedestal to the proper diameter for the dowel

pins, which should be a slight interference fit. Clean out chips and insert dowel pins.

3. Install nuts on dowel pin threads. The nuts are provided to remove the dowel pins when

required.

4. Dowel the driver in accordance with driver manufacturers instructions.

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3.13 Site Storage

Upon equipment arrival at the job site, the contractor or user must take over its handling and

storage and such tasks as rotating shafts and adding desiccants (for long-term storage), and

preparing for customers final in-plant painting.

0 Keep protective covers or wrappings removed during inspection and recrate the

equipment. Store equipment in a dry and protected indoor location, keeping it free of dirt

and grit both internally and externally.

0 Keep protective piping covers tight and renew if damaged. Do not remove them until the

pump is to be connected to the system piping. Shafts, bearings, and other finished

parts subject to attack by moisture should be inspected occasionally, and the protective

coating renewed if necessary.

0 During storage, once a month, rotate the pump shaft a minimum of two and a half

revolutions in the direction indicated on the nameplate. Position the shaft 1800 from its

previous resting position.

0 For long term storage periods (over six months), contact your nearest Flowserve

Corporation, FPD office for additional requirements.

SECTION FOUR - OPERATION

This section list precautions and checks that must be observed when operating the

pump. The procedure for starting and stopping the pump must be developed by the

customer since valving and piping to and from the pump may vary among customers.

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4.1 OPERATING PRECAUTIONS

CAUTION

0 OPERATE THE PUMP ONLY WITHIN THE DESIGN PARAMETERS SPECIFIED IN

SECTION ONE, DESIGN DATA AND THE PERFORMANCE TEST CURVE, SECTION

SEVEN.

0 DO NOT OPERATE THE PUMP BELOW THE MINIMUM FLOW RATE AS

SUFFICIENT FLOW WILL LEAD TO PUMP OVERHEATING AND GREATLY REDUCED

PUMP LIFE.

0 DO NOT ALLOW PUMP TO RUN DRY, AS POSSIBLE DAMAGE TO THE UNIT MAY

OCCUR.

0 DO NOT ALLOW PUMP TO OPERATE BELOW NPSH REQUIRED AS SPECIFIED IN

SECTION ONE, DESIGN DATA, AS POSSIBLE DAMAGE TO THE UNIT MAY

OCCUR.

0 PUMPED LIQUID MUST BE FREE OF EXCESSIVE AIR OR GAS. THE PRESENCE

OF EXCESSIVE AIR OR GAS IN THE LIQUID WILL RESULT IN A REDUCTION IN

CAPACITY AND HEAD WHICH CANNOT BE PREDICTED WITH ACCURACY, AND

MAY LEAD TO EXCESSIVE WEAR OR DAMAGE OF THE UNIT.

0 FLOWSERVE CORPORATION, FPD MAKES NO GUARANTEE AGAINST THE

EROSIVE ACTION OF SAND OR ABRASIVE MATERIAL IN PUMPED LIQUID.

SMALL AMOUNTS OF ABRASIVES WILL PASS THROUGH THE UNIT WITH

SLIGHT IMMEDIATE EFFECT, BUT IT IS ONLY A QUESTION OF TIME UNTIL

OPERATION UNDER THIS CONDITION WILL DAMAGE THE WORKING PARTS

OF THE PUMP.

4.2 PRELIMINARY CHECK

1. Check that the thrust bearing nut/oil pump drive has been tightened and locked by lock

washer.

2. Before starting the pumping operation, check the security of all bolting, piping and wiring.

3. Check all gages, valves and instruments for proper working order.

4.3 OPERATING CHECK

As soon as possible after the pumping operation begins, repeat the applicable portions of the

checking procedure of paragraph 4.2, be certain that all gages and instruments indicate as

specified. Other than monitoring of flows, pressures, temperatures and lubrication, the pump

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should require no attention during operation. In the event symptoms of trouble occur, stop the

pump and refer to the Trouble-Shooting Chart and Maintenance Procedures of Section Five.

SECTION FIVE - MAINTENANCE

5.1 GENERAL

Routine performance of preventive maintenance tasks will enable early detection of most

problems that may arise. Periodic dismantling of the pump for inspection is not necessary

unless there is reason to suspect excessive wear or other internal damage. If a pump

malfunction is suspected, refer to Trouble-Shooting, paragraph 5.3. When major maintenance

is undertaken, refer to the procedures of paragraph 5.7 for pump disassembly operations and

paragraph 5.9 for pump reassembly operations.

5.2 PREVENTIVE MAINTENANCE

Monitoring of pump performance is recommended to establish the maintenance requirements

for the pumps particular application. The following items should be checked on a regular

basis:

0 Integrity of the base plate and pump and driver mounting fasteners – tighten as

necessary

0 All piping for evidence of leakage due to loosening or damage - repair as necessary

0 Instrumentation and wiring for possible damage - replace or repair as necessary

0 Changing Lubricating Oil - Drain and refill the lubricating oil for the pump bearings

approximately every six months. Ordinarily, oil replenishment is not required between

changes. The recommended lubricant is specified in Section One - Design Data.

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5.3 TROUBLE-SHOOTING

The following chart lists most of the troubles that can be encountered during pump

operation, their possible causes, and recommended remedies:

TROUBLE PROBABLE CAUSE REMEDY

Hot Bearings a. Inadequate oil flow a. Verify oil flow

b. Contaminated oil b. Drain and clean oil

reservoir, refill with clean oil

c. Defective Bearings c. Repair or replace

Excessive Leakage a. Worn sealing device a. Replace sealing device

Around Shaft b. Excessive injection pressure b. Reduce injection pressure

Reduced Flow or Low a. Air leaks in Suction a. Check suction line for

Discharge Pressure leaks

b. Speed too low b. Check driver speed

c. NPSH too low c. Check suction side of

system for flow

restrictions, air leaks

d. Clogged suction line d. Clean out suction line

strainer

e. Clogged impeller e. Clean out impeller

f. Impeller damaged f. Replace impeller

g. Wrong rotation g. Check driver rotation

No Flow a. Pump not primed a. Prime Pump

b. Speed too low b. Check driver speed

c. Plugged impeller c. Clean out impeller

d. Clogged suction strainer d. Clean out strainer

e. Damaged impeller e. Replace impeller

Pump Vibration a. Clogged impeller a. Clean out impeller

Excessive b. Damaged impeller b. Replace impeller

c. Misalignment c. Check driver-to-pump

alignment

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5.4. SITE EQUIPMENT REQUIRED (CUSTOMER SUPPLIED)

NOTE

In addition to common millwright tools used in this type of work, the following equipment should be

available at the job site when disassembling or assembling the pump:

0 A hoist, crane, or derrick - strong enough to handle the load to be lifted.

0 Spreader bar and shackles (clevis-and-pin type adapters) - suitably sized for attaching

lifting lines to equipment lifting lugs.

0 Lifting eyebolts, padded or nylon slings - for handling the equipment when lifting lugs are

not provided.

0 Dow Corning DC-55M silicone grease or equivalent - for lubricating o-rings.

0 Dow Corning Molykote G paste or equivalent - for lubricating rotating element

components

5.5 HANDLING INSTRUCTIONS

NOTE

The approximate weight of the pump and driver are shown on the Pump Outline Drawing, Section Seven.

5.5.1 Handling Precautions

WARNING

DO NOT WORK OR STAND UNDER A HEAVY SUSPENDED OBJECT UNLESS

THERE IS A POSITIVE SUPPORT UNDER IT TO PROTECT PERSONNEL SHOULD A

HOIST OR SLING FAIL.

0 When handling the pump or its components, always work carefully to prevent

accidents.

0 Be sure lifting devices (paragraph 5.4) are in good condition and capable of safely

handling the weights being lifted.

0 Adjust lifting equipment so that the load hook is directly over the equipment center of

gravity. Watch for overhead obstructions.

0 Use care to prevent bumping, pushing or scraping of pump parts, especially the shaft

and other machined surfaces and fits.

0 Prevent foreign materials or dirt from entering the working parts of the pump or its

driver.

0 Note that the driver lifting points are designed for lifting the driver only.

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5.5.2 Lifting Method

Baseplate with or without equipment installed - Use lifting Iugs provided on each corner of

baseplate or, as an alternate method, use chains or slings passed under the baseplate.

Pump assembled - Use lifting holes provided in webs of top case.

Pump bearing housing - Use eyebolt installed into one of the vent, holes.

Pump case; top half - Use lifting holes provided in webs of top case.

Rotating element assembly - Use nylon slings at each end of the shaft.

Driver - Handle driver in accordance with manufacturers instructions.

5.6 PUMP DISASSEMBLY

WARNING

OBSERVE THE HANDLING INSTRUCTIONS OF PARAGRAPH 5.5 WHEN

DISASSEMBLING THE PUMP.

NOTE

Refer to pump sectional drawing, Section Seven, for location of parts described in disassembly.

5.6.1 Preparation For Disassembly

1. Before removing a component, be certain of the following:

0 Driver is stopped with controls locked open and tagged.

0 Driver lead wires are disconnected and tagged.

0 Pump discharge and suction line shutoff valves are closed and tagged.

2. Drain the pump of all liquid.

3. Drain the bearing housings of all lubricating oil.

4. Disconnect and remove the following components, as applicable, if the pump

is so equipped:

0 Seal injection and drain lines.

0 Bearing housing constant level oilers.

0 Vibration and temperature monitoring devices and other instrumentation.

0 Any pump secondary piping (drain lines, etc).

5.6.2 Coupling Removal

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NOTE

If the same coupling is to be reinstalled, match mark spacer to hubs and hubs to driver and

pump shafts. Note arrangement and location of all components removed for reinstallation in

same location.

1. Remove coupling guard, then disconnect and remove spacer from coupling.

2. Scribe a reference mark on the pump shaft for locating hub at reinstallation.

3. Remove two setscrews from face of pump coupling nut.

4. Remove coupling nut from pump shaft.

5. The pump coupling hub and shaft are a tapered fit. With a puller and broad flame torch,

heat the hub evenly and then remove it from shaft. Remove coupling key from shaft.

5.6.3 Thrust Bearing and Housing Disassembly

1. Loosen setscrew (optional) and slide inboard deflector on pump shaft away

from bearing housing.

2. Remove cap screws securing outboard cover and gasket. Remove cover and

gasket. Discard gasket.

3. Remove oil ring from oil ring retainer.

4. Remove dowel pins and cap screws securing top half of bearing housing to

bottom half.

5. Using suitable lifting equipment remove the top half of bearing housing.

6. Remove outer race stop.

7. Loosen set screws and remove oil ring retainer.

8. Release tabs of lock washer, then remove locknut.

9. Using a suitable puller, remove the ball bearings and shaft

pump shaft. Discard bearings.

10. Remove top half of sleeve bearing. Remove outer oil ring and move inner oil

ring aside.

11. Remove bottom half of sleeve bearing by revolving it around the pump shaft

while supporting the shaft to relieve weight and provide clearance.

12. With suitable lifting equipment supporting the bottom half bearing housing,

remove the dowel pins and cap screws securing bearing housing half to pump

case and remove bottom half bearing housing.

13. Remove remaining oil ring and inboard deflector from pump shaft. Discard

deflector o-ring.

5.6.4 Radial Bearing and Housing Removal

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1. Loosen setscrews (optional) securing both the inboard and outboard deflectors

to the pump shaft. Slide the outboard deflector off the pump shaft and slide

inboard deflector on shaft away from radial bearing housing. Remove and

discard outboard deflectors 0-ring.

2. Remove dowel pins and cap screws securing the top half of bearing housing to

the bottom half.

3. With suitable lifting equipment remove the top half of bearing housing.

4. Remove the top half of sleeve bearing.

5. Remove outboard oil ring and move inboard oil ring aside.

6. Remove the bottom half of sleeve bearing by revolving it around the pump

shaft while supporting the shaft to relieve weight and provide clearance.

7. With suitable lifting equipment supporting the bottom half bearing housing,

remove the dowel pins and cap screws securing the bearing housing half to

pump case and remove the bottom half bearing housing.

8. Slide inboard oil ring and inboard deflector off pump shaft. Discard deflector

0-ring.

5.6.5 Shaft Seal Removal

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1. Starting at either end of the pump and referencing the mechanical seal drawing

in Section Seven, check to make sure the setting/spacer plate is reinstalled so

the gland plate assembly and shaft sleeve is locked as a cartridge assembly.

2. Loosen the set screws securing the seal sleeve to the pump shaft.

3. Remove heavy hex nuts and washers securing mechanical seal cartridge to

stuffing box.

4. Remove the cartridge from pump shaft and protectively wrap cartridge.

5. Remove the mechanical seal from the other end of the pump following the

above procedure.

21

5.6.6. Pump Case Disassembly

1. Remove the cap nuts from case studs.

2. Use back-off screws in the taps provided to break the gasket joint of the

case top half to the case bottom.

CAUTION

PROTECT THE CASE-TO-GASKET MATING SURFACE. SCRATCHING OR SCORING

OF THE MATING SURFACE MAY CAUSE LEAKAGE DURING PUMP OPERATION.

3. Using suitable lifting equipment, remove the case top half case and place it carefully aside

on a clean surface.

4. Remove the rotating element from the bottom half of case and place on V- blocks or other

suitable supports.

5. Remove the following loose components from rotating element:

0 Throat bushings from shaft.

0 Case wear ring from its fit on each end of impeller.

5.6.7 Rotating Element Disassembly

The impeller and shaft sleeve are installed on the pump shaft with a shrink and

slide fit. The shaft sleeve/impeller nut is secured by screwing into the pump shaft

against the impeller. Impeller movement on the shaft is prevented by its key,

while the movement of shaft sleeve and impeller nut are prevented by set screws.

To facilitate removal and installation of the parts from the shaft, the shaft is

machined in steps so that the largest diameter fit is at the center with decreasing

diameter fits towards each end.

WARNING

WEAR HEAT RESISTANT GLOVES WHEN HANDLING HEATED SLEEVES AND

IMPELLERS.

22

CAUTION

USE A NEUTRAL ACETYLENE OR MAP TORCH WITH A BROAD FLAME AND ROTATE

THE HEAT FOR EVEN DISTRIBUTION. KEEP THE FLAME AWAY FROM PUMP SHAFT

WITH A PIPE SLEEVE OR DAMP CLOTH.

THE USE OF TEMPIL-STICK (CONTROLLED MELTING POINT MATERIAL,

PRODUCT OF TEMPIL MFG. CO.) OR EQUAL PRODUCT IS RECOMMENDED TO

OBTAIN PROPER TEMPERATURE OF 400°F (204.4°C).

SHOULD AN IMPELLER OR SLEEVE BIND ON THE SHAFT DURING REMOVAL

COOL IT AND THE SHAFT WITH AN AIR BLAST, FOLLOWED BY A COMPLETE

COOLING WITH CLEAR WATER. REHEAT AND TRY REMOVAL AGAIN. AVOID

FORCING THE COMPONENT OFF THE SHAFT.

5.6.7.1 Shaft Sleeve Removal

Loosen the shaft sleeve set screws and screw the sleeve from shaft. Removal of

shaft sleeve should not require application of heat. If required, tap the sleeve with

a soft hammer to help break it loose.

NOTE: One sleeve has left hand threads.

5.6.7.2 Impeller Removal

NOTE

Before heating the impeller, remove the case wear rings and shaft sleeves.

Using a neutral acetylene or map torch, heat the impeller to approximately 400°F

(204°C) around the outside, from the outer diameter to the running fit. Rotate the

torch for even heat distribution. Heat the impeller for approximately 1 to 1-1/2

minutes on each side. After heating the outside of the impeller, apply heat to the

hub and inside of the suction eye last (avoid applying heat to the shaft). Use a

babitted hammer to help break the impeller loose. Then quickly pull the impeller

off the shaft. Remove the impeller key from pump shaft.

5.6.7.3 Impeller Wear Ring Removal and Replacement (If Applicable)

NOTE

Each wear ring is attached to its impeller by at least three set screws.

23

1. Remove the set screws used to secure wear ring to impeller.

2. Using a diamond pointed chipping tool, segment the wear ring in three places

and remove wear ring segments.

3. Remove any burrs from the impeller wear ring area.

4. Install replacement wear ring on impeller.

5. Drill and tap new holes approximately 1-inch from location of previously

drilled holes. Drill the holes to accept a tap of the same thread size as the

set screws removed in step 1.

6. Secure wear ring with socket set screws and stake or Locktite set screws.

5.7 PARTS CLEANING AND INSPECTION

1. Discard and provide replacement parts for all gaskets and o-rings removed during

disassembly.

2. Wash all parts thoroughly in acetone or other suitable solvent. Air dry the parts, or

dry the parts with a clean, lint-free cloth.

3. Check all parts for wear, erosion, or corrosion. Discard and provide replacement

parts for all parts worn, eroded or corroded to the extent which would damage

pump operation.

4. Using a micrometer, determine that the faces of the shaft locating ring are ground

parallel and perpendicular to the bore within 0.0005 (.013 mm).

5. Determine that the pump shaft is free of dirt and burrs. Mount the shaft in a lathe

(between centers, or on V-blocks, or on rollers (at bearing locations).

Use a dial indicator to check the shaft for runout. Total indicator reading at any

point must not exceed .002 (.05 1 mm).

6. Check the diametrical running clearances of wear rings and bearings (See

Section One -Design Data). The diametrical running clearances given are

factory tolerances for a new or rebuilt pump.

7. For pumps with a pivot shoe bearing arrangement, check both the inner and

outer set of thrust pads, check the button to face height of each pad. The

maximum variance within a set shall be no more than 0.002 (.05 1 mm.)

8. For pumps with a pivot shoe bearing arrangement, determine that the thrust

disc faces are true as follows:

a. Mount shaft locating ring, thrust disc key and thrust disc and thrust bearing

nut on pump shaft and determine that the thrust disc is completely

secured on shaft.

24

b. Mount shaft in a lathe and use a dial indicator to determine that both faces

of the thrust disc are not more than .0005 (.013 mm) out of true at the outside

diameter.

c. Remove thrust disc from shaft for pump reassembly.

5.8 PUMP REASSEMBLY

Thoroughly clean all parts and gasket seats before reassembly. Replace all gaskets

with new ones; never reuse old gaskets. Reassemble the pump as directed in the following

paragraphs. For parts identification and location, refer to Pump Sectional Drawing, Section

Seven.

WARNING

OBSERVE THE HANDLING INSTRUCTIONS OF PARAGRAPH 5.5 WHEN

ASSEMBLING THE PUMP

N OTE

Refer to pump sectional drawing, Section Seven, for location of pans described in reassembly.

5.8.1 Preparation for Reassembly

1. Select a clean work area.

2. Verify all parts have been thoroughly cleaned and inspected.

3. Provide new gaskets and o-rings.

4. Check keys for snug keyway fits on pump shaft and on impellers or sleeves.

5. Lay out all components of rotating element in the order in which they are to be

assembled on the pump shaft.

5.8.2 Rotating Element Reassembly

CAUTION: USE ANY SAFE HEATING METHOD AND PROVIDE PROTECTION FOR

PERSONNEL HANDLING THE HEATED COMPONENTS.

1. Replace impeller wear rings that may have been removed and secure with set screws

These wear parts are a light press fit and may require heating or cooling to ease

assembly. When heat is used, apply the heat evenly and use care to avoid

overheating the parts.

2. Make sure impeller and pump shaft are clean. Replacement of the impeller on the

shaft will require application of heat, however, if the impeller is heated, apply the

heat slowly and evenly to obtain uniform expansion, and do not overheat the piece.

25

When installing the impeller, first install key on the shaft. Using a hammer, tap gently

to help drive the impeller onto the shaft. After the impeller is properly positioned

against the shaft sleeve/shaft shoulder, use a spanner wrench to reinstall the shaft

sleeve/impeller nuts (left-hand and right hand threaded) and securely tighten retaining

screw.

CAUTION: VERIFY THE IMPELLER IS NOT INSTALLED BACKWARDS.

3. Balance the rotating element to the requirements given in Section One - Design Data.

4. Complete the assembly of the rotating element by installing the remaining parts as

follows:

a. Case wear ring on its fit on each end of impeller

b. Throat bushings on pump shaft

5.8.3 Pump Case Reassembly

CAUTION

EXERCISE EXTREME CARE IN HANDLING THE CASE HALVES IN ORDER NOT TO

DAMAGE THE MATING SURFACES. DAMAGING THESE SURFACES CAN CAUSE

SERIOUS OPERATIONAL DIFFICULTIES.

5.8.3.1 Pump Case Gasket Fabrication and Installation

1. Clean both halves of pump case at the split joint. If dowel pins are installed, remove

them.

2. Remove the studs (if applicable) from the top half pump case.

3. Place a thin coat of non-hardening sealer (Permatex or equivalent) on the mating

surface of the top case half. This will prevent the gasket material from moving when

forming the gasket.

4. Lay and clamp gasket in place on the top case.

5. Use a soft (lead) ball peen hammer and outline the interior contour of the case, stud

case, stud and dowel pin holes. Cut out the outlined contour and holes.

6. Remove the gasket from the upper case and place on lower case.

7. Place the upper case on the lower case and cut or peen the outside case contour.

Leave approximately 1/4 (6.35 mm) gasket material protruding from case at

Stuffing box faces. Gasket will be trimmed after final installation of half in following

paragraph.

8. Remove upper case.

26

5.8.3.2 Rotating Element and Upper Case Reinstallation

1. To ease installation, lubricate the outside diameter of case wear rings with a light coat

of Dow Corning Molykote 6 paste or equivalent.

2. Lift the rotating element and center it over the case bottom half. Before lowering it,

rotate both case wear rings and throat bushings so that the locating pin of each

piece is towards the top of the rotating element.

3. Slowly lower the rotating element assembly into the lower case while fining the bushings,

and case wear rings with their respective grooves in the lower case. Rotate the

throat bushings and wear rings one-quarter turn to engage their locating pin with

the corresponding counter sink hole in the lower case.

4. If removed, install the upper case dowel pins.

5. Place the upper case on the lower case and install the stud cap nuts. Tighten nuts

to the torque value specified in Table 5-3.

6. Cut the excess gasket material extending over each end of the case flush with the

case.

5.8.4 Shaft Settings Check

If the bearing housings, rotating element or shaft locating/adjusting ring have been

altered or replaced, the radial and/or axial shaft settings should be checked in

accordance with procedure listed in Section Seven, Reference Materials.

5.8.5 Shaft Seal Installation

1. Starting at either end of the pump and referencing the mechanical seal drawing in Section

Seven verify that all visible o-rings are installed prior to installing the mechanical seal.

2. Slide the seal cartridge onto pump shaft and into stuffing box. Secure the cartridge by

installing its fiat washers and nuts. Tighten nuts to value given in Table 5-2

3. Do not tighten the setscrews that lock the cartridge to the pump shaft until the pump is

fully assembled.

4. Repeat the above procedure to install the seal cartridge on the other end of the pump.

5.8.6 Thrust Bearing and Housing Reinstallation

1. Slide inboard deflector with a new 0-ring installed in its bore on pump shaft so as not

to interfere, with the installation of bearing housing.

2. Lift, position and secure the bottom half bearing housing to pump case with dowel pins

and cap screws. Tighten cap screws to value specified in Table 5-1.

3. Place inboard oil ring on pump shaft so that it will be located on the inboard

slide of sleeve bearing.

27

4. Using a piece of wood to pry on the pump shaft, lift the shaft as necessary to provide

clearance and roll bottom half of sleeve bearing into bottom half bearing housing.

5. Place the outboard oil ring on the pump shaft above the bottom half sleeve bearing

then position both the inboard and outboard oil rings on the pump shaft to mate with

the grooves in the top half sleeve bearing. Install top half sleeve bearing on bottom

half sleeve bearing.

6. Install locating ring on pump shaft against shoulder on pump shaft, then press duplex

bearing, back to back on pump shaft against locating ring.

7. Place outer race stop around bearing. Secure with screws and nuts.

8. Install Iockwasher and lock nut. Tighten locknut then secure lock nut with tabs of

lockwasher.

9. Slide oil ring retainer on pump shaft against lock nut. Secure retainer in place with

set screws.

10. Place oil ring on oil ring retainer.

11. Place top of half of thrust bearing housing on bottom half housing and install securing

hex head cap screws. Tighten cap screws to value specified in Table 5-1.

12. Install outboard thrust bearing housing cover with a new gasket and secure with

cap screws. Tighten cap screws to value specified in Table 5-1.

13. Slide inboard deflector on pump shaft against housing, then back it off 1/32”

(.79 mm) and secure with set screw (optional).

5.8.7 Radial Bearing and Housing Reinstallation

1. Place inboard deflector with a new 0-ring installed in its bore and on the pump

shaft so that it will not interfere with the installation of the radial bearing housing.

2. Lift, position and secure bottom half radial bearing housing to pump case with

dowel pins and cap screws. Tighten cap screws to value specified in Table 5-1.

3. Place one of the two oil rings on pump shaft so that it will be located on the inboard

side of sleeve bearing.

4. Using a piece of wood to pry on the pump shaft, lift the shaft as necessary to provide

clearance and roll bottom half of sleeve bearing into bottom half bearing housing.

5. Place the outboard oil ring on the pump shaft above the bottom half sleeve bearing,

then position both the inboard and outboard oil rings on the pump shaft to mate

with the grooves in the top half sleeve bearing. Install top half sleeve bearing on

bottom half sleeve bearing.

6. Place top half radial bearing housing on bottom half housing and install securing

28

cap screws. Tighten cap screws to value specified in Table 5-1.

7. Slide inboard deflector on pump shaft against housing, then back off 1/32 inch

(.79 mm) and secure to pump shaft with setscrew (optional).

8. Install a new 0-ring in bore of outboard deflector. Slide outboard deflector on pump

shaft against housing then back off 1/32 inch (.79 mm) and secure to pump shaft

with setscrew (optional).

5.9 FINAL ASSEMBLY

1. Install coupling key in key way on pump shaft. Align pump hub with key and place on

shaft.

2. Install coupling lock nut with lock washer on end of pump shaft. Using a spanner wrench

tighten nut until the hub touches mark previously scribed on shaft. Secure lock nut by

bending at least one tab of lock washer into the slot of lock nut.

3. If removed, reinstall the assembled pump on the baseplate and reconnect facility main

piping.

4. If mechanical seals are installed, tighten drive collar set screws. Disengage seal setting

plates from rotating parts and secure in place.

5. Connect any piping and instrumentation removed.

6. Install pump coupling and perform driver-to-pump alignment in accordance with

instructions in Section Three.

7. Provide lubricating oil to bearing housings before operating the pump.

29

TABLE 5-1. TORQUE VALUES FOR STUDS OTHER THAN CASE PARTING

Nominal Number Diameter Area Torque Torque

Diameter of at Root of at Root of

Threads Thread Thread

Inches Per Inch Inches Sq. Inch FT. Lbs. Joules

1/4 20 .185 .027 4 6

5/16 18 .240 .045 8 11

3/8 16 .294 .068 12 16

7/16 14 .345 .093 20 27

1/2 13 .400 .126 30 41

9/16 12 .454 .162 45 61

5/8 11 .507 .202 60 80

3/4 10 .620 .302 100 136

7/8 9 .731 .419 160 217

1 8 .838 .551 245 332

1-1/8 8 .963 .728 355 481

1-1/4 8 1.088 .929 500 678

1-3/8 8 1.213 1.155 680 922

1-1/2 8 1.338 1.405 800 1085

1-5/8 8 1.463 1.680 1100 1492

1-3/4 8 1.588 1.980 1500 2034

1-7/8 8 1.713 2.304 2000 2712

2 8 1.838 2.652 2200 2983

2-1/4 8 2.088 3.423 3180 4312

2-1/2 8 2.338 4.292 4400 5966

2-3/4 8 2.588 5.259 5920 8028

3 8 2.838 6.324 7720 10468

Data adapted from Crane Co. Catalog No. 60,1960

30

Torque values based on threads well lubricated with FEL-PRO-N or equivalent.

TABLE 5-2. TORQUE VALUES FOR CASE PARTING STUDS

Nominal Number Diameter Area

Diameter of at Root of at Root of

Threads Thread Thread Torque Torque

Inches Per Inch Inches Sq. Inch Ft. Lbs Joule

3/4 10 .620 .302 160 217

7/8 9 .731 .419 255 346

1 8 .838 .551 425 576

1-1/8 8 .963 .728 600 814

1-1/4 8 1.088 .929 850 1153

1-3/8 8 1.213 1.155 1200 1627

1-1/2 8 1.338 1.405 1600 2170

1-5/8 8 1.463 1.680 1950 2644

1-3/4 8 1.588 1.980 2600 3526

1-7/8 8 1.713 2.304 3250 4407

2 8 1.838 2.652 3900 5288

2-1/4 8 2.088 3.423 5600 7594

Torque values based on threads well lubricated with FEL-PRO-N or equivalent.

31

FLOWSERVE CORP.

Pump Division

LONG TERM STORAGE

INSPECTION AND MAINTENANCE REQUIREMENTS

A. Purpose

The purpose of this procedure is to establish the proper methods for inspecting and

preserving the pump on site after it is removed from its shipping packaging.

Domestic shipments should follow this procedure commencing immediately upon delivery

of the pump to the job sight.

Export packaging will provide one year long term storage without further maintenance.

After one year of storage the pump should be unpacked and this procedure followed. This

storage should also be followed as soon as the pump is unpacked even if it has been in

storage less than a year.

B. Indoor Storage

For domestic packaging, perform steps 3, 4, 5, and B of paragraph D, below, every month,

commencing immediately after receipt.

For export packaging perform steps 1 through 8 of paragraph 0, below, commencing one

year after shipment. These activities need only be performed on a yearly basis if the

barrier material is re-sealed immediately after performing inspection and maintenance.

C. Outdoor Storage

Maintenance and inspection is the same as B, above, except that the schedule shall be

increased to once every two weeks.

D. Procedure

1. Open box and barrier.

2. Remove old desiccant and replace with new.

3. Inspect all rust preventive coatings and replace with new, as necessary.

4. Rotate shaft by hand, minimum of two and a half revolutions, in the direction indicated

on the nameplate. Position the shaft 180° from its previous resting position.

5. Fog interior of beating housing and shaft with a rust preventative by spraying through

the plugged tap-holes in top of the bearing housings.

6. Re-seal barrier and remove air.

7. Close and secure wooden box.

8. Document this inspection and maintenance.

32

E. The inspection and maintenance described above is the responsibility of the customer. A

log should be maintained documenting the above steps, the dates, and performed by

whom. Any repairs/replacements required due to customers failure to preserve equipment

properly shall be at customer’s expense.

F. Drivers and accessories manufactured by others must be maintained in accordance with

the manufactures recommendations.

G. It is highly recommended that any pump stored in excess of 6 months be inspected by a

Flowserve Service Representative prior to start-up. This service is available at additional

cost.

H. All long term storage recommendations of this procedure assume normal site conditions.

If severe conditions are known to exist, the customer must advise Flowserve of those

conditions so that proper factory evaluation of storage and preservation methods, and

costs, may be performed.

SECTION SIX - SPARE PARTS

6.1 RECOMMENDED

See following page and/or sectional drawing part list in Section Seven.

6.2 ORDERING

Standard Parts - When ordering standard replacement parts, be certain to state:

0 The pump type, serial number and service as shown on pump nameplate.

0 Correct part name and part number as shown on the following page.

Parts for pumps on which operating conditions have been changed - If operating

conditions have been changed since pump was purchased, add full particulars of new

operating conditions. This is especially important in selection of new impellers.

NOTE

Should a change in operating conditions be considered, consult

nearest Flowserve , Pump Division representative or

the dealer from whom the unit was purchased to determine

whether such a change is feasible.

33

Oversized or Undersized Parts - If oversized or undersized parts are required add:

0 Dimensions (with sketch of part, if possible).

0 Pump Division to finish or Leave rough - customer to finish.

NOTE

Customer finishes parts at customers own risk.

Field Alterations – FLOWSERVE CORP., Pump Division, accepts no responsibility

for incorrect replacement of original parts or for parts that have been altered in the field.

6.3 STORAGE

In general, spare metal parts can be stored indefinitely if adequately protected from

moisture and physical damage. Rubber parts such as spare o-rings have a shelf life of

up to 3 years if stored in original heat sealed packaging and are adequately protected

from air, light, ozone, radiation, excessive temperature (1 20°F) (48.9°C) contamination

and physical damage.