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USER INSTRUCTIONS

Vertical Turbine PumpsWet Pit (VTP)

Double Casing (VPC)

Installation

OperationMaintenanceE, S and A series VTPs in wet pit and suction barrel designs

ranging in sizes from 50 mm (6 in.) to 1300 mm (52 in.) witha single or multiple stages. (This manual does not coverVTPs fitted with thrust bearing assemblies and VTPs builtfor cryogenic service).

PCN=71569224 10-13(E), Based on VTP-QS-0896 OriginalInstructions

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

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VERTICAL TURBINE PUMPS (VTPS) CENTRIFUGAL PUMPS ENGLISH 71569224 – 10-13

Page 2 of 76 flowserve.com

CONTENTSPAGE

PAGE

1 INTRODUCTION AND SAFETY ....................... 4 1.1 General ............................................................ 4 1.2 CE Marking and Approvals .............................. 4 1.3 Disclaimer ........................................................ 4

1.4

Copyright ......................................................... 4

1.5 Duty Conditions ............................................... 4 1.6 Safety .............................................................. 5 1.7 Safety Labels Summary .................................. 8 1.8 Specific Machine Performance ........................ 8 1.9 Noise Level ...................................................... 8 1.10 Specific machine performance ................ 9

2 TRANSPORT AND STORAGE ....................... 10 2.1 Consignment receipt and unpacking ............. 10 2.2 Handling ........................................................ 10 2.3 Lifting ............................................................. 10 2.4 Storage .......................................................... 14 2.5 Recycling and End of Product Life ................ 14

3 DESCRIPTION ................................................ 14 3.1 Configuration ................................................. 14 3.2 Nomenclature ................................................ 16 3.3 Design of Major Parts .................................... 17 3.4 Performance and Operation Limits................ 21

4 INSTALLATION ............................................... 21 4.1 Location ......................................................... 21 4.2 Preparation .................................................... 21 4.3 Foundation..................................................... 21 4.4 Grouting ......................................................... 23 4.5 Lifting and Assembly ..................................... 24 4.6 Initial Alignment ............................................. 30

4.7

Piping ............................................................. 31

4.8 Electrical Connections ................................... 34 4.9 Final Shaft Alignment Check ......................... 34 4.10 Protection Systems ................................ 34

5 COMMISSIONING, STARTUP, OPERATIONAND SHUTDOWN ........................................... 35

5.1 Pre-commissioning Procedure ...................... 35 5.2 Pump Lubricants ........................................... 35 5.3 Impeller Adjustment ....................................... 38 5.4 Direction of Rotation ...................................... 41 5.5 Guarding ........................................................ 41 5.6 Priming and Auxiliary Supplies ...................... 41 5.7 Starting the Pump .......................................... 42 5.8

Operating the Pump ...................................... 45

5.9 Stopping and Shutdown ................................ 46 5.10 Hydraulic, mechanical and electrical duty46

6 MAINTENANCE ............................................... 46 6.1 General .......................................................... 47 6.2 Maintenance Schedule .................................. 47 6.3 Spare Parts .................................................... 49

6.4

Recommended Spares and Consumables .... 49

6.5 Tools Required ............................................... 49 6.6 Fastener Torques ........................................... 50 6.7 Setting Impeller Clearance............................. 51 6.8 Disassembly ................................................... 51 6.9 Examination of Parts ...................................... 51 6.10 Assembly ................................................ 55

7 FAULTS; CAUSES AND REMEDIES ............. 56

8 DRAWINGS AND PARTS LISTS .................... 58 8.1 Cross Section: Product Lubricated VTP ........ 58 8.2 Cross Section: Enclosed Tube VTP ............... 61 8.3 Cross Section: Suction Barrel VTP ................ 64

8.4

General Arrangement Drawing ...................... 67

9 CERTIFICATION .............................................. 67

10 OTHER RELEVANT DOCUMENTATION ANDMANUALS ........................................................ 67

10.1 Supplementary User Instructions ........... 67 10.2 Change Notes ........................................ 67

11 APPENDIX ....................................................... 68 11.1 Bill of Materials Reference Numbers ..... 68

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INDEXPAGE

PAGE

Alignment of shafting (see 4.3, 4.6 and 4.9) Assembly (6.10) ....................................................... 55 ATEX marking (1.6.4.2) ............................................. 7

Bill of materials reference numbers (11.1) …….......68CE marking and approvals (1.2) ................................ 4Certification (9) ........................................................ 67Change notes (10.2) ................................................ 67Clearances, impeller (6.7) ....................................... 51Commissioning and operation (5) ........................... 35Compliance, ATEX (1.6.4.1) ...................................... 6Configurations (3.1) ................................................. 14Copyright (1.4) ........................................................... 4Design of major parts (3.3) ...................................... 17Direction of rotation (5.4) ......................................... 41Disassembly (6.8) .................................................... 51Disclaimer (1.3) ......................................................... 4Dismantling (6.8, Disassembly) ............................... 51Drawings (8) ............................................................ 58Duty conditions (1.5) .................................................. 4Electrical connections (4.8) ..................................... 34End of product life (2.5) ........................................... 14Examination of parts (6.9) ....................................... 52Fastener torques (6.6) ............................................. 50Faults; causes and remedies (7) ............................. 56Foundation (4.3) ...................................................... 21General arrangement drawing (8.4) ........................ 67General assembly drawings (8) ............................... 58Grouting (4.4)........................................................... 23Guarding (5.5).......................................................... 41Handling (2.2) .......................................................... 10

Hydraulic, mechanical and electrical duty (5.10) ..... 46Impeller clearance (6.7) ........................................... 51Inspection (6.2.1 and 6.2.2) ..................................... 48Installation (4) .......................................................... 21Lifting (2.3) ............................................................... 10Location (4.1) ........................................................... 21Lubrication (5.2) ....................................................... 35Maintenance (6) ....................................................... 47Maintenance schedule (6.2) .................................... 47Name nomenclature (3.2) ........................................ 16Nameplate (1.7.1) ...................................................... 8Nozzle loads (4.7.2) ................................................. 31Operating limits (3.4.1) ............................................ 21

Ordering spare parts (6.3.1) .................................... 49Parts lists (8) ............................................................ 58Performance (3.4) .................................................... 21Piping (4.7) .............................................................. 31Pre-commissioning (5.1) .......................................... 35Priming and auxiliary supplies (5.6) ........................ 41Protection systems (4.10) ........................................ 34Reassembly (6.10, Assembly) ................................. 55Receipt and unpacking (2.1).................................... 10Recommended spares (6.4) .................................. 499

Recycling (2.5) ......................................................... 14Replacement parts (6.3 and 6.4) ............................. 49Running the pump (5.8) ........................................... 45

Safety action (1.6.3) ................................................... 5Safety labels (1.7.2) ................................................... 8Safety markings (1.6.1) .............................................. 5Safety, protection systems (see 1.6 and 4.10)Sealing arrangements (3.3.7) .................................. 19Sectional drawings (8).............................................. 58Setting impeller clearance (6.7) ............................... 51Sound pressure level (1.9, Noise level) ..................... 8Spare parts (6.3) ...................................................... 49Specific machine performance (1.8) .......................... 8Starting the pump (5.7) ............................................ 42Stop/start frequency (5.7.8) ..................................... 45Stopping and shutdown (5.9) ................................... 46Storage, pump (2.4) ................................................. 14Storage, spare parts (6.3.3) ..................................... 49Supplementary manuals or info. sources (10) ......... 67Supplementary User Instructions (10.1) .................. 67Thermal expansion (4.6.1) ....................................... 30Tools required (6.5) .................................................. 49Torques for fasteners (6.6) ...................................... 50Trouble-shooting (7) ................................................. 56Vibration (5.7.7) ........................................................ 44

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1 INTRODUCTION AND SAFETY

General1.1

These instruc tions must always be keptclose to the product's operating location ordirectly with the product.

Flowserve products are designed, developed andmanufactured with state-of-the-art technologies inmodern facilities. The unit is produced with greatcare and commitment to continuous quality control,utilizing sophisticated quality techniques, and safetyrequirements.

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

These instructions are intended to facilitatefamiliarization with the product and its permitted use.Operating the product in compliance with theseinstructions is important to help ensure reliability inservice and avoid risks. The instructions may nottake into account local regulations; ensure suchregulations are observed by all, including thoseinstalling the product. Always coordinate repairactivity with operations personnel, and follow all plantsafety requirements and applicable safety and healthlaws and regulations.

These instructions must be read prior toinstalling, operating, using and maintaining theequipment in any region worldwide. Theequipment must not be put into service until allthe conditions relating to safety noted in theinstructions , have been met. Failure to followand apply the present user instructions isconsidered to be misuse. Personal injury,product damage, delay or failure caused bymisuse are not covered by the Flowservewarranty.

CE Marking and Approvals1.2It is a legal requirement that machinery and equipment

put into service within certain regions of the world shallconform with the applicable CE Marking Directivescovering Machinery and, where applicable, Low VoltageEquipment, Electromagnetic Compatibility (EMC),Pressure Equipment Directive (PED) and Equipment forPotentially Explosive Atmospheres (ATEX).

Where applicable the Directives and any additional Approvals cover important safety aspects relating tomachinery and equipment and the satisfactory provision

of technical documents and safety instructions. Whereapplicable this document incorporates informationrelevant to these Directives and Approvals.To confirm the Approvals applying and if the product isCE marked, check the serial number plate markingsand the Certification. (See section 9, Certification.)

Disclaimer1.3Information in these User Instructions is believedto be complete and reliable. However, in spite ofall of the efforts of Flowserve Corporation toprovide comprehensive instructions, goodengineering and safety practice should always beused.

Flowserve manufactures products to exactingInternational Quality Management System Standardsas certified and audited by external Quality Assuranceorganizations. Genuine parts and accessories havebeen designed, tested and incorporated into the

products to help ensure their continued product qualityand performance in use. As Flowserve cannot testparts and accessories sourced from other vendors theincorrect incorporation of such parts and accessoriesmay adversely affect the performance and safetyfeatures of the products. The failure to properly select,install or use authorized Flowserve parts andaccessories is considered to be misuse. Damage orfailure caused by misuse is not covered by theFlowserve warranty. In addition, any modification ofFlowserve products or removal of original componentsmay impair the safety of these products in their use.

Copyright1.4 All rights reserved. No part of these instructions maybe reproduced, stored in a retrieval system ortransmitted in any form or by any means without priorpermission of Flowserve.

Duty Conditions1.5This product has been selected to meet thespecifications of your purchase order. Theacknowledgement of these conditions has been sentseparately to the Purchaser. A copy should be keptwith these instructions.

The product must not be operated beyond

the parameters specified for the application. Ifthere is any doubt as to the suitability of theproduct for the application intended, contactFlowserve for advice, quoting the serial number.

If the conditions of service on your purchase orderare going to be changed (for example liquid pumped,temperature or duty) it is requested that the userseeks the written agreement of Flowserve beforestart up.

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Safety1.6

Summary of safety markings1.6.1These User Instructions contain specific safetymarkings where non-observance of an instruction wouldcause hazards. The specific safety markings are:

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

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

This symbol indicates “hazardous and toxic fluid”safety instructions where non-compliance would affectpersonal safety and could result in loss of life.

This symbol indicates safety

instructions where non-compliance will involve somerisk to safe operation and personal safety and woulddamage the equipment or property.

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

This symbol is used in safety instructions toremind not to rub non-metallic surfaces with a drycloth; ensure the cloth is damp. It is used in safetyinstructions where non-compliance in the hazardous

area would cause the risk of an explosion.

This sign is not a safety symbol but indicatesan important instruction in the assembly process.

Personnel qualification and training1.6.2 All personnel involved in the operation, installation,inspection and maintenance of the unit must bequalified to carry out the work involved. If thepersonnel in question do not already possess thenecessary knowledge and skill, appropriate trainingand instruction must be provided. If required theoperator may commission the manufacturer/supplierto provide applicable training.

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

Safety action 1.6.3This is a summary of conditions and actions toprevent injury to personnel and damage to theenvironment and to equipment. For products

used in potentially explosive atmospheressection 1.6.4 also applies.

NEVER DO MAINTENANCE WORKWHEN THE UNIT IS CONNECTED TO POWER

GUARDS MUST NOT BE REMOVED WHILE

THE PUMP IS OPERATIONAL

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

FLUORO-ELASTOMERS (When fitted.)When a pump has experienced temperatures over250 ºC (482 ºF), partial decomposition of fluoro-elastomers (example: Viton) will occur. In thiscondition these are extremely dangerous and skincontact must be avoided.

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

APPLYING HEAT TO REMOVE IMPELLERThere may be occasions when the impeller has eitherbeen shrunk fit on to the pump shaft or has becomedifficult to remove due to products of corrosion.

If you elect to use heat to remove the impeller, it mustbe applied quickly to the impeller boss. TAKEGREAT CARE!

Before applying heat ensure any residual hazardousliquid trapped between the impeller and pump shaft isthoroughly drained out through the impeller keywayto prevent an explosion or emission of toxic vapour.This must be carried out with the shaft in the verticalposition. On some pump sizes a cavity exists in theimpeller bore so on occasions a significant volume ofliquid may drain out.

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

HOT (and cold) PARTSIf hot or freezing components or auxiliary heatingsupplies can present a danger to operators andpersons entering the immediate area action must be

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taken to avoid accidental contact. If completeprotection is not possible, the machine access mustbe limited to maintenance staff only, with clear visualwarnings and indicators to those entering theimmediate area. Note: bearing housings must not beinsulated and drive motors and bearings may be hot.

If the temperature is greater than 80 ºC (175 ºF) orbelow -5 ºC (23 ºF) in a restr icted zone, or exceedslocal regulations, action as above shall be taken.

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

Gland packing must not be used when pumping

hazardous liquids.

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

ENSURE CORRECT LUBRICATION(See section 5, Commissioning, startup, operationand shutdown.)

START THE PUMP WITH OUTLET

VALVE PARTLY OPENED(Unless otherwise instructed at a specific point in theUser Instructions.)This is recommended to minimize the risk ofoverloading and damaging the pump motor at full orzero flow. Pumps may be started with the valvefurther open only on installations where this situationcannot occur. The pump outlet control valve mayneed to be adjusted to comply with the duty followingthe run-up process. (See section 5, Commissioningstart-up, operation and shutdown.)

NEVER RUN THE PUMP DRY

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

DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATESOperating at a flow rate higher than normal or at a flowrate with no back pressure on the pump may overload

the motor and cause cavitations. Low flow rates maycause a reduction in pump/bearing life, overheating ofthe pump, instability and cavitation/vibration.

Products used in potentially explosive1.6.4atmospheres

Measures are required to:

Avoid excess temperature

Prevent build up of explosive mixtures

Prevent the generation of sparks

Prevent leakages

Maintain the pump to avoid hazard

The following instructions for pumps and pump unitswhen installed in potentially explosive atmospheresmust be followed to help ensure explosion protection.For ATEX, both electrical and non-electricalequipment must meet the requirements of EuropeanDirective 94/9/EC. Always observe the regional legalEx requirements eg Ex electrical items outside theEU may be required certified to other than ATEX egIECEx, UL.

Scope of compliance1.6.4.1

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

Where Flowserve has supplied only the bare shaft

pump, the Ex rating applies only to the pump. Theparty responsible for assembling the ATEX pump setshall select the coupling, driver and any additionalequipment, with the necessary CE Certificate/Declaration of Conformity establishing it is suitable forthe area in which it is to be installed.

The output from a variable frequency drive (VFD) cancause additional heating affects in the motor and so, forpumps sets with a VFD, the ATEX Certification for themotor must state that it is covers the situation whereelectrical supply is from the VFD. This particularrequirement still applies even if the VFD is in a safe area.

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Marking1.6.4.2 An example of ATEX equipment marking is shownbelow. The actual classification of the pump will beengraved on the nameplate.

II 2 GD c IIC 135 ºC (T4)

Equipment GroupI = MiningII = Non-mining

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

Gas and/or dustG = GasD = Dust

c = Constructional safety(in accordance with EN13463-5)

Gas GroupIIA – Propane (typical)IIB – Ethylene (typical)IIC – Hydrogen (typical)

Maximum surface temperature (Temperature Class)(see section 1.6.4.3.)

Avoiding excessive surface1.6.4.3temperatures

ENSURE THE EQUIPMENT TEMPERATURECLASS IS SUITABLE FOR THE HAZARD ZONE

Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate. These are basedon a maximum ambient of 40 ºC (104 ºF); refer toFlowserve for higher ambient temperatures.

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

Temperature classto EN13463-1

Maximum surfacetemperature permitted

Temperature limit ofliquid handled *

T6

T5T4T3T2T1

85 °C (185 °F)

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

Consult Flowserve

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

* The table only takes the ATEX temperature class into consideration.Pump design or material, as well as component design or material,may further limit the maximum working temperature of the liquid.

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

The operator is responsible to ensure that thespecified maximum liqu id temperature is notexceeded

Temperature classification “Tx” is used when theliquid temperature varies and the pump could beinstalled in different hazarous atmospheres. In thiscase the user is responsible for ensuring that thepump surface temperature does not exceed thatpermitted in the particular hazardous atmosphere.

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

Where there is any risk of the pump being runagainst a closed valve generating high liquid andcasing external surface temperatures, fit an externalsurface temperature protection device.

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

In dirty or dusty environments, make regular checksand remove dirt from areas around close clearances,

bearing housings and motors.

Preventing the buildup of explosive1.6.4.4mixture

ENSURE THE PUMP IS PROPERLY FILLED AND VENTED AND DOES NOT RUN DRYEnsure the pump and relevant suction and dischargepipeline system is totally filled with liquid at all timesduring the pump operation, so that an explosiveatmosphere is prevented. In addition it is essential tomake sure that seal chambers, auxiliary shaft sealsystems and any heating and cooling systems areproperly filled.

If the operation of the system cannot avoid thiscondition, fit an appropriate dry run protection device(for example liquid detection or a power monitor).

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

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The usual approach is to control the exposure time to

the noise or to enclose the machine to reduce

emitted sound. You may have already specified a

limiting noise level when the equipment was ordered,

however if no noise requirements were defined, then

attention is drawn to the following table to give an

indication of equipment noise level so that you cantake the appropriate action in your plant.

Pump noise level is dependent on a number ofoperational factors, flow rate, pipework design andacoustic characteristics of the building, and so thevalues given are subject to a 3 dBA tolerance andcannot be guaranteed.

Similarly the motor noise assumed in the “pump andmotor” noise is that typically expected from standardand high efficiency motors when on load directly drivingthe pump. Note that a motor driven by an inverter may

show an increased noise at some speeds.

If a pump unit only has been purchased for fitting withyour own driver then the “pump only” noise levels in thetable should be combined with the level for the driverobtained from the supplier. Consult Flowserve or anoise specialist if assistance is required in combiningthe values.

It is recommended that where exposure approachesthe prescribed limit, then site noise measurementsshould be made.

The values are in sound pressure level LpA at 1 m

(3.3 ft) from the machine, for “free field conditionsover a reflecting plane”.

For estimating sound power level LWA (re 1pW) thenadd 17 dBA to the sound pressure value.

The noise levels shown in table 1.9.1 areextracted from typical motor manufacturer’sdata/catalogue to provide the average expectedmotor noise values at no load for reference only andare not guaranteed. The values could varydepending upon the test and surrounding conditions.

The combined noise level of the pump and the motorcould exceed the values shown. It is to be noted thatadding motors with similar noise levels increases thetotal noise level. Therefore, the dB correction to thevalues listed above is required to obtain thecombined noise levels of motor and the pump.

Actual on-site noise measurement by experts isrecommended and safety measures are to be takenaccordingly.

Typical vertical motor noise data (Hollow1.9.1and Solid shafts)

MotorFrameSize.

NEMA

RPM SoundPressure

(dBA )(WP- I

enclosure)

SoundPower(dBA )(WP- I

enclosure

180 3600 70.0 78.0

1800 60.0 68.0

1200 & slower 55.0 63.0

210 3600 70.0 78.2

1800 60.0 68.2

1200 & slower 55.0 63.2

250 3600 75.0 83.4

1800 70.0 78.4

1200 & slower 60.0 68.4

280 3600 75.0 83.8

1800 70.0 78.8

1200 & slower 60.0 68.8

320 3600 75.0 84.0

1800 65.0 74.0

1200 & slower 65.0 74.0

360 3600 75.0 84.21800 65.0 74.2

1200 & slower 65.0 74.2

400 3600 80.0 89.5

1800 70.0 79.5

1200 & slower 65.0 74.5

440 3600 80.0 90.0

1800 70.0 80.0

1200 & slower 70.0 80.0

449 1800 85.0 97.8

1200 & slower 80.0 92.8

5000 3600 90.0 102.8

1800 85.0 97.8

1200 & slower 80.0 92.8

5800 3600 90.0 103.7

1800 90.0 103.7

1200 & slower 80.0 93.76800 1800 90.0 103.9

1200 & slower 85.0 98.8

8000 1800 90.0 104.7

1200 & slower 85.0 99.7

Specific machine performance1.10For performance, parameters see section 1.5, Dutyconditions. Whenever there is a contractrequirement to incorporate specific machineperformance into User Instructions, those areincluded here. In cases where performance data hasbeen supplied separately to the purchaser, the sameshould be retained with these User Instructions, if

required.

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2 TRANSPORT AND STORAGE

Consignment receipt and unpacking2.1Immediately after receipt of the equipment it must bechecked against the delivery and shippingdocuments for its completeness and that there hasbeen no damage in transportation. Any shortage andor damage must be reported immediately toFlowserve and received in writing within one monthof receipt of the equipment. Later claims cannot beaccepted.

Check any crates, boxes and wrappings for anyaccessories or spare parts which may be packedseparately with the equipment or attached to sidewalls of the box or equipment.

Each product has a unique serial number. Check thatthis number corresponds with that advised andalways quote this number in correspondence as well

as when ordering spare parts or further accessories.

Handling2.2Boxes, crates, pallets or cartons may be unloadedusing fork lift vehicles or slings dependent on theirsize and construction.

Lifting2.3

Equipment in excess of 25Kg (55lbs) should belifted by mechanical means. Fully trained personnelmust carry out lifting, in accordance with localregulations.

Before lifting the driver alone, refer to themanufacturer’s instructions.

Lifting of W-type cast discharge head2.3.1(head only-pump not attached)

Lift the unassembled cast discharge heads (pumpnot attached) by installing eyebolts as shown usingthe flange mounting holes. Lower the head overshaft into place.

PIN

EYE BOLTS

CAST HEAD UNASSEMBLED

Do not use the lifting pins at the baseof the discharge head while lifting unassembled castdischarge heads unless the discharge head issecured by slings to prevent overturning. Never liftthe completely assembled pump with eyeboltsthrough this flange.

Lifting of type-W cast discharge head with2.3.2pump attached

Cast discharge heads with pump attached arerecommended to be lifted by using pins suitable withthat head size (refer to the table shown). The slingsare attached as shown maintaining minimum lengthof the sling from the shaft end as shown in the detail.

PIN

CAST HEADWITH PUMP ATTACHED

305 mm (12 in.) MIN.

" L "

Cast heads with discharge size mm (in.)

100(4)

150(6)

200(8)

250(10)

300(12)

PinDia.

25(1)

32(1.25)

32(1.25)

32(1.25)

38(1.5)

L1220(48)

1370(54)

1370(54)

1520(60)

1520(60)

“L” is approximate length

Lifting of fabricated discharge heads with2.3.3or without the pump

If the pump is supplied with a fabricated dischargehead use 2 point or 3 point method of lifting as shownin the details provided in 2.3.3.1 & 2.3.3.2. Thismethod is applicable to the lifting of discharge headswith or without the pump.

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Two point lifti ng of fabricated discharge2.3.3.1head types TF, UF & HFH (with orwithout pump attached)

Fabricated heads with discharge size mm (in.)

100-200(4-8)

250-600(10-24)

700-900(28-36)

PinDia. 32 (1.25) 38 (1.50) 44 (1.75)

Weight

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Lifting of suction barrel2.3.5Suction barrel (also referred as ‘Can’) is alwayssupplied separately and has to be installed into thesump first. Install eyebolts on the flange of thesuction barrel and attach slings and straps to bringthe suction barrel to a vertical position. Move thebarrel for installation. Provide hand support toprevent the suction barrel from swaying duringmovement.

Example: Lifting of suction barrel

Lifting of fully assembled pumps2.3.6If the pump is fully assembled, it has to beadequately strapped and supported at least twoplaces before it can be lifted from the shipping crateand moved to the installation site. See detailsshown. Same rules are applicable when the pump ispulled out from the sump and moved to anotherlocation.

S U C T I O N

B A R R E L ( C A N )

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Pump must be supported

at least two places

when lifted.

Do not use chains

to wrap around.

Two (2)

cranes arerequired

Examples shown here are for illustration only. See section 2.3 1~2.3.6 for specific liftinginstructions based on design variations. The pumps vary in weight, length and physical appearances from thetypes shown here.

Therefore, before lifting is attempted, exercise caution to prevent any injuries or loss of life.

Pump must be supported at

least two places when lifted.

Do not use chains to wrap around.

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Storage2.4

Store the pump in a clean, drylocation away from vibration. Leave pipingconnection covers in place to keep dirt and otherforeign material out of pump casing. Turn the pump

at frequent intervals to prevent brinelling of thebearings and the seal faces, if fitted, from sticking.

Inspection before storage2.4.1a) Inspect the preservative coating/painted surfaces

on the various parts. Touch up the areas, Ifnecessary.

b) Inspect all covers over pump openings and pipingconnections. If found damaged, remove thecovers and inspect interiors of the opening for anydeposits of foreign materials or water.

c) If necessary, clean and preserve the interior partsas noted above to restore the parts to the "as

shipped" condition. Replace covers and fastensecurely.

d) Exercise caution with pumps exposed to weather.Containers are not leak proof. Parts may becoated with a residual amount of protectivecoating, which will wash away if exposed toelements.

Short term storage (up to 6 months)2.4.2Follow the steps given in section 2.4.1. Select astorage space so that the unit will not be subjected toexcess moisture, extreme weather conditions,corrosive fumes, or other harmful conditions.

Driver storage instructions: Check drivermanufacturer’s User Instructions

Long term or extended storage2.4.3If a situation arises for a long-term storage, ( morethan 6 months) please contact Flowserve for specialstorage instructions and warranty related information.

Recycling and End of Product Life2.5 At the end of the service life of the product or itsparts, the relevant materials and parts should berecycled or disposed of using an environmentally

acceptable method and local regulations. If theproduct contains substances which are harmful to theenvironment, these should be removed and disposedof in accordance with current regulations. This alsoincludes the liquids and or gases in the "seal system"or other utilities.

Make sure that hazardous substances ortoxic fluids are disposed of safely and that the correct

personal protective equipment is used. The safetyspecifications must be in accordance with the currentregulations at all times.

3 DESCRIPTIONShould questions arise concerning the pump,

Flowserve pump division will require the completeserial number to be of assistance. The serial numberis stamped on a metal nameplate affixed to thedischarge head assembly. The driver will have aseparate nameplate attached to it. If you arerequesting information on the driver, please provideboth the driver serial number and the pump serialnumber for Flowserve representative.

Configuration3.1VTPs, are engineered pumps as:(a) Wet pit type and(b) suction barrel (can) type pumps. Most pumps arebuilt with customer specific features and forapplications such as water pumping stations, deep

wells, storm water service, industrial and cryogenicapplications. The pumps vary in size, impeller typesand length, whether it is an open shaft or enclosedshaft designs and type of discharge head used.

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Sump and deep well VTP3.1.1

DRIVER

DISCHARGE

HEAD

ASSEMBLY

COLUMN

ASSEMBLY

BOWL

ASSEMBLY

Suction barrel (Can) VTP3.1.2

SUCTION

BARREL

(CAN)

BOWL

ASSEMBLY

COLUMN

ASSEMBLY

DISCHARGE

HEAD

ASSEMBLY

DRIVER

Most common VTP models3.1.3The VTP configurations shown in sec 3.1.1 and 3.1.2are typical for variety of VTP models with the bowlassembly types such as EB, EG, EH, EJ, EK, EL,EM, EN, EP, EQ, SK, SL, SN, SP, SR, ST, & AV.The impeller models in each of these pumps aredesignated separately (see section 3.2 for moredetails) and the pump sizes could vary from 150mm(6 in) to 1300 mm (52 in.). The size expressed is in

terms of nominal bowl diameter and is always ininches.

Some units will not require a columnassembly. In such cases, the bowl assembly isconnected directly to the discharge head. Verticalturbine pumps can have single or multiple stages.

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Nomenclature3.2The pump size/ serial number will be engraved onthe nameplate typically as below: The nameplate isattached to the discharge head assembly.

Bowl assembly nomenclature3.2.1

12 E J H-3

Nominal Bowl Diameter-inches

Impeller Type (A or E or S) A=Axial, E=Enclosed, S=Semi-open

Bowl Model TypesB,J,K,H,L,M,N,P,Q,R,T,V….

Impeller Model DesignationL, M, H, Y…..

No. of Stages

The typical nomenclature above is the general guideto the VTP configuration description. Identify theactual pump size and serial number from the pumpnameplate. The driver will have a separatenameplate attached it.

Discharge head nomenclature3.2.2Consists of alphanumeric code as follows.Examples: 8W16, 10HF20, 6TF16,…….

10 HF 20

Nominal driver base diameter in inches

Discharge head type (see details below)

Nominal discharge diameter in inches

W = Cast head- for horizontal above the ground dischargeHF = Fabricated head for above the ground dischargeTF & LF = Fabricated heads with base flange

UF = Fabricated head for below ground dischargeHFL = Fabricated head for above ground discharge - Low H.PHFH = Fabricated head for above the ground discharge -High H.P.

Please see section 3.2.2.1 for discharge head typesand identification.

Types of discharge heads3.2.2.1Typical discharge head types. Details (a) thru (g).

a) W type cast discharge head

b) HF type fabricated discharge head

(Typically with square base plate)

c) TF type fabricated discharge head

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d) LF type fabricated discharge head(Typically with a circular base plate- ANSI type.

Also available with suction barrel mounting)

e) UF type fabricated discharge head

f) HFL type fabricated discharge head

g) HFH type fabricated discharge head

The discharge heads shown in section3.2.2.1 (a) thru (g) are for illustration only. The shaftand coupling arrangements vary. For the actualconfiguration of the pump that has been purchased,please refer to the drawings supplied with the pumpor order specific sectionals from Flowserve.

Design of Major Parts3.3

Please refer to appendix for Europump partnumber equivalents

Drivers3.3.1 A variety of drivers may be used, however, electricmotors are most common. For the purposes of thismanual, all types of drivers can be grouped into twocategories.

a) Hollow shaft drivers: where the head shaft extendsthrough a tube in the center of the rotor and isconnected to the driver by a clutch assembly at the topof the driver.

b) Solid shaft drivers: where the rotor shaft is solidand projects below the driver-mounting base. This

type driver requires an adjustable coupling forconnecting to the pump.

Discharge Head Assembly3.3.2(See also section 3.2.2.1)The discharge head supports the driver and bowlassembly as well as supplying a discharge connectionin most cases.

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A shaft sealing arrangement is located in thedischarge head to seal the shaft at its exit from theliquid chamber.

The shaft seal will usually be either a mechanicalseal assembly or stuffing box with an open lineshaftor a tube-packing box with an enclosed lineshaft.

Column assembly3.3.3The column assembly consists of column pipe, whichconnects the bowl assembly to the discharge headand carries the pumped fluid to the discharge head.Houses and supports the shaft and may containbearings. Typical column assemblies are:

a) flanged column assembly

b) threaded column assembly: from 100 mm~355mm (4~14 in.) sizes only.

The column supports shaft assembly, that is either

a) Open lineshaft construction utilizing the fluid being

pumped to lubricate the lineshaft bearings.Orb) Enclosed lineshaft construction has an enclosing

tube around the lineshaft and utilizes oil or otherfluid to lubricate the lineshaft bearings.

The shafts are threaded or key coupled with thruststud design or clamp ring design.

See sectional drawings supplied with the pump forexact column assembly details as per the order. Thesize and configuration vary depending upon thespecific order requirements and application criteria.

Bowl assemblies3.3.4The bowl assembly consists of impellers rigidlymounted on the pump shaft coupled to an electricmotor. Impellers are cast wheels with multiple diffuservanes and are generally coated to meet the hydraulicrequirements. See section 8.0 for cross sectional andpart details.

Suction strainers3.3.5VTPs can also be fitted with strainers [316] to preventforeign particles from entering the pump. The type ofstrainers and the mesh size depends on theapplication. Examples are shown below. Strainersare fastened [422] directly to the suction bell [55] orattached using clips [421]. Cone shaped strainers

are provided with internal or external threads toattach it to the main assembly.

a) Slip-on strainer

b) Clip-on strainer

c) Cone (threaded) strainer

SUCTION BELL (55)

CLIP

(421)

CAP SCREW (422)

STRAINER (316)

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d) Bolt on strainer

Impellers3.3.6VTP’s are supplied with enclosed, or semi openimpeller types. Impellers are low, medium and highcapacity type designed for maximum coverage of allVTP applications. Impellers are cast and machinedto match each order and to provide required surfacefinish to achieve hydraulic characteristics. Impellersare dynamically balanced and held in position on the

shaft by a tapered lock collet or split ring and key.

Stuffing box3.3.7Some VTPs are fitted with stuffing boxes. In suchcases, stuffing boxes are normally adequate forworking pressures up to 20.7 bar (300 psi). Refer tostuffing box User Instructions for specifications.

Low pressure stuffing box3.3.7.1This type of packing box is fitted on to an openlineshaft for pressures less than 6.5 bar (100 psi) andused only on W-type discharge heads (see Section3.2.2.1 to see for W type discharge head detail).

High pressure stuffing box3.3.7.2This type of packing box is fitted on to an open lineshaft for pressures up to 20 bar (300 psi) uses six rings ofpacking with two lantern rings and allows grease lubrication.

(17) PACKING GLAND

(354) STUD

(355) HEX NUT

(13) PACKING SET

PRESSURE

REDUCING

BUSHING (117)

STUFFING BOX (83)

O-RING (347)

HEX NUT (327A)

STUD (326A)

SLINGER (346)

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Extra high pressure stuffing box3.3.7.4In cases where the pressures are expected to cross 20 bar (300 psi) up to 65 bar (1000 psi), extra high-pressure stuffing box is used.

3.3.8 Mechanical shaft sealVTP’s can also be fitted with a mechanical seal. The requirement to fit the mechanical seal to be provided atthe time of contract.

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Accessories3.3.8 Accessories may be fitted when specified by thecustomer.

Performance and Operation Limits3.4This product has been selected to meet thespecifications of the purchase order. See section 1.5.

The following data is included as additional information tohelp with the installation. It is typical and factors such astemperature, materials and seal type may influence thisdata. If required, a definitive statement for your particularapplication can be obtained from Flowserve.

Operating limits3.4.1

Pumped liquid temperaturelimits*

5 ºC (40 ºF) to +80 ºC (176 ºF)

Maximum ambienttemperature*

Up to +40 ºC (104 ºF)

Maximum pump speed refer to the nameplate

*Subject to written agreement from Flowserve.Special designs and materials may be available forpumps operating above and below these specifiedlimits. Contact Flowserve for upgrade optionsavailable for your specific application.

4 INSTALLATION

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

Location4.1When equipment has been in storage for greater than 6months, a complete inspection should be conducted inaccordance with section 2.4.3. The pump should belocated to allow room for access, ventilation,maintenance and inspection with ample headroom forlifting and should be as close as practicable to thesupply of liquid to be pumped. Refer to the generalarrangement drawing for the pump set.

Inspection prior to installation4.1.1Six months prior to the scheduled installation date, aFlowserve Pump Division representative is to beemployed to conduct an inspection of the equipmentand the facility. If any deterioration of equipment isnoticed, the Flowserve Pump Division representativemay require a partial or complete dismantling of theequipment including restoration and replacement ofsome components.

Preparation4.2The pump should be located to allow room for access,ventilation, maintenance and inspection with ampleheadroom for lifting and should be as close aspracticable to the supply of liquid to be pumped.

Refer to the general arrangement drawing for the pumpdimensions and details.

General installation check-list4.2.1The following checks should be made before startingactual installation.

a) Make sure that motor nameplate ratings and thepower supply system match correctly.

b) Check the sump depth and pump length match-up.

c) Check the liquid level in the sump.d) Check the installation equipment to be sure that it

will safely handle the pump weight and size.e) Check all pump connections (bolts, nuts etc) for

any shipping and handling related problems.

Always support shafting in at leastthree places when lifting or installing. No installationshould be attempted without adequate equipmentnecessary for a successful installation.

On hollow shaft drivers, check the clutch sizeagainst the shaft size, which must go through theclutch

On solid shaft drivers, check the motor shaft sizeagainst the coupling bore size

Apply thread lubricant sparingly tomale shaft threads only at the time of making upshaft connection. Excess lubricant should beavoided.

Always check motor rotation beforeconnecting driver to pump. Reserve rotation due to

improper motor direction can cause extensive damageto the pump.

Foundation/Anchor Bolts4.3

There are many methods of installingpump units to their foundations. The correct methoddepends on the size of the pump unit, its location andvibration limitations. Non-compliance with the

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provision of correct foundation and installation maylead to failure of the pump and, as such, would beoutside the terms of the warranty.

The foundation must consist of material that will affordrigid support to the discharge head and will absorbexpected stresses that may be encountered in service.

Concrete foundations should have anchor boltsinstalled in sleeves that allow alignment and haveholes in the mounting plate as illustrated in the detailbelow. Sleeve should be filled with non-bondingmoldable material after sleeve is set in place.

When a suction barrel is supplied as in the case of thetype "TF" discharge head, the suction vessel mustprovide permanent, rigid support for the pump andmotor.

All foundation / anchor boltrecommendations should be verified by prevailingindustry standards.

Detail of a typical foundation bolt, grouted.

Leveling of pumps mounted on the4.3.1discharge head flange

Example of a typical discharge head with themounting flange

Some wet pit pumps are installed directly by usingthe flange that comes as an integral part of thedischarge head. The pump is lowered into the pitand aligned with the anchor bolts [372].

The mounting flange is shimmed to achieve requiredlevel by using a precision machinist’s level. Thepump is to be leveled to within 0.16 mm/m(0.002 in./ft). The data to be recorded for futurereference. Anchor bolt nuts [373] are tightenedsufficient enough to hold down the pump in place.

Grout is poured and allowed to set for at least 72~80hours (cure as required) before any further work isdone on the pump.

If leveling nuts are used to level thebase, they must be backed off as far as possible prior

to grouting.

Always shim near foundation bolts and then back offthe leveling nuts. Now tighten the foundation bolts. Ifdone otherwise there is a risk of significantly loweringthe structural natural frequency that could result inseparation of the base from the grout.

Directly mounted pumps are not userfriendly for service. Re-installation of these pumpsrequires re-leveling and re-grouting.

Leveling of pumps mounted on a4.3.2 soleplate and the soleplate is groutedSome pumps are mounted on a separate plateknown as soleplate [23]. In such cases, the levelshall be set with a master level or a precisionmachinist’s level. The mounting surface needs to beleveled to within 0.16 mm/m (0.002 in./ft).

The level should not exceed 0.125 mm (0.005 in.)elevation difference taken on any two points on theindividual soleplate. Accurate shimming and groutingof the soleplate is very important. Record the levelingdata for future reference. Grout the soleplate andallow to set at least 72~80 hours (cure as required)before the pump is lowered into the pit. Align thedischarge head boltholes with the anchor bolts [372].Check and adjust the pump level to within0.16 mm/m (0.002 in./ft) with respect to the soleplateand torque the nuts [373] to the required level.

DISCHARGE

HEAD FLANGE

CONCRETE

372

373

101

MOUNTING PLATE ANCHOR BOLT

GROUT

NUT

NON-BONDINGMOLDABLE MATERIAL

FOUNDATION

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Example of pump mounted on a soleplate

Leveling of pumps with the suction barrel4.3.3(also referred as “Can” VTPs)

The suction barrel [315] is first lowered into the pit andaligned with the anchor bolts [372]. The suction barrel

flange is leveled by using a master level or a precisionmachinist’s level. Levels should be taken on theequipment mounting surfaces. The suction barrelflange mounting surface needs to be leveled to within0.16 mm/m (0.002 in./ft) using shims and grouted.

Allow the grout to set for at least 72~80 hours beforethe pump is installed. Check the barrel mountingsurface level after the grout is set and then proceedwith the pump installation. Lower the pump assemblyinto the pit and align the discharge head flange boltholes to the anchor bolts [372].

Check and adjust the pump level with respect to thebarrel flange to within 0.16 mm/m (0.002 in./ft) andfinal torque the nuts [373]. The leveling data to berecorded for future reference.

Example of a pump installed with a suction barrel.

Leveling of pumps with suction barrel4.3.4mounted on a soleplate

The soleplate [23] is installed on the foundation andaligned with the anchor bolts [372]. Level thesoleplate with the help of a machinist’s level to within0.16 mm/m (0.002 in./ft). Tighten the nuts [373] andgrout. Cure and allow grout to set for 72~80 hours.Lower the suction barrel into the pit and level againwith respect to the soleplate [23] to within 0.16 mm/m(0.002 in./ft). The level should not exceed 0.125 mm(0.005 in.) elevation difference taken on any twopoints on the soleplate. The pump [101] is nowlowered into the suction barrel and installed. Makesure that the discharge head flange is still in levelwithin 0.16 mm/m (0.002 in./ft) with respect to thesuction barrel [315].

Example of pump with a suction barrel mounted on asoleplate

Grouting4.4Where applicable, grout in the foundation bolts.

After adding pipe work connections and re-checkingthe coupling alignment, the mounting plate/soleplateshould then be grouted in accordance with goodengineering practice. If in any doubt, please contactFlowserve service center for advice.

Grouting provides solid contact between the pumpunit and foundation that prevents lateral movement ofrunning equipment and dampens resonant vibrations.Care should be taken to ensure maximum surfacecontact with grout between the pump base, soleplate, suction can and foundation (no voids).

Foundation bolts should only be fullytightened after the grout has been cured.

372

373

CONCRETE

FOUNDATION101

304

SOLE

PLATE

23

DISCHARGE

HEAD FLANGE

DISCHARGE

HEAD FLANGE

372

373

374

CONCRETE

FOUNDATION

315

101

304

374

372

373

CONCRETE

FOUNDATION

315

101

304

SOLE

PLATE

DISCHARGE

HEAD FLANGE23

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Lifting and Assembly4.5Motors may be supplied separately from the pumps.It is the responsibility of the installer to ensure thatthe motor is assembled to the pump and aligned asdetailed in section 4.5. Discharge head columnpiping and the pump assembly are supplied either

separately or as fully assembled depending upon thepump size and weight. If the parts are shippedseparately, it is the customer’s responsibility to installand align the pump with driver to the satisfaction ofFlowserve’s installation instructions.

Installation of pumps that are shipped4.5.1unassembled

Lifting4.5.1.1See lifting methods in section 2.3.

Equipment and tools required for4.5.1.2

installation of unassembled pumps

The following list covers the principal tools/itemsrequired for installation.

a) Two (2) mobile cranes capable of hoisting andlowering the pump and/or motor.

b) Two (2) steel clamps of suitable size.c) Two (2) sets of chain tongs & cable sling for

attaching to the pump and motor lifting eyes.d) Pipe clamp for lifting bowl assembly and the

column pipe. Approximately 4.5 m (15 ft) of 19mm (3/4 in.) diameter rope may be required.

e) General purpose hand tools, pipe wrenches, endwrenches, socket set, screwdrivers, Allenwrenches, wire brush, scraper and fine emerycloth.

f) Thread sealing compound designed for stainlesssteel and light machinery oil.

Parts and accessories may be placedinside shipping containers or attached to skids inindividual packages. Inspect all containers, cratesand skids for attached parts before discarding.

Uncrating and cleaning of unassembled4.5.1.3

pumpa) Clean the parts of any dirt, packing material and

other foreign matter.b) Flush the pump inside and outside with clean

water. Clean all machined surfaces.c) Remove any rust spots found on the machined

surfaces with fine emery cloth.d) Clean all threaded connections and any accessory

equipment.

Lineshaft when shipped separatelyshould be left in the crate to avoid damage or loss ofstraightness.

Installing the bowl and column4.5.1.4assembly

a) Sump and piping should be thoroughly cleanedof all loose debris before starting installation.

b) Check all bolts for tightness.c) Do not lift or handle the bowl assembly by the

pump shaft.d) When installing bowl assemblies in sizes of 152

mm (6 in.) or 203 mm (8 in.), leave bowl securelyfastened to the wooden skid that is attached forshipping until the bowl assembly is raised to avertical position. This will help prevent breakingthe bowls or bending the shaft.

e) If a strainer is to be used, attach it to the bowlassembly using fasteners as necessary..

f) Position lifting equipment so it will center over thefoundation opening.

g) If a base plate is used, level the plate to 0.16 mmper m (0.002 in. per ft) and then grout and anchorin place.

h) Check for axial clearance or endplay and recordthat number for future reference (while bowls arein a horizontal position you should be able to pushor pull the pump shaft indicating axial clearance).

i) Carefully lift the suction barrel and the bowlassembly with suitable straps or clamps (See section 2.4 for lifting and safety rules).

j) Lower the bowl assembly into the well or sump.

Set clamp or holding device that is attached tobowls on a flat surface. This is to stabilize bowlassembly and reduce possibility of cross threadingthe shaft.

k) Proceed to install the column assembly (refer tospecific column pipe drawings).

Installation of discharge head4.5.1.5 Choose one of the following discharge head typeinstallation procedure that is appropriate to the pumpconfiguration that has been purchased

Installation of discharge head with product4.5.1.5.1 lubrication

Pump head may be shipped with the sealinghousing installed. For ease of assembly and toprevent damage, we recommend removing thehousing before putting the head on the pump.

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For pumps supplied with hollow shaft drivers and aone-piece headshaft (headshaft couples belowsealing housing) proceed to step (a).

For pumps supplied with a two-piece headshaft(headshaft couples above the sealing housing) orsolid shaft drivers, proceed to step (b) directly

skipping step (a).

a) Attach the headshaft to the lineshaft with acoupling and tighten (left hand threads).

b) Lift discharge head over shaft and lower carefullyinto place (See section 2.3 for recommendedlifting methods and safety instructions). Be surenot to bend the shaft. Fasten the top columnflange and bearing retainer, if supplied to bottomof head. (Note that W heads do not have abearing retainer at the top column flange).

c) If baseplate is not included use shims or wedgesbetween the pump and foundation to level the

pump. The shaft must be centered in thedischarge head.

See section 4.4.4 for coupling installation on solidshaft drivers and section 4.2.1~4.2.4 for pumpleveling details

Installation of discharge head with the4.5.1.5.2enclosing tube

Pump head may be shipped with the sealinghousing installed. For ease of assembly and toprevent damage, we recommend removing thehousing before putting the head on the pump.

For pumps supplied with hollow shaft drivers and aone-piece headshaft (headshaft couples belowsealing housing) proceed to step (a). For pumpssupplied with a two-piece headshaft (headshaftcouples above the sealing housing) or solid shaftdrivers, proceed to step (b) directly skipping step (a).

a) Attach the headshaft to the lineshaft with acoupling and tighten (left hand threads).

b) Attach the top enclosing tube to the columnenclosing tube and tighten (left hand threads).

c) Lift the discharge head over shaft and enclosingtube then lower carefully into place ( See section2.3 for recommended lifting methods and safetyinstructions). Be sure, not to bend the shaft.Fasten the top column flange and alignment ring ifsupplied to bottom of head. (W heads do not havean alignment ring at the top column flange).

d) Use shims or wedges between the pump andfoundation to level the pump. The shaft must becentered in the discharge head.

See section 4.4.4 for coupling installation on solidshaft drivers and section 4.2.1~4.2.4 for pumpleveling details.

Installation of pumps that are shipped4.5.2fully assembled

Lifting4.5.2.1See lifting methods in section 2.3.

Equipment and tools required for4.5.2.2installation of a fully assembled pump

a) Mobile crane capable of hoisting and lowering theentire weight of the pump and motor.

b) Cable slings for attaching to the pump and motorlifting eyes.

c) Ordinary hand tools: Pipe wrenches, endwrenches, socket set, screwdrivers, Allenwrenches, wire brush, scraper and fine emery

cloth.d) Thread sealing compound designed for type ofconnection and light machinery oil.

The single most common cause of pumpvibration is from a bent shaft. Shafting isstraightened to stringent tolerances prior to shippingand great care must be exercised in its handling.

Always support shafting in at least three places whenlifting or installing.

Parts and accessories may be placedinside shipping containers, or attached to skids inindividual packages.

Inspect all containers, crates and skids for attachedparts before discarding.

Lifting heavy objects is dangerous. Use ofappropriate tools and procedures is must.

Uncrating and cleaning of a fully4.5.2.3assembled pump

a) Clean the parts of all dirt, packing material andother foreign matter.

b) Flush the pump inside and outside with cleanwater.

c) Clean all machined surfaces. Remove any rustspots found on the machined surfaces with fineemery cloth.

d) Clean all threaded connections and any accessoryequipment.

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Installing the fully assembled pump4.5.2.4If a base plate is used, level the plate to 0.16 mm perm (0.002 in. per ft), grout and anchor in place.

See sections 4.2.1~4.2.4 for pump leveling details.

Position lifting equipment so it will center over thefoundation opening.

Sump and piping should bethoroughly cleaned of all loose debris before startinginstallation.

Set up installation unit so that the lifting cable will becentered directly over the well or sump. Carefully liftthe bowl assembly and suction barrel with a clamp.Lower the bowl assembly into the well or sump. Setthe clamps or holding device that is attached to bowlson a flat surface. This is to stabilize bowl assembly

and reduce possibility of cross threading the shaft.

a) When installing 152 mm (6 in.) or 203 mm (8 in.)pump assembly, leave the pump securelyfastened to the wooden skid (as shipped) until thebowl assembly is raised to a vertical position

b) Lift the pump to a vertical position. If a strainer isused, attach it to the bowl assembly.

c) Position pump over sump or suction barrel. Alignthe discharge of the pump with external pipingthen lower onto the base. Level the entire pump.

d) If a stuffing box and a hollow shaft driver areincluded, attach the head shaft to the pump shaft

(left hand threads).e) If a mechanical seal is included, install the seal at

this point per the attached instructions.

If the pump includes a suction barrel (can), follow theprocedure as listed below. (See lifting instructions insection 2.3)

a) Install the suction barrel first and grout themounting flange and bolts directly to thefoundation.

b) If soleplate is used, mount and grout thesoleplate and mount the suction barrel onto the

soleplate.c) Level the soleplate & the suction barrel flange asrequired.

d) Check to ensure suction barrel is free of debrisand other foreign material.

e) Install the pump.

Installation of couplings on solid shaft4.5.3drivers.

If the pump purchased is having a solidshaft driver, one of the following couplingarrangement between the driver and the pump shaftis applicable. Choose the procedure appropriate tothe coupling arrangement required.

Clean threads on pump shaft and onadjusting nut. Check for burrs and nicks.

All burrs, nicks and rust must be removed from allmating parts of flanged coupling and pump beforeinstallation. Failure to remove all burrs, nicks andrust may result in misalignment causing pump to fail.

Installation of adjustable flanged4.5.3.1coupl ing WA/PA.

a) The key [46A] for the driver shaft keyseat shouldbe a snug or tight fit in the shaft keyseat, and asliding fit in the keyseat of the driver half coupling[42].

b) The key with pin [46] should be a sliding fit inpump shaft keyseat and a snug or tight fit in pumphalf coupling [44] keyseat.

c) Side clearance of keys in keyseats should bechecked with a feeler gauge. Clearance forWA/PA coupling should not exceed 0.076 mm(0.003 in.) for a snug fit or 0.127mm (0.005 in) fora sliding fit. These are maximum allowableclearances. Closer fits are preferred, if possible.

It may be necessary to file-dress keys to obtainproper fit.d) Insert the key [46] with pin into pump half of

coupling [44] putting the pin in the hole in keyseat.The key should not extend below coupling.

e) Lubricate pump coupling half and key assemblywith light oil and slide it onto pump shaft [12A] withflange up. Slide it past threads.

f) Lubricate adjusting nut [66A] with light oil andthread it onto pump shaft [12A] (left hand threads)with male register down. Thread it on until top ofshaft and top of nut are even.

g) Uncrate and lift driver to allow access to driveshaft.

The driver must be set on supportscapable of carrying the entire weight of the driverbefore proceeding to step (h). Failure of supportscould cause damage to the motor or loss of life.

h) Clean and check driver shaft. Remove any burrs.

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i) Check the fit of the straight key and split thrustrings [312A] in their respective keyseats. (Refer toparagraph (a) regarding fit of the straight key).

j) Install straight key into keyseat. The bottom of thekey must be above the top of circular keyseat forthe split thrust rings.

k) Lubricate driver half coupling lightly and slide itonto driver shaft. Slide bottom of coupling abovethe top of the keyseat for split thrust rings.

l) Install split thrust rings into circular keyseat andslide the coupling down over them.

m) Tighten the coupling bolts as follows.

Coupling bolts tightening torques

Couplingsize

Flange diametermm (in.)

Torque N·M(In·lb)

1 & 2112 & 137(4.4 & 5.4)

121.5 (1075)

3, 4 & 5156, 188, & 213(6.1, 7.4, & 8.4)

237.0 (2100)

6 251(9.9) 424.0 (3750)

Torque values are for standard fasteners lubricated with a highstress lubricant (such as, graphite and oil, moly-disulphite, white leadetc.). For stainless steel bolts, multiply listed torques by 0.80.

n) Proceed with the driver installation.

TYPE WA/PA COUPLING DETAIL

Installation of adjustable flanged spacer4.5.3.2coupling WSA/PSA.

Follow procedure from (a) thru (l) as listed in section4.5.4.1.

c) Bolt spacer [314] to the driver half coupling [42]using the short set of socket head cap screws[364]. The male register should be pointingdown. Tighten all cap screws evenly to the bolttorques as listed in 4.5.4.1 under item (m).

d) Proceed with the driver installation.

TYPE- WSA/PSA COUPLING DEATILS

(12A) TOP SHAFT

(46) KEY ASSEMBLY

(364) CAP SCREW

(44) DRIVEN COUPLING

(66A) ADJUSTING NUT

(312A) SPLIT THRUST

(46A) DRIVE KEY

(42) DRIVER COUPLING

MOTOR SHAFT

HALF

HALF

RING

(12A) TOP SHAFT

(46) KEY ASSEMBLY

(364) CAP SCREW



(312A) SPLIT THRUST

(363) HEX NUT

MOTOR SHAFT

HALF

RING

HALF

(364) CAP SCREW

(314) SPACER

(46A) DRIVE KEY

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Installation of non-adjustable flanged4.5.3.3coupling WNA/PNA.

Follow procedure from (a) thru (e) as listed in section4.5.4.1.

f) Install one set of split thrust rings [312A] in to thecircular keyway in pump shaft. Pull up the pumphalf of the coupling [44] over the split keys.

g) Slide driver half coupling [42] onto driver shaft inthe same manner as the pump half of thecoupling.

h) Set the spacer ring [314] between the two halvesof the coupling together. Tighten all cap screws[364] evenly to the bolt torques as listed in4.5.4.1 under item (m).

i) Proceed with the driver installation.

TYPE-WNA/PNA COUPLING DETAILS

Installation of drivers4.5.4

Drivers will come with either hollow shaft orsolid shaft as specified on the order/contract.Choose the correct installation procedure from thefollowing paragraphs.

Reverse rotation with the pump shaftconnected can cause extensive damage to the pump.

Always check rotation before connecting driver topump.

Installation of hollow shaft driver4.5.4.1a) Clean driver mounting flange on discharge head

and check for burrs or nicks on the register andmounting face. Oil lightly.

b) Remove driver clutch.c) See (j) regarding installation of motor guide

bushing, if required.

d) Lift driver and clean mounting flange, checking forburrs and nicks.

e) Center motor over pump and rotate to alignmounting holes.Electric motors - rotate junction box into desiredposition.Gear Drives - rotate input shaft into desiredposition.

f) Lower carefully into place making certain that thefemale register on the driver mates over the maleregister on the pump.

g) Bolt driver to discharge head.h) Check the driver manufacturer's instruction

manual for special instructions includinglubrication instructions and follow all "startup"directions.

i) Electric motors should be checked for rotation atthis time. Make certain the driver clutch has beenremoved. Make electrical connections and"bump" motor (momentarily start, then stop) tocheck rotation. DRIVER MUST ROTATECOUNTERCLOCK-WISE when looking down attop end of motor. To change the direction ofrotation on a three-phase motor, interchange anytwo line leads. To change direction of rotation ona two phase motor, interchange the leads of eitherphase

j) Some motors will be supplied with a "lower guidebushing" or "steady bushing" which is installed atthe bottom of the motor to stabilize the shaft at thispoint. Some motor manufacturers mount thisguide bushing before shipping while others willship the guide bushing with instructions for fieldmounting.

MOTOR SHAFT


(363) HEX NUT

(46A) DRIVE KEY

(312A) SPLIT THRUST

(314) SPACER RING

(312A) SPLIT THRUST


(364) CAP SCREW

(46) KEY ASSEMBLY

(12A) TOP SHAFT

HALF

RING

RING

HALF

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k) Check the packing slip to see if a guide bushing isrequired, if so, determine if the bushing is alreadymounted or not and proceed accordingly. Refer tomotor instruction manual.

l) Carefully install drive clutch on driver making surethat it fits down properly.

m) Clean threads on top of head shaft and head shaftnut. Lubricate male threads lightly. Install headshaft.

n) Install gib key [335] in clutch and shaft. This mustbe a sliding fit and may require filing and dressing.Do not force.

o) Thread adjusting nut down on shaft until it bearsagainst clutch. (Threads on 43 mm (1.68 in.) andlarger head shaft adjusting nuts are left-handedand all others are right handed). Do not threadnut further at this time. See impeller adjustinginstructions in section 5.3.

Installation of solid shaft driver without4.5.4.2 jacking screws

When lowering the motor and driverhalf of coupling onto pump, do not let pump half ofthe coupling touch the driver half of the coupling.

Before bumping motor make sure coupling halvesare not touching and that the driver can rotate freely,without rotating the pump

Driver half coupling must be in proper position so thecircular key will not come out.

a) Clean driver mounting flange on discharge headand check for burrs or nicks on the register andmounting face. Oil lightly.

b) Center motor over pump and rotate to alignmounting holes.Electric motors: Rotate junction box into desiredposition.Gear Drives: Rotate input shaft into desiredposition.

c) Lower driver carefully into place making certainthat the female register on the driver mates overthe male register on the pump.

d) Bolt driver to discharge head.

e) Check driver manufacturer's instructions forspecial instructions including lubricationinstructions and follow all "startup" instructions.

f) Electric drivers should be checked for rotation atthis time. Make electrical connections "bump"motor (momentarily start, then stop) to checkrotation. DRIVER MUST ROTATECOUNTERCLOCKWISE when looking down attop end of motor. To change the direction ofrotation on a three-phase motor, interchange anytwo line leads. To change direction of rotation ona two-phase motor, interchange the leads of eitherphase.

g) See impeller adjustment instructions (section 5.3)before bolting the pump and driver half of thecoupling together.

Installation of solid shaft driver with4.5.4.3 jacking screws

a) Clean driver mounting flange on discharge headand check for burrs or nicks on the register andmounting face. Oil lightly.

b) Center motor over pump and rotate to alignmounting holes.Electric motors: Rotate junction box intodesired position.Gear Drives: Rotate input shaft into desiredposition.

c) Lower driver carefully into place. Mount the dialindicator base on the O.D. of the motor halfcoupling. Set the indicator on the pump shaft,position the dial to zero being careful that the

indicator is in direct line with one of the jackscrews. Record this reading then rotate themotor shaft and indicator 180 degrees. Recordthis reading being careful to note plus or minusvalues. Take the difference of the two readingsand using the jackscrews move the motor one-half of the difference. Repeat this step until theT.I.R. reading is a maximum of 0.051mm(0.002in.). Then repeat this step for the set of

jack screws located 90 degrees to the first set.Once all readings are within 0.051mm (0.002in.),tighten motor bolts and check for any movementin readings.

d) Check driver manufacturer's instructions forspecial instructions including lubricationinstructions and follow all "startup" instructions.

e) Electric drivers should be checked for rotation atthis time. Make electrical connections and"bump" motor (momentarily start, then stop) tocheck rotation. DRIVER MUST ROTATECOUNTER-CLOCKWISE when looking down attop end of motor. To change the direction ofrotation on a three-phase motor, interchange any

(334) LOCK SCREW

COUPLING

HEAD SHAFT (10)

HEAD SHAFT NUT (66)DRIVER

GIB KEY(335)

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two line leads. To change direction of rotation ona two-phase motor, interchange the leads ofeither phase.

f) See impeller adjustment instructions (section 5.3before bolting the pump and driver half of thecoupling together.

Initial Alignment4.6

Thermal expansion4.6.1

The pump and motor will normallyhave to be aligned at ambient temperature andshould be corrected to allow for thermal expansion atoperating temperature. In pump installationsinvolving high liquid temperatures greater than 300°F,the unit should be run at the actual operatingtemperature, shut down and the alignment checkedimmediately.

Preparation before alignment4.6.2To ensure proper alignment the following items arevery important.

a) All machined mating surfaces (such as themating flanges of pump and motor) must beclean and free of burrs and nicks.

b) Exterior strain must not be transmitted to thepump. The most common cause of trouble isforcing the piping to mate with the pump. It isrecommended that flexible connectors be installedin the piping adjacent to the pump.

c) All threads should be checked for damage andrepaired if necessary. Lubricate all threadedconnections with a suitable thread lubricant (ananti-galling compound).

Alignment methods4.6.3

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

The alignment MUST be checked. Although the pump will have been aligned at thefactory it is most likely that this alignment will have

been disturbed during transportation or handling.If necessary, align the motor to the pump, not thepump to the motor.

Adding or removing shims between themotor and the discharge head helps alignment in thevertical direction. The motor assembly may alsohave to be adjusted in the horizontal direction to lineup the driver and shaft centers. Alignment screws

are provided to lock the motor assembly in its finalaligned position.

See section 5.3.2.1 for final coupling alignment forsolid shaft.

Before bumping motor make sure that thecoupling halves are not touching and that the drivercan rotate freely without rotating the pump. Driverhalf coupling must be in proper position so thecircular key will not come out.

Angular and parallel misalignment4.6.4

Check the direction of pump rotationbefore the coupling is fully connected. The powersupply to the driver to be connected only after thefinal alignment is complete.

a) Angular Offset: The median lines of shaftintersect halfway between the ends of the twoshafts.

b) Axial Offset: Another offset is the displacementof one or both of the shafts. A typical example isthermal expansion.

c) Parallel Offset: The median lines run parallel.The maximum allowable parallel offset dependson the size of coupling and is indicated in theinstruction manual of manufacturer of coupling.

For couplings with narrow flanges use a dial indicatoras shown in the detail to check both parallel andangular alignment.

Parallel offset

Angular offset

Axial offset

a)

b)

c)

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Parallel

Angular

a) Pumps with thick flanged non-spacer couplingscan be aligned by using a straight-edge acrossthe outside diameters of the coupling hubs andmeasuring the gap between the machined facesusing feeler gauges, measuring wedge orcalipers.

b) When the electric motor has sleeve bearings, it is

necessary to ensure that the motor is aligned torun on its magnetic centerline.

Refer to the motor User Instructions for details.

If the motor does not run in itsmagnetic center the resultant additional axial forcemay overload the pump thrust bearing.

If the pump is handling hot liquid, the alignment mustbe rechecked in warm condition of the unit. Thealignment of the unit shall be checked again after 200

service hours.

Piping4.7

Protective covers are fitted to the pipeconnections to prevent foreign particles or objectsentering the pump during transportation andinstallation. Ensure that these covers are removedfrom the pump before connecting pipes.

Pipe work velocities4.7.1In order to minimize friction losses and hydraulicnoise in the pipe work it is good practice to choosepipe work that is one or two sizes larger than thepump suction and discharge.

Typically, main pipe velocities should not exceed 2m/s (6 ft/sec) on the suction and 3 m/s (9 ft/sec) ondischarge.

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

Never use the pump as a support forpiping.

Maximum forces and moments allowed on4.7.2VTP pump flanges (See table 4.6.2.1)

Maximum forces and moments allowed on the pump

flanges vary with the pump size and type. Tominimize these forces and moments that may, ifexcessive, cause misalignment, hot bearings, worncouplings, vibration and possible failure of the pumpcasing. The following points should be strictlyfollowed.

a) Prevent excessive external pipe load.b) Never draw piping into place by applying force to

pump flange connections.c) Do not mount expansion joints so that their force,

due to internal pressure, acts on the pumpflange.

Ensure piping and fittings are flushedbefore use.

Ensure that the piping arrangement has beenprovided to flush the pump before removal in casesof hazardous liquid pumps.

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Table of maximum forces and moments allowed on VTP pump flanges4.7.2.1

HeadType

Forces &Moments

Discharge Head Size mm(in.)

100(4)

150(6)

200(8)

255(10)

305(12)

355(14)

400(16)

460(18)

508(20)

610(24)

760(30)

915(36)

W

Fx0.53

(120)

0.80

(180)

1.13

(255)

1.47

(330)

1.67

(375)

1.78

(400)

Fy0.67(150)

1.00(225)

1.47(330)

1.83(410)

2.00(450)

2.23(500)

Fz0.45

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