Flowserve APKD User Manual
USER INSTRUCTIONS
APKD
Double-Case, Double Suction Vertical Pump
PCN=26999903 07-13 (E) "Original Instructions"
Installation
Operation
Maintenance
These instructions must be read prior to installing,
operating, using and maintaining this equipment
APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
1 INTRODUCTION AND SAFETY ....................... 3
1.1 General ......................................................... 3
1.2 CE marking and approvals ........................... 3
1.3 Disclaimer ..................................................... 3
1.4 Copyright ...................................................... 3
1.5 Duty conditions ............................................. 3
1.6 Safety ............................................................ 4
1.7 Safety labels summary ................................. 7
1.8 Noise level .................................................... 7
1.9 Specific machine performance ..................... 8
2 TRANSPORT AND STORAGE ........................ 8
2.1 Consignment recipt and unpacking .............. 8
2.2 Handling........................................................ 9
2.3 Lifting ............................................................ 9
2.4 Storage ....................................................... 12
2.5 Recycling and end or product life ............... 12
3 DESCRIPTION ............................................... 12
3.1 Configuration .............................................. 12
3.2 Nomenclature ............................................. 13
3.3 Design of major parts ................................. 15
3.4 Performance and operation limits ............... 16
4 INSTALLATION .............................................. 17
4.1 Location ...................................................... 17
4.2 Part Assemblies .......................................... 22
4.3 Foundation .................................................. 22
4.4 Grouting ...................................................... 24
4.5 Initial Alignment .......................................... 24
4.6 Piping .......................................................... 25
4.7 Electrical Connections ................................ 27
4.8 Final shaft alignment check ........................ 27
4.9 Protection systems ..................................... 27
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN ................................................... 28
5.1 Pre-commissioning procedure .................... 28
5.2 Pump lubricants .......................................... 28
5.3 Impeller adjustment .................................... 28
5.4 Direction of rotation .................................... 30
5.5 Guarding ..................................................... 30
5.6 Priming and auxiliary supplies .................... 31
5.7 Starting the pump ....................................... 31
5.8 Operating the pump .................................... 33
5.9 Stopping and shutdown .............................. 34
5.10 Hydraulic mecanical and electrical duty . 34
6 MAINTENANCE .............................................. 35
6.1 General ....................................................... 35
6.2 Maintenance schedule ................................ 36
6.3 Spare parts ................................................. 37
6.4 Recommended spares and consumables .. 38
6.5 Tools required ............................................. 38
6.6 Fastener torques ........................................ 39
6.7 Setting impeller clearance .......................... 39
6.8 Disassembly ............................................... 39
6.9 Examination of parts ................................... 40
6.10 Assembly ................................................ 43
7 FAULTS, CAUSES AND REMEDIES ............. 44
8 DRAWINGS AND PARTS LISTS ................... 46
8.1 Cross section: Product lubricated APKD .... 46
8.2 Cross section: Suction barrel APKD ........... 49
8.3 General arrangement drawing .................... 52
9 CERTIFICATION ............................................. 52
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ................................................................ 52
10.1 Supplementary user instructions ............ 52
10.2 Change notes ......................................... 52
10.3 Additional sources of information ........... 52
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilizing sophisticated quality techniques, and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety noted in the
instructions, have been met. Failure to follow
and apply the present user instructions is
considered to be misuse. Personal injury,
product damage, delay or failure caused by
misuse are not covered by the Flowserve
warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and equipment
put into service within certai n regions of t he world sha ll
conform with the applicable CE Marking Directive s
covering Machinery and, where ap plicable, L ow Voltag e
Equipment, Electromagnetic Compatibility (EMC),
Pressure Equipment Directive (PED) and Equipment for
Potentially Explosive Atmospheres (ATEX).
Where applicable the Directives and any additional
Approvals cover important safety aspects relating to
machinery and equipment and the satisfactory provision
of technical documents and safety instructions. Where
applicable this document incorporates information
relevant to these Directives and App rovals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certification.)
1.3 Disclaimer
Information in these User Instructions is believed
to be complete and reliable. However, in spite of
all of the efforts of Flowserve Corporation to
provide comprehensive instructions, good
engineering and safety practice should always be
used.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Qual ity Assurance
organizations. Genuine parts and accessories have
been designed, tested and incorporated into the
products to help ensure their continued product quality
and performance in use. As Flowserve cannot test
parts and accessories sourced fr om other vendo rs the
incorrect incorporation of such parts and accessories
may adversely affect the performance and safety
features of the products. The failure to properly select,
install or use authorized Flow serve parts an d
accessories is considered to be misuse. Damage or
failure caused by misuse is not cov ered by the
Flowserve warranty. In addition, any modification of
Flowserve products or removal of original components
may impair the safety of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order
are going to be changed (for example liquid pumped,
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
temperature or duty) it is requested that the user
seeks the written agreement of Flowserve before
start up.
1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction would
cause hazards. The specific safety markings are:
This symbol indicates electrical safety
instructions where non-compliance will involve a high
risk to personal safety or the loss of life.
This symbol indicates safety instruct ions where
non-compliance would affect personal safety and
could result in loss of life.
This symbol indicates “hazardous and toxic fluid”
safety instructions where non-compliance would affect
personal safety and could result in loss of life.
This symbol indicates safety
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but indicates
an important instructi on in t he assem bly proce ss.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
prevent injury to personnel and damage to the
environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur . In this
condition these are extremely dangerous and skin
contact must be avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.
APPLYING HEAT TO REMOVE IMPELLER
There may be occasions when the impeller has either
been shrunk fit on to the pump shaft or has become
difficult to remove due to products of corrosion.
If you elect to use heat to remove the impeller , it must
be applied quickly to the impeller boss. TAKE
GREAT CARE!
Before applying heat ensure any residual hazardous
liquid trapped between the impeller and pump shaft is
thoroughly drained out through the impeller keyway
to prevent an explosion or emission of toxic vapour.
This must be carried out with the shaft in the vertical
position. On some pump sizes a cavity exists in the
impeller bore so on occasions a significant volume of
liquid may drain out.
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
in damage or breakage of components and should be
avoided.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
If the temperature is greater than 80 ºC (175 ºF) or
below -5 ºC (20 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoi d exposure t o the liq uid by
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.
Gland packing must not be used when pumping
hazardous liquids.
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
in writing, so that their force, due to internal pressure,
acts on the pump flange.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation
and shutdown.)
START THE PUMP WITH OUTLET
VALVE PARTLY OPENED
(Unless otherwise instructed at a specific point in the
User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve
further open only on installations where this situation
cannot occur. The pump outlet control valve may
need to be adjusted to comply with the duty following
the run-up process. (See section 5, Commissioning
start-up, operation and shutdown.)
NEVER RUN THE PUMP DRY
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than norma l or at a flo w
rate with no back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/beari ng life, ov erheatin g of
the pump, instability and cavitation/vibrat ion.
1.6.1 Products used in potentially explosive
atmospheres
Measures are required to:
Avoid excess temperature
Prevent build up of explosive mixtures
Prevent the generation of sparks
Prevent leakages
Maintain the pump to avoid hazard
The following instru ctions fo r pumps a nd pum p units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protecti on.
For ATEX, both electrical and non-electrical equipment
must meet the requirements of E uropean Directiv e
94/9/EC. Always observe the reg ional le gal Ex
requirements eg Ex elect rical item s out side the E U may
be required certified to other than ATEX eg IECEx, UL.
1.6.1.1 Scope of compliance
Use equipment only in the zone for whic h it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certifie d for the classi fication of the
specific atmosphere in which they are to be inst alled.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the ATEX pump set
shall select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so, for
pumps sets with a VFD, the ATEX Certification for the
motor must state that it is covers the situation where
electrical supply is from the VFD. This particular
requirement still applies even if the VFD is in a safe area.
INLET VA LVES TO BE FULLY OPE N
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the pump and mechanical seal.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
1.6.1.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = high level protection
3 = normal level of protection
Gas and/or dust
G = Gas
D = Dust
c = Constructional safety
(in accordance with EN13463-5)
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3.)
1.6.1.3 Avoiding excessive surface
temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 ºC (104 ºF); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends on
the temperature class and must not exceed the
values in the table that follows.
Temperature class
to EN13463-1
T6
T5
T4
T3
T2
T1
* The table only takes the ATEX tem perature class int o consideration.
Pump design or material, as well as component design or m aterial,
may further limit the maximum working temperature of the liquid .
Maximum surface
temperature permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of
liquid handled *
Consult Flowserve
Consult Flowserve
115 °C (239 °F)
180 °C (356 °F)
275 °C (527 °F)
400 °C (752 °F)
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
Temperature classification “Tx” is used when the
liquid temperature varies and the pump could be
installed in different hazarous atmospheres. In this
case the user is responsible for ensuring that the
pump surface temperature does not exceed that
permitted in the particular hazardous atmosphere.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
contact between rotating and stationary components.
Where there is any risk of the pump being run
against a closed valve generating high liquid and
casing external surface temperatures, fit an external
surface temperature protection device.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
power monitor and make routine vibration monitoring
checks.
In dirty or dusty environments, make regular checks
and remove dirt from areas around close clearances,
bearing housings and motors.
1.6.1.4 Preventing the build up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
atmosphere is prevented. In addition it is essential to
make sure that seal chambers, auxiliary shaft seal
systems and any heating and cooling systems are
properly filled.
If the operation of the system cannot avoid this
condition fit an appropriate dry run protection device
(for example liquid detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
1.6.1.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking.
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.
Avoid electrostatic charge: do not rub n on-metalli c
surfaces with a dry cloth; ensure cloth is damp.
For ATEX application sthe coupling must be selected
to comply with 94/9/EC. Correct coupling alignment
must be maintained.
Additional requirement for metallic pumps on
non-metallic baseplates
When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.
1.6.1.6 Preventing leakage
The pump must only be used to handle liquids
for which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump a nd associat ed
piping due to closing of suct ion an d discharg e valves,
which could cause dangerous excessiv e pressures to
occur if there is heat input t o the liqu id. This ca n occur if
the pump is stationary or running.
Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the pump
and ancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to atmosphere can result in a
hazard, install a liquid detection device.
1.6.1.7 Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with maintenance
instructions is with the plant operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
1.7 Safety labels summary
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity, or separate documentation included with
these User Instructions.
1.7.2 Safety labels
Oil lubricated units only:
1.8 Noise level
Attention must be given to the exposure of personnel
to the noise, and local legislation will define when
guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA.
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 can
take the appropriate action in your plant.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.
Similarly the motor noise a ssumed in t he “pump and
motor” noise is that typically expected f rom sta ndard
and high efficiency motors when on load dire ctly driving
the 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 with
your own driver then the “pump only” noise levels in the
table should be combined with the level for the driver
obtained from the supplier. Consult Flowserv e or a
noise specialist if assistance is required in combining
the values.
It is recommended that where exposure approaches
the prescribed limit, then site noise measurements
should be made.
The values are in sound pressure level L
at 1 m
pA
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.
For estimating sound power level L
(re 1pW) then
WA
add 17 dBA to the sound pressure value.
1.8.1 Typical vertical motor noise data
Motor
Frame
Size.
NEMA
180
210
250
280
320
360
400
440 3600 80.0 90.0
RPM Sound
Pressure
(dBA )
(WP- I
enclosure)
3600 70.0 78.0
1800 60.0 68.0
1200 & slower 55.0 63.0
3600 70.0 78.2
1800 60.0 68.2
1200 & slower 55.0 63.2
3600 75.0 83.4
1800 70.0 78.4
1200 & slower 60.0 68.4
3600 75.0 83.8
1800 70.0 78.8
1200 & slower 60.0 68.8
3600 75.0 84.0
1800 65.0 74.0
1200 & slower 65.0 74.0
3600 75.0 84.2
1800 65.0 74.2
1200 & slower 65.0 74.2
3600 80.0 89.5
1800 70.0 79.5
1200 & slower 65.0 74.5
Sound
Power
(dBA )
(WP- I
enclosure
1800 70.0 80.0
1200 & slower 70.0 80.0
449
5000
5800
6800
8000
1800 85.0 97.8
1200 & slower 80.0 92.8
3600 90.0 102.8
1800 85.0 97.8
1200 & slower 80.0 92.8
3600 90.0 103.7
1800 90.0 103.7
1200 & slower 80.0 93.7
1800 90.0 103.9
1200 & slower 85.0 98.8
1800 90.0 104.7
1200 & slower 85.0 99.7
The noise levels shown in table 1.8.1 are
extracted from typical motor manufacturer’s
data/catalogue to provide the average expected
motor noise values at no load for reference only and
are not guaranteed. The values could vary
depending upon the test and surrounding conditions.
The combined noise level of the pump and the motor
could exceed the values shown. It is to be noted that
adding motors with similar noise levels increases the
total noise level. Therefore, the dB correction to the
values listed above is required to obtain the
combined noise levels of motor and the pump.
Actual on-site noise measurement by experts is
recommended and safety measures are to be taken
accordingly.
1.9 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. Where performance data has
been supplied separately to the purchaser these
should be obtained and retained with these User
Instructions if required.
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery and shipping
documents for its completeness and that there has
been no damage in transportation. Any shortage and
or damage must be reported immediately to
Flowserve and received in writing within one month
of receipt of the equipment. Later claims cannot be
accepted.
Check any crates, boxes and wrappings for any
accessories or spare parts which may be packed
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check that
this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
A crane must be used for all pump
sets or components in excess of 25 kg (55 lb). Fully
trained personnel must carry out lifting, in
accordance with local regulations.
To avoid distortion, the pump unit should be
lifted by using lifting equipment certified to local
standards.
The pumps are generally very heavy therefore,
size/shape factors will have to be considered before
attempting to lift them. It is strongly recommended to
attempt lifting from a safe distance to prevent any
injury or loss of life. Consulting with experts is
recommended.
Pump heads may be shipped with the seal
housing installed. For ease of assembly and to
prevent damage, we recommend removing the
housing before putting the head on the pump.
Flowserve will not supply eyebolts neither
fixed nor separately with the pump. It is the
responsibility of the installer to arrange appropriate
hardware that can handle the weights and results in
safe and successful installation.
Before lifting the driver alone, refer to the
manufacturer’s instructions.
2.3.1 Lifting of fabricated discharge heads with
or without the pump
If the pump is supplied with a fabricated discharge
head use 2 point or 3 point method of lifting as shown
in the details provided in 2.3.1.1 & 2.3.1.2. This
method is applicable to the lifting of discharge heads
with or without the pump.
2.3.1.1 Two point lifting of fabricated discharge
head types TF, UF & HFH (with or
without pump attached)
Figure 2.1
"L"
FABRICATED WITH
2 POINT LIFTING
50 mm (2in.) HOLE
Fabricated heads with discharge size mm (in.)
100
Pin
Dia.
1070
L
(42)
“L” is approximate length
(4)
25
(1)
150
(6)
32
(1.25)
1220
(48)
200
(8)
32
(1.25)
1220
(48)
250
(10)
32
(1.25)
1370
(54)
300
(12)
38
(1.5)
1370
(54)
2.3.1.2 Three point lifting of fabricated
discharge head of type HFL (with or
without pump attached)
Figure 2.2
HFL STYLE FABRICATED
WITH 3 POINT LIFTING
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
2.3.2 Lifting of bowl assembly only
Clamp the bowl assembly and center the lifting hook
for lifting and lowering the assembly into the
sump/suction barrel.
a) Lower the bowl assembly until the clamp
extensions rest on the foundation (use
appropriate supports).
b) Build the very first section of the column piping,
and lower the entire assembly to assemble the
next column section.
c) Continue to build until it is ready for discharge
head assembly.
d) Install the discharge head.
e) Assemble the motor.
Example: Lifting of bowl assembly
Figure 2.3
2.3.3 Lifting of suction barrel
Suction barrel (also referred as ‘Can’) is always
supplied separately and has to be installed into the
sump first. Install eyebolts on the flange of the
suction barrel and attach slings and straps to bring
the suction barrel to a vertical position. Move the
barrel for installation. Provide hand support to
prevent the suction barrel from swaying during
movement.
Example: Lifting of suction barrel
Figure 2.4
SUCTION BARREL (CAN)
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
2.3.4 Lifting of fully assembled pumps
If the pump is fully assembled, it has to be adequately strapped and supported at least two places before it can
be lifted from the shipping crate and moved to the installation site. See details shown. Same rules are
applicable when the pump is pulled out from the sump and moved to another location.
Figure 2.5
Examples shown here are for illustration only. See section 2.3 1 for specific lifting instructions
based on design variations. The pumps vary in weight, length and physical appearances from the types shown
here. Therefore, before lifting is attempted, exercise caution to prevent any injuries or loss of life.
Figure 2.6
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
2.4 Storage
Store the pump in a clean , dry location
away from vibration. Leave piping connection covers
in place to keep dirt and other foreign material out of
pump casing. Turn the pump at frequent intervals to
prevent brinelling of the bearings and the seal faces,
if fitted, from sticking.
2.4.1 Inspection before storage
a) Inspect the preservative coating/painted surfaces
on the various parts. Touch up the areas, If
necessary.
b) Inspect all covers over pump openings and piping
connections. If found damaged, remove the
covers and inspect interiors of the opening for any
deposits of foreign materials or water.
c) If necessary, clean and preserve the interior parts
as noted above to restore the parts to the "as
shipped" condition. Replace covers and fasten
securely.
2.4.2 Short term storage (up to 6 months)
Follow the steps given in sect ion 2.4. 1. Select a
storage space so that the unit will not be subjected to
excess moisture, extreme weather conditions,
corrosive fumes, or other harmful conditions.
Driver storage instructions: Check driver
manufacturer’s User Instructions
2.4.3 Long term or extended storage
If a situation arises for a long-term storage, ( more
than 6 months) please contact Flowserve for special
storage instructions and warranty related information.
2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and local regulations. If the
product contains substances which are harmful to the
environment, these should be removed and disposed
of in accordance with current regulations. This also
includes the liquids and or gases in the "seal system"
or other utilities.
3 DESCRIPTION
Should questions arise concerning the pump,
Flowserve pump division will require the complete
serial number to be of assistance. The serial number
is stamped on a metal nameplate affixed to the
discharge head assembly. The driver will have a
separate nameplate attached to it. If you are
requesting information on the driver, please provide
both the driver serial number and the pump serial
number for Flowserve representative.
3.1 Configuration
APKD’s, are engineered pumps as:(a) Wet pit type
and (b) suction barrel (can) type pumps. The pumps
vary in size, impeller types and length, and type of
discharge head used
3.1.1 Sump and deep well VTP
Figure 3.1
Make sure that hazardous substances or
toxic fluids are disposed of safely and that the correct
personal protective equipment is used. The safety
specifications must be in accordance with the current
regulations at all times.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
3.1.2 Suction barrel (Can) VTP
Figure 3.2
3.2 Nomenclature
The pump size/ serial number will be engraved on
the nameplate typically. The nameplate is attached
to the discharge head assembly. Identify the actual
pump size and serial number from the pump
nameplate. The driver will have a separate
nameplate attached to it.
3.2.1 Discharge head nomenclature
Consists of alphanumeric code as follows.
Examples: 10HF20, 6TF16,…….
10 LF 30
Nominal driver base diameter in inches
Discharge head type (see details below)
Nominal discharge diameter in inches
HF = Fabricated head for above the ground discharge
TF & LF = Fabricated heads with base flange
HFL = Fabricated head for above ground discharge - Low H.P
HFH = Fabricated head for above the ground discharge -High H.P.
Please see section 3.2.1.1 for discharge head types
and identification.
3.1.3 Most common VTP models
The VTP configurations shown in sec 3.1.1 and 3.1.2
are typical.
Some units will not require a column
assembly. In such cases, the bowl assembly is
connected directly to the discharge head. Vertical
turbine pumps can have single or multiple stages.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
3.2.1.1 Types of discharge heads
Typical discharge head types. Details (a) thru (e).
a) HF type fabricated discharge head
(Typically with square base plate)
Figure 3.3
b) TF type fabricated discharge head
Figure 3.4
d) HFL type fabricated discharge head
Figure 3.6
e) HFH type fabricated discharge head
Figure 3.7
c) LF type fabricated discharge head
(Typically with a circular base plate- ANSI type.
Also available with suction barrel mounting)
Figure 3.5
The discharge heads shown in section
3.2.1.1 (a) thru (e) are for illustration only. The shaft
and coupling arrangements vary. For the actual
configuration of the pump that has been purchased,
please refer to the drawings supplied with the pump
or order specific sectionals from Flowserve.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
3.3 Design of major parts
3.3.1 Drivers
Solid shaft drivers: where the rotor shaft is solid and
projects below the driver-mounting base. This type
driver requires an adjustable coupling for connecting to
the pump.
3.3.2 Discharge Head Assembly
(See also section 3.2.2.1)
The discharge head supports the driver and bowl
assembly as well as supplying a discharge connection
in most cases.
A shaft sealing arrangement is located in the
discharge head to seal the shaft at its exit from the
liquid chamber.
The shaft seal will usually be either a mechanical
seal assembly or stuffing box with an open lineshaft
or a tube-packing box with an enclosed lineshaft.
3.3.3 Column assembly
The column assembly consists of column pipe, which
connects the bowl assembly to the discharge head
and carries the pumped fluid to the discharge head.
Houses and supports the shaft and may contain
bearings. T ypical column assembly shown below:
a) flanged column assembly
Figure 3.8
3.3.4 Bowl assemblies
The bowl assembly consists of impellers rigidly
mounted on the pump shaft coupled to an electric
motor. Impellers are cast wheels with multiple diffuser
vanes and are generally coated to meet the hydraulic
requirements. See section 8.0 for cross sectional and
part details.
3.3.5 Suction strainers
Ina new installation, great care should be taken to
prevent dirt, scale and welding beads from entering
the pump, as it is particularly important to protect the
numerous close running fits form abrasive matter
present in new piping.
The suction system should be thoroughly flushed
before installation the suction and making up suction
piping to the pump
The suction strainer should be installed 4 pipe
diameters away from suction.
Cone Type Strainer
Figure 3.9
The column supports shaft assemblies, that are of an
open lineshaft construction utilizing the fluid being
pumped to lubricate the lineshaft bearings. The shafts
are key coupled with clamp ring design.
See sectional drawings supplied with the pump for
exact column assembly details as per the order. The
size and configuration vary depending upon the
specific order requirements and application criteria.
3.3.6 Impellers
The double suction first stage impeller (3A) is keyed
and held in position on pump end shaft (10A) by shaft
nut. The shaft nut is secured to the shaft with set
screws. The remaining single suction intermediate
impellers are also keyed. Each impeller is held in
position on the upper shaft by use of a split lock
collar secured with cap screws. All impellers are of
the enclosed type, one piece constructions, and are
dynamically balanced.
3.3.7 Stuffing box
Some APKD’s are fitted with stuffing boxes. In such
cases, stuffing boxes are normally adequate for
working pressures up to 20.7 bar (300 psi). Refer to
stuffing box User Instructions for specifications.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
3.3.7.1 High pressure stuffing box
This type of packing box is fitted on to an open lineshaft for pressures up to 20 bar (300 psi) uses six rings of
packing with one seal cage and allows grease lubrication.
Figure 3.10
3.3.8 Mechanical shaft seal
APKD’s can also be fitted with a mechanical seal.
The requirement to fit the mechanical seal to be
provided at the time of contract.
3.3.9 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operation limits
This product has been selected to meet the
specifications of the purchase order. See section 1.5.
The following data is included as additional
information to help with the installation. It is typical
and factors such as temperature, materials and seal
type may influence this data. If required, a definitive
statement for your particular application can be
obtained from Flowserve.Operating limits
Pumped liquid temperature
limits*
Maximum ambient
temperature*
Maximum pump speed refer to the nameplate
5 ºC (40 ºF) to +80 ºC (176 ºF)
Up to +40 ºC (104 ºF)
*Subject to written agreement from Flowserve.
Special designs and materials may be available for
pumps operating above and below these specified
limits. Contact Flowserve for upgrade options
available for your specific application.
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APKD DOUBLE-CASE, DOUBLE-SUCTION USER INSTRUCTIONS 26999903 07-13
4 INSTALLATION
Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
Inspection prior to installation
Six months prior to the scheduled installation date, a
Flowserve Pump Division representative is to be
employed to conduct an inspection of the equipment
and the facility. If any deterioration of equipment is
noticed, the Flowserve Pump Division representative
may require a partial or complete dismantling of the
equipment including restoration and replacement of
some components.
4.1 Location
The pump should be located to allow room for acce ss,
ventilation, maintenance and insp ection with ampl e
headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped.
Refer to the general arrangement drawing for the pump
set.
4.1.1 General installation check-list
The following checks should be made before starting
actual installation.
a) Make sure that motor nameplate ratings and the
power 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 least
three places when lifting or installing. No installation
should be attempted without adequate equipment
necessary for a successful installation.
shaft connection. Excess lubricant should be
avoided.
4.1.2 Installation of pumps that are shipped
unassembled
4.1.2.1 Lifting
See lifting methods in section 2.3.
4.1.2.2 Equipment and tools required for
installation of unassembled pumps
The following list covers the principal tools/items
required for installation.
a) Mobile crane capable of hoisting and lowering 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 4.57 m (15 ft) of 19
mm (3/4 in.) diameter rope may be required.
e) General purpose hand tools, pipe wrenches, end
wrenches, socket set, screwdrivers, Allen
wrenches, wire brush, scraper and fine emery
cloth.
f) Thread sealing compound designed for stainless
steel and light machinery oil.
Parts and accessories may be placed
inside shipping containers or attached to skids in
individual packages. Inspect all containers, crates
and skids for attached parts before discarding.
4.1.2.3 Uncrating and cleaning of unassembled
pump
a) 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.
Be sure to check the motor shaft size against the
coupling bore size
Apply thread lubricant sparingly to
male shaft threads only at the time of making up
Page 17 of 55 flowserve.com
should be left in the crate to avoid damage or loss of
straightness.
4.1.2.4 Installing the bowl and column assembly
a) Sump and piping should be thoroughly cleaned of
all loose debris before starting installation.
b) Check all bolts for tightness.
Lineshaft when shipped separately
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