Flowserve BP User Manual

BP

USER INSTRUCTIONS

Installation

Operation

Multi-stage, horizontal, barrel pump

PCN= 85392725 10-09 (E) Original instructions.

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

CONTENTS

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 Nameplate and safety labels ........................ 8

1.8 Specific machine performance...................... 8

1.9 Noise level .................................................... 9

2 TRANSPORT AND STORAGE........................ 10

2.1 Consignment receipt and unpacking .......... 10

2.2 Handling...................................................... 10

2.3 Lifting .......................................................... 10

2.4 Storage........................................................ 10

2.5 Recycling and end of product life................ 10

3 DESCRIPTION ................................................ 11

3.1 Configurations............................................. 11

3.2 Name nomenclature ................................... 11

3.3 Design of major parts.................................. 11

3.4 Performance and operating limits............... 12

6.8 Examination of parts................................... 29

6.9 Replacement of pressed in components.... 31

6.10 Assembly .................................................... 31

7 FAULTS; CAUSES AND REMEDIES .............. 37

8 PARTS LISTS AND DRAWINGS..................... 40

8.1 Section & Parts List .................................... 40

8.2 General arrangement drawing.................... 42

9 CERTIFICATION ............................................. 42

10 OTHE RELEVANT DOCMENTS AND

MANUALS ....................................................... 42

10.1 Supplementary User Instruction manuals .. 42

10.2 Change notes ............................................. 42

10.3 Additional sources of information ............... 42

10.4 Technical Data Sheet.................................. 43

4 INSTALLATION................................................ 14

4.1 Location ...................................................... 14

4.2 Part assemblies ..........................................14

4.3 Foundation .................................................. 14

4.4 Grouting ...................................................... 14

4.5 Initial alignment........................................... 15

4.6 Piping .......................................................... 16

4.7 Electrical connections ................................. 19

4.8 Final shaft alignment check ........................ 19

4.9 Protection systems...................................... 19

5 COMMISSIONING, START-UP, OPERATION

AND SHUTDOWN ........................................... 20

5.1 Pre-commissioning procedure .................... 20

5.2 Pump lubricants .......................................... 20

5.3 Impeller clearance....................................... 21

5.4 Direction of rotation..................................... 21

5.5 Guarding ..................................................... 21

5.6 Priming and auxiliary supplies .................... 21

5.7 Starting the pump........................................ 22

5.8 Running the pump ...................................... 22

5.9 Stopping and shutdown .............................. 22

5.10 Hydraulic, mechanical and electrical duty ..23

6 MAINTENANCE............................................... 24

6.1 General ....................................................... 24

6.2 Maintenance schedule................................ 24

6.3 Spare parts.................................................. 25

6.4 Recommended spares................................ 26

6.5 Tools required ............................................. 26

6.6 Fastener torques......................................... 27

6.7 Disassembly................................................ 27

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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

INDEX

Page

Alignment, coupling (4.5.2)...................................15

Assembly (6.9)......................................................31

ATEX Marking (1.6.4.2) ..........................................7

Bearing Sizes (5.2.1) ............................................20

CE marking and approvals (1.2).............................4

Certification (9) .....................................................42

Change notes (10.2).............................................42

Commissioning and operation (5).........................20

Compliance, ATEX (1.6.4.1)...................................6

Configurations (3.1) ..............................................11

Copyright (1.4) ........................................................4

Design of major parts (3.3) ...................................11

Direction of rotation (5.4) ......................................21

Disassembly (6.7).................................................27

Disclaimer (1.3).......................................................4

Dismantling (6.7, Disassembly) ............................27

Drawings (8) .........................................................40

Duty conditions (1.5)...............................................4

Electrical connections (4.7) ..................................19

End of product life (2.5) ........................................10

Examination of parts (6.8) ....................................29

Fastener torques (6.6) ..........................................27

Faults, causes and remedies (7) ..........................37

Foundation (4.3) ...................................................14

General arrangement drawing (8.2) .....................42

General assembly drawings (8)............................40

Grouting (4.4)........................................................14

Guarding (5.5).......................................................21

Handling (2.2) .......................................................10

Hydraulic, mechanical and electrical duty (5.9)....23

Inspection (6.2.1 and 6.2.2)..................................25

Installation (4) .......................................................14

Lifting (2.3)............................................................10

Location (4.1)........................................................14

Lubrication schedule (5.2.2) .................................20

Maintanence (6)....................................................24

Page

Maintenance schedule (6.2) ................................ 24

Name nomenclature (3.2) .................................... 11

Nameplate (1.7.1) ...................................................8

Nozzle loads (4.6.4)............................................. 17

Operating limits (3.4.1) ........................................ 12

Ordering of spares (6.3.1).................................... 25

Part assemblies (4.2)........................................... 14

Parts list (8).......................................................... 40

Performance (3.4)................................................ 12

Piping (4.6)........................................................... 16

Pre-commissioning (5.1)...................................... 20

Priming and auxiliary supplies(5.5)...................... 21

Protection systems (4.9) ...................................... 19

Reassembly (6.9, Assembly) ............................... 31

Receipt and unpacking (2.1)................................ 10

Recommended fill quantities (see 5.2.2) ............. 20

Recommended spares (6.4) ................................ 26

Recycling (2.5) ..................................................... 10

Running the pump (5.7) ....................................... 22

Safety action (1.6.3)................................................5

Safety labels (1.7.2)................................................8

Safety markings (1.6.1)...........................................5

Sectional drawings (8) ......................................... 40

Sound pressure level (1.9, Noise level)..................9

Sources, additional information (10.3)................. 42

Spare parts (6.3).................................................. 25

Specific machine performance (1.8).......................8

Starting the pump (5.6) ........................................ 22

Stopping and shutdown (5.8)............................... 22

Storage of spares (6.3.2) ..................................... 26

Storage, pump (2.4)............................................. 10

Supplementary User Instructions (10.1) .............. 42

Thermal expansion (4.5.1)................................... 15

Tools required (6.5) ............................................. 26

Torques for fasteners (6.6) .................................. 27

Trouble-shooting (see 7)...................................... 37

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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

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,
utilising 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/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 certain regions of the world shall
conform with the applicable CE Marking Directives
covering Machinery and, where applicable, Low Voltage
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 Approvals. 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 reliable. In spite of all the efforts of
Flowserve Corporation to provide sound and all
necessary information the content of this manual
may appear insufficient and is not guaranteed by
Flowserve as to its completeness or accuracy.

Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality
Assurance organisations. 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 from other vendors 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 authorised Flowserve parts and accessories is
considered to be misuse. Damage or failure caused
by misuse is not covered 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 Pump Division.

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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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

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 instructions 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 instruction in the assembly process.

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 help
prevent injury to personnel and damage to the
environment and to equipment. For prod ucts used
in potentially explosive atmosphere s 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
pieces that cannot be comfortably lifted by hand use
a crane appropriate for the mass and in accordance
with current local regulations.

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.

NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapour could cause an explosion.

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 (176 ºF) or
below -5 ºC (23 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.

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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid 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, so that their force, due to internal
pressure, acts on the pump flange, unless allowed by
Flowserve in writing.

NEVER RUN THE PUMP DRY

ENSURE CORRECT LUBRICATION

(See section 5, Commissioning, startup, operation and
shutdown.)

ONLY CHECK DIRECTION OF
MOTOR ROTATION WITH COUPLING ELEMENT/
PINS REMOVED
Starting in reverse direction of rotation will damage the
pump.

START THE PUMP WITH OUTLET
VALVE PART 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 or 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.)

INLET VALVES TO BE FULLY OPEN
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.

DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow
rate with no back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/vibration.

1.6.4 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 instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
For ATEX both electrical and non-electrical equipment
must meet the requirements of European Directive
94/9/EC. Always observe the regional legal Ex
requirements e.g. Ex electrical items outside the EU
may be required Certified to other than ATEX e.g.
IECEx, UL.

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of the
specific 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. 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 (speed) drive
(VFD) can cause additional heating effects 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.

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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

1.6.4.2 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.)

1.6.4.3 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.

The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.

Temperature

class to

EN13463-1

T6
T5
T4
T3
T2
T1

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 (* depending on

material and construction

variant - check which is lower)

Consult Flowserve
Consult Flowserve

115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *

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 when the pump is required to be
used in differently classified potentially explosive
atmospheres. In this case the user is responsible for
ensuring that the pump surface temperature does not
exceed that permitted in its actual installed location.

Do not attempt to check the direction of rotation with the
coupling element/pins fitted due to the risk of severe
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 it is recommended that users 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, regular checks must
be made and dirt removed from areas around close
clearances, bearing housings and motors.

1.6.4.4 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 the fitting of an appropriate dry run
protection device is recommended (for example liquid
detection or a power monitor).

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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.

1.6.4.5 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 earth contact on the
baseplate must be used.

Avoid electrostatic charge: do not rub non-metallic

surfaces with a dry cloth; ensure cloth is damp.

For ATEX the coupling must be selected to comply
with 94/9/EC. Correct 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.

1.6.4.6 Preventing leakage

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 Nameplate and safety labels

1.7.1 Nameplate

The following nameplate will be found on the bearing
housing [3200] of the pump.

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 and associated
piping due to closing of suction and discharge valves,
which could cause dangerous excessive pressures to
occur if there is heat input to the liquid. This can 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, the installation of a liquid detection device is
recommended.

1.6.4.7 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.

1.7.2 Safety labels

The pump will be supplied with all relevant safety
labels that are required for the safe operation of the
pump.

1.8 Specific machine performance

For performance parameters see section 1.5, Duty
conditions. Where performance data has been supplied

separately to the purchaser these should be obtained
and retained with these User Instructions if required.

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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

1.9 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.

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 assumed in the “pump and
motor” noise is that typically expected from standard
and high efficiency motors when on load directly 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 Flowserve 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
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.

For estimating sound power level L

WA

add 14 dBA to the sound pressure value.

at 1 m

pA

(re 1 pW) then

Typical sound pressure level LpA at 1 m

Motor size
and speed

kW (hp)

30 (40) 79 83 79 83

37 (50) 80 83 80 83

45 (60) 81 85 81 85

55 (75) 82 85 82 85

75 (100) 84 87 84 87

90 (120) 84 87 84 87

110 (150) 85 90 85 90

132 (180) 85 90 85 90

150 (200) 86 90 86 90

185 (250) 86 90 86 90

200 (270) 87 90 87 90

315 (420) 87 90 87 90

400 (535) 89 92 89 92

475 (635) 89 92 89 92

630 (845) 91 92 91 92

800 (1070) 92 93 92 93

1000 (1340) 93 93 93 93

1120 (1500) 93 93 93 93

1250 (1675) 94 94 94 94

1500 (2000) 95 95 95 95

1700 (2280) 95 95 95 95

1800 (2400) 96 96 96 96

2000 (2680) 96 96 96 96

Pump

reference 20 μPa, dBA

3 550 r/min 2 900 r/min

only

Pump

and

motor

Pump

only

Pump

and

motor

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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be
checked against the delivery/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 Pump Division
and must be received in writing within one month of
receipt of the equipment. Later claims cannot be
accepted.

Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
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.. Fully
trained personnel must carry out lifting, in accordance
with local regulations.

Slings, ropes and other lifting gear should be
positioned where they cannot slip and where a
balanced lift is obtained.

2.3.1 Bare pump

The bare pump should be lifted by the lifting eye as
shown:

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

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

The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.

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 requirements. If the
product contains substances that 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 that may be used in
the "seal system" or other utilities.

Make sure that hazardous substances 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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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

3 DESCRIPTION

3.1 Configurations

The BP type barrel pump is a process pump that is
operated under high pressure/high temperature
processing conditions. The casing consists of an
outer casing (casing barrel) and an inner casing
(diffusers). As the suction and discharge nozzle are
made of forged carbon steel and integral with the
casing by welding, the pump is able to be dismantled
and reassembled without disturbing suction and
discharge piping.

3.2 Name nomenclature

The pump size will be engraved on the nameplate
typically as below:

6BP-1411S

 “6” = Nominal discharge size in inches
 “BP” = Pump Designation
 ”14” = Nominal Impeller size in inches
 “11” = Number of Stages, 4-14
 “S” = Special Impeller Design

3.2.1 Discharge sizes

2, 3, 4, 6, and 8 Inches

3.2.2 Pump Designations

BP= Single Suction Impeller
BPD= Double Suction Impeller

3.2.3 Impeller sizes

8, 9, 10, 11, 12, 14, and 18 Inches

3.3 Design of major parts

Refer to Section 8 for sectional drawings.

3.3.1 Outer Casing(Casing Barrel)

A carbon controlled forged steel is used for the outer
casing. The outer casing is supported at the
horizontal centreline of the pump to minimize
coupling misalignment. The barrel is designed as a
whole to reduce any stress concentration by applying
FEM analysis for the optimum design.

3.3.2 Inner Casing(Diffuser, Inner Element)

Inner casing consists of stage pieces (1460.1-3) and
diffusers (1411, 1412, 1413). The inner casing is
designed for easy disassembling and assembling
since the diffusers and stage pieces are in one
integrated configuration. Each diffuser is mounted
with a shrink fit and a dowel pin to prevent the
rotation of the diffuser. The entire inner

element(diffuser) is pushed and secured axially
against the shoulder of the casing barrel with a
circular element spring(4260) located between last
stage piece and discharge head due to high
discharge pressure generated during pump
operation. The entire inner element is also prevented
from rotating by a dowel pin located between last
stage diffuser and discharge head. The inner
assembly expands and contracts freely due to
temperature variations without introducing thermal
stress in any of the pump parts. Self-flushing liquid for
mechanical seals is extracted from liquid in the first
stage piece through the flow passage drilled in the
first stage and the casing barrel.

3.3.3 Impellers and Wearing rings

Impellers are of the single suction closed type. They
are dynamically balanced individually and keyed to
the shaft. They are also secured on the shaft in
position with a spilt ring and a Spirolox ring, if
required. The first stage impeller is usually designed
with a lager inlet to reduce N.P.S.H requirements.
The diffuser rings are made of hardened chrome
steel. Each ring is pressed into its diffuser. If required,
replaceable impeller wearing rings can be furnished.

3.3.4 Shaft

The shaft is grooved to accommodate the split rings,
spirolox rings, if required, and a thrust ring for
positioning impellers and balancing drum.

3.3.5 Balancing Drum

The pump is hydraulically balanced by a balancing
drum and balancing ring. The balancing drum is
secured against axial movement by a thrust ring and
against rotational movement by keys.

3.3.6 Discharge Head

The discharge head is subjected to the full discharge
pressure of the pump. It is made of a forged carbon
steel using a Spiral Wound GASKET as the high
pressure seal. The discharge head contains the
balancing ring and supports the outboard stuffing box
and thrust end bearing housing.

3.3.7 Stuffing Box and Suction Head

Outboard stuffing box and inboard suction head are
fixed to the discharge head and the casing barrel
respectively with casing studs and nuts. Both of them
have cooling water chambers or steam jackets and
are supplied with the mechanical seals suitable for
the conditions of service. For details about the
installed mechanical seals, refer to manufacturer’s
instructions at the appendix.

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BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

3.3.8 Bearings

The BP pump is equipped with heavy duty, externally
mounted antifriction bearings or with babbitted sleeve
and Kingsbury type thrust bearing depending on size
of pump and application.
In the case of the anti-friction bearing, the outboard or
thrust bearing is a double row, angular contact ball
bearings mounted back to back. It has a shrink fit on
the shaft and is secured axially with a bearing nut and
lock-washer. The outer races are contained between
a shoulder in the bearing housing and a spigot on the
thrust bearing cover to prevent end movement. All
expansion due to heat is directed away from the
thrust bearing. The lubricating oil reservoir is water­cooled.
The inboard or line bearing also has a shrink fit on
the shaft and is of the single row anti-friction type.
Clearance in the bearing housing allows the outer
race to move axially to prevent shaft bending or
binding of internal parts as a result of axial shaft
expansion due to heat. Slight rotation of the outer
race in the housing is actually beneficial in extending
bearing life should it occur. All rotor expansion due to
heat occurs away from the thrust bearing (toward the
driver).
In the thrust and line bearing housing, positive
circulation of lubricating oil is assured by the oil
flinger and the trough on the inside of the bearing
housing. Proper oil level in the oil reservoir is
maintained by the constant level oiler.
For the sleeve-Kingsbury arrangement, the sleeve
bearings used are the thin wall automotive type. The
Kingsbury bearing is a JHJ double six shoe self
equalizing type.

3.3.9 Couplings

An all-metal flexible coupling of the spacer type is
standard for connecting pump and driver shafts on all
sizes of BP or WCH pumps. This coupling permits
dismantling the pump without disturbing the driver
and casing barrel. For operating instruction and
maintenance of coupling, if supplied. refer to the
manufacturer’s instruction in the appendix.

3.3.10 Accessories

Accessories may be fitted when specified by the
customer.

3.4 Performance and operating 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 your 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.

3.4.1 Operating limits

Maximum operating temperature: 425°C (820°F)
Maximum pump speed: 6000rpm
Maximum operating pressure: 29 MPa (4260 psi)

Page 12 of 44 flowserve.com

Notes:

BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

Page 13 of 44 flowserve.com

BP USER INSTRUCTIONS ENGLISH 85392725 10-09 (E)

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.

4.1 Location

The pump should be placed so that it is easily
accessible for inspection during operation while
giving due attention to the desirability of simplifying
the suction and discharge piping layout.
There should be ample place to allow the use of an
overhead crane or other lifting device with sufficient
capacity to lift the heavy parts of the unit. Refer to the
general arrangement drawing for the pump set.

4.2 Part assemblies

On baseplated pump sets the coupling elements are
supplied loose. It is the responsibility of the installer
to ensure that the pump set is finally lined up as

detailed in section 4.5.2, Alignment methods.

4.3 Foundation

4.4 Grouting

Grouting provides solid contact between the pump unit
and foundation, prevents lateral movement of vibrating
equipment and dampens resonant vibrations.

4.4.1 Foundation Preparation

a) Chip the surface of the foundation by about 10 to

20 mm (0.40 to 0.80 in). The surface of
foundation will be reasonably rough but not so
rough as to interfere with proper placing of the
grout.

b) Construct mortar beds in order to install the

parallel liners as shown on Fig. 4-3. For the
position of parallel liners see Fig. 4-1 and Fig. 4-

2.

Anchor bolt

Liner Base plate

Levering point

Levering point

There are many methods of installing
pump units to their foundations. The correct method
depends on the size of the pump unit, its location and
noise and vibration limitations. Non-compliance with
the provision of correct foundation and installation
may lead to failure of the pump and, as such, would
be outside the terms of the warranty.

Ensure the following are met:
a) The baseplate should be mounted onto a firm

foundation, either an appropriate thickness of
quality concrete or sturdy steel framework. It
should NOT be distorted or pulled down onto the
surface of the foundation, but should be
supported to maintain the original alignment.

b) Install the baseplate onto packing pieces evenly

spaced and adjacent to foundation bolts.

c) Level with shims between baseplate and packing

pieces.

d) The pump and driver have been aligned before

dispatch however the alignment of pump and motor
half coupling must be checked. If this is incorrect, it
indicates that the baseplate has become twisted
and should be corrected by re-shimming.

e) If not supplied, guarding shall be fitted as necessary

to meet the requirements of ISO 12100 and EN953.

Foundation

Fig. 4-1

30-50mm (1.25-2in)

Parallel liners

Base plate

Taper liners

Foundation

Fig. 4-2

c) Install the parallel liners on the mortar beds,

close to the anchor bolt holes as shown on Fig.
4-3. And adjust the level of parallel liners before
the mortar has solidified.

Page 14 of 44 flowserve.com