Flowserve Byron Jackson Type M User Manual
Byron Jackson Type M
Double Mechanical Seal
Submersible Pumping Unit
USER INSTRUCTIONS:
INSTALLATION, OPERATION, MAINTENANCE
PCN=85392711 1042.293/9 • Edition June 2004
®
Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
CONTENTS
PAGE
1
INTRODUCTION AND SAFETY ...................5
1.1 About the product and these user
instructions........................................... 5
1.2 CE marking and approvals ..................5
1.3 Disclaimer............................................5
1.4 Copyright ............................................. 6
1.5 Duty conditions....................................6
1.6 Safety................................................... 6
1.6.1 Safety symbols................................6
1.6.2 General safety instructions..............7
1.6.3 Personnel qualification, training
and protective clothing ....................7
1.6.4 Authorized and prohibited use.........7
2 TRANSPORT AND STORAGE.....................9
2.1 Consignment receipt and
unpacking ............................................ 9
2.2 Transport ........................................... 10
2.2.1 Safety instructions.........................10
2.2.2 Equipment and personnel
required ........................................ 10
2.2.3 Transport of the motor................... 10
2.2.4 Transport of the pump bowl
assembly....................................... 11
2.3 Storage and shipping......................... 12
2.4 Recycling and end of product life ...... 13
3 DESCRIPTION.............................................14
3.1 Configurations.................................... 14
3.1.1 General Description.......................14
3.1.2 Main Components.........................14
3.1.3 Motor serial number ...................... 14
3.5 Electrical requirements.......................17
3.5.1 General electrical requirements.... 17
3.5.2 Motor protection............................ 18
3.5.3 Short circuit protection .................. 18
4 INSTALLATION AND
UNINSTALLATION..................................... 19
4.1 Fitter ...................................................19
4.2 Equipment and personnel required....19
4.2.1 Equipment and tools supplied
with motor ..................................... 19
4.2.2 Equipment and tools to be
supplied by operator ..................... 19
4.2.3 Personnel required........................ 21
4.3 Hydraulic connection..........................21
4.4 Installation..........................................23
4.4.1 Safety instructions......................... 23
4.4.2 Sequence of installation................ 23
4.4.3 Prepare installation site................. 23
4.4.4 Arrange components for
installation..................................... 24
4.4.5 Inspect components...................... 25
4.4.6 Install motor .................................. 26
4.4.7 Install coupling.............................. 27
4.4.8 Install pump bowl assembly.......... 30
4.4.9 Install impeller............................... 32
4.4.10 Vent motor..................................... 33
4.4.11 Install power cable ........................ 35
4.4.12 Fasten the power cable to the
cable guard................................... 39
4.4.13 Install riser pipe, fasten power
cable to riser pipe.......................... 40
4.4.14 Connect power cable to
terminal box .................................. 43
4.4.15 Connect terminal box to main
power supply ................................. 43
4.5 Uninstallation......................................45
4.5.1 Safety instructions......................... 45
4.5.2 Uninstallation ................................ 45
3.2 Design of major parts.........................14
3.3 Performance and operating limits......15
3.3.1 Normal operating conditions..........15
3.3.2 Design changes ............................15
3.4 Preconditions at the installation
site .....................................................16
3.4.1 Survey of well................................ 16
3.4.2 Crooked well .................................16
3.4.3 Development of the well................16
3.4.4 Suction and submergence
requirements.................................16
3.4.5 Effect of pumping sand..................16
3.4.6 Effect of air or gas.........................16
3.4.7 Oxidizing and corrosive effects
of chemicals, air and gases...........16
5 COMMISSIONING STARTUP,
OPERATION AND SHUTDOWN................ 46
5.1 Safety instructions..............................46
5.2 Direction of rotation............................46
5.3 Starting the pump...............................46
5.3.1 First-time start-up of the pump...... 46
5.3.2 Normal start-up of the pump ......... 47
5.4 Running or operation..........................47
5.4.1 Performance and operating
limits ........................................ 47
5.4.2 Motor operation............................. 48
5.4.3 Starting frequency......................... 48
5.5 Stopping and shutdown......................49
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
6 MAINTENANCE ..........................................50
6.1 Safety instructions .............................50
6.2 Maintenance schedule....................... 50
6.3 Working substances and auxiliary
agents................................................51
6.4 Motor maintenance............................ 51
6.5 Pump maintenance............................51
6.6 Pump test run .................................... 51
6.7 Periodic testing of motor and pump... 52
6.8 Electrical tests of the motor ...............53
6.8.1 Insulation test................................ 53
6.8.2 Continuity testing...........................53
6.9 Spare parts........................................ 54
6.9.1 Recommended spares and
consumable items ......................... 54
6.9.2 Ordering spare parts ..................... 54
6.9.3 Storage of spare parts................... 54
6.10 Tools for repair and maintenance...... 55
7 FAULTS, CAUSES AND REMEDIES.........56
8 PARTS LIST AND DRAWINGS..................59
9 CERTIFICATION.........................................60
10 OTHER RELEVANT DOCUMENTATION
AND MANUALS ..........................................61
10.1 Change notes ....................................61
10.2 Abbreviations..................................... 61
11 GLOBAL CONTACT POINTS, EU CE
MARKER AND SERVICE CONTACTS ......62
12 APPENDIX...................................................63
12.1 Scope of delivery ...............................64
12.2 Data sheet .........................................65
12.3 Tightening torques............................. 66
12.4 Safety data sheet for motor oil...........67
Page 4 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
1 INTRODUCTION AND SAFETY
1.1 About the product and these user
instructions
NOTE These user instructions must always
be kept close to the product's operating location of operation or directly
with the product so that they are
available to the operating personnel at
any time.
ned, developed and
Flowserve's products are d
manufactured with state-of-the-art technologies in
modern facilities. The pumping 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 im-
ent a
provem
formation about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate familiarization
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.
NOTE These instructions should be read
These user instructions outline the general proce-
s
that must be observed to ensure long, trou-
dure
ble free performance of the pumping unit. However, it is assumed that plant personnel are familiar
with the basic principles and tools involved in the
installation, operation and maintenance of a pumping unit. Successful pumping unit operation is dependent on careful study of these user instructions
nd being at service for any further in-
with
the product and its permitted use.
prior to ins
and maintaining the equipment in
any region worldwide.
The equipment must not be put into
ce until all the conditions relat-
i
serv
ing to safety, noted in the instructions, have been met.
esig
t
alling, operating, using
and a well planned and observed maintenance
program.
In these user instructions, the numbers in brackets
umbers, e. g.: shaft button screw
are item
(806-2). Refer to the drawings in Chapter 8 "Parts
list and drawings", Page 59, for the position of the
respective item.
n
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) and Pressure Equipment
Directive (PED).
Where applicable, the Directives and any addi-
ovals cover important safety aspects
tional App
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 check if the approvals apply and if the product
itself is CE marked, check
markings and the Certification, see Section 9
"Certification", Page 60.
r
the seri
al number plate
1.3 Disclaimer
Information in these user instructions is believed
to be reliable. In spite of all the efforts o
Flowserve Pump Division to provide sound and all
necessary information the content of these use
instructions may appear insufficient and is not
guaranteed by Flowserve as to its completeness
or accuracy.
Flowserve manufactures products according to
International Quality Management System Standards as certified and audited by external Quality
Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure continued
product quality and performance in use.
As Flowserve cannot test parts and accessories
ced from other vendors the incorrect installa-
r
sou
tion 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 Flowserve parts and accessories is
considered to be misuse. Damage or failure
caused by misuse is not covered by Flowserve's
warranty. In addition, any modification of
Page 5 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
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 user 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 user instructions.
NOTE The product must not be operated
beyond the parameters specified fo
the application.
If there is any doubt as to the suitability of the product for the application intended, contact Flowserve fo
advice, quoting the serial number.
If the conditions of service on your purchase order
are changed (for example liquid pumped, temperature or duty) it is requested that the user seeks our
written agreement before start up.
1.6 Safety
1.6.1 Safety symbols
These user instructions contain specific safety
symbols where non-observance of an instruction
would cause hazards.
Safety symbol and safety
word
DANGER This symbol indicates an
This symbol indicates a
CAUTION This symbol indicates a
The following symbols may be added to the above symbols
CAUTION This word indicates a situation
NOTE This sign is not a safety symbol
This symbol indicates a
This symbol indicates a
Table 1 Safety symbols in these user instructions
Meaning
imminent hazardous situation.
The situation, if not avoided, will
result in death or serious injury.
potentially hazardous situation.
The situation, if not avoided,
could result in death or serious
injury.
potentially hazardous situation.
The situation, if not avoided,
could result in minor or moderate
injury.
which, if not avoided, could
damage the equipment.
but indicates an important
instruction in the assembly
process.
potentially hazardous situation
due to hazardous and toxic fluid.
The situation, if not avoided,
could result in death or serious
injury.
This symbol indicates a
potentially hazardous situation
due to strong magnetic field.
The situation, if not avoided,
could result in death or serious
injury to persons with pacemaker
implant.
Further, the situation could
damage instruments and stored
data sensitive to magnetic fields.
potentially hazardous situation in
an explosive atmosphere
according to ATEX.
The situation, if not avoided in
the hazardous area, could cause
an explosion.
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
1.6.2 General safety instructions
NOTE Always follow
• legal regulations
• plant regulations
• these user instructions
concerning safety.
Absolutely heed all information placed directly on
the pumping unit and given in Chapter 12.2 "Data
sheet", as for example
• rotation arrow
• labeling of connections
• rating plate.
Danger of injury by
• knocking against parts, tools o
equipment
• jamming fingers or hands in o
between parts, tools or equipment
• dropping parts, tools or equipment on parts of the body.
DANGER
ll work on the electrical system
may only be performed by qualified
electricians!
All work on the hydraulic connections may only be performed by
qualified fitters.
Protective clothing
During transport, installation and removal of the
pumping unit, all personnel must wear
• helmet
• safety boots
•
protective gloves
During operation of the pumping unit at the control
center, all personnel must wear
•
protective gloves
NOTE Also follow
• legal regulations
• plant regulations
concerning protective clothing.
1.6.3 Personnel qualification, training and protective clothing
Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the pumping unit
must be qualified and authorized 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 co-ordinate repair activity with operations
and health and safety personnel, and follow all
plant safety requirements and applicable safety
and health laws and regulations.
1.6.4 Authorized and prohibited use
The safe operation of the pumping unit can only be
guaranteed if it is operated as authorized.
The only authorized utilization of the pumping unit
is to pump water from a well. The pumping unit is
to be operated submerged in water.
NOTE Not all components or sub-
assemblies of a pumping unit are
necessarily supplied by Flowserve
or part of this delivery.
These user instructions apply only
to the components or subassemblies supplied by Flowserve
in this delivery, see Chapter 12.1
"Scope of delivery".
By not heeding this user instructions, product liability is rendered void.
Page 7 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
Non-authorized utilization of the pumping unit includes:
• operating the pumping u
nit in a known mal-
functioning state
• operating the pumpin
g unit in conditions other
than those given in Chapter 3.3.1 "Normal operating conditions", Page 15.
• making modifications of the pumping unit that
are not auth
orized by Flowserve
• using spare parts that are not authorized by
Flowse
rve.
CAUTION Alterations to the pumping unit are
only
permitted a
fter written permis-
sion by Flowserve.
Only use spare parts that have been
autho
rized b
y Flowserve.
Flowserve is not liable for any dam-
ause
age c
d by the use of parts ob-
tained from third parties.
Page 8 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpack-
ing
A submersible pumping unit consists of
• Motor
• Pump bowl assembly
• Non-return valve
• Powe
• Riser pipe
• Cable or bracket to fasten the motor power
• Wellhead (surface plate)
• Terminal box or jun
• Tools for inst
NOTE Not all components or sub-
Flowserve generally ships the pumping unit in two
packa
• Main compon
• Tools described in
All components and parts are suitably protective
ppe
wra
ate.
The motor is shipped nearly completely filled with
oil, with
mounted outside of the motor to allow thermal expansion and contraction of the motor oil.
r cable
(discharge column)
cabl
e onto the riser pipe
ction box
allation and maintenance.
assemblies
of a pumping unit are
necessarily supplied by Flowserve
or part of this delivery.
These user instructions apply only
to the c
omponen
ts or subassemblies supplied by Flowserve
in this delivery, see Chapter 12
"Scope of delivery".
s:
ge
ents described in Chapter 3.1.2
"Main Components", Page 14.
Chapter 4.4.4 ”Arrange
components for installation", Page 24.
d, crated or mounted on skids as appropri-
oil expansion bag (shipping bladder)
an
The power cable, if included in the delivery, is
ship
ped on a reel with a sh
ipping cap or other pro-
tective covering installed to protect the connectors.
Immediately after receipt of the equipment
1. Uncrate all parts.
Check all crates, boxes and wrappings for any
accessorie
s or spare parts which may be
packed separately with the equipment or attached to side walls of the box or equipment.
2. Check the scope of delivery.
• Che
ck the delivery against the delivery
and shippi
ng documents for its com-
pleteness.
Each product has a unique serial num-
at this number corresponds
ber. Ch
eck th
with that advised.
NOTE Make sure you can always quote
t
each par
's serial number in correspondence and when ordering
spare parts or further accessories.
• Ins
pect the delivery for trans
damage.
Immediately report any shortage and or dam-
age to Flowserve and the ship
ping company.
Claims must be reported in writing within one
month of receipt of the equipment. Flo
does not accept latter claims.
3. Check the available power against the res given on the motor data plate and
ment
quire
in Chapter 12.2 "Data sheet".
If the equipment is to be stored
• continue with Chapter 2.3 "Storage and ship-
ping", Page 1
2.
If the equipment is to be installed
• contin
ue with Chapter 4.4 "Installation",
Page 23.
portation
wserve
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
2.2 Transport
2.2.1 Safety instructions
Transport is the process of moving the pumping
unit or its components from the installation site to a
storage site, maintenance site or repair site, or vice
versa.
During transport, always
• Work carefully to avoid accidents.
• Handle equipment carefully.
• Be sure lifting devices are in good condition
and are capable of safely handling the
weights to be lifted.
• Mark and seal off the transport route so that
unauthorized personnel do not enter the danger area.
• Take precautions to prevent foreign materials
or dirt from entering the working parts of pump
and motor.
2.2.3 Transport of the motor
Do not raise or move the motor by
the power cables!
CAUTION The motor is a dynamically bal-
anced machine and should be handled accordingly.
Take precautions to prevent foreign
materials or dirt from entering the
working parts of the motor.
1. Refer to Figure 1.
Place hitching line under lifting lugs.
Take care that the hoist has an adequate carrying force. For weight see
Chapter 12.2 "Data sheet".
Never step under floating load.
Watch for and avoid overhead ob-
structions including power lines.
2.2.2 Equipment and personnel required
Provide the following equipment for the transport:
• Portable crane with adequate carrying force.
For weight see Chapter 12.2 "Data sheet.
• Also see Chapter 4.2 "Equipment and personnel required", Page 19.
Flowserve recommends that 2 persons plus 1
crane operator perform the transport.
Figure 1 Hitching line under lifting lugs
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
2. Refer to Figure 2.
Place a wire around the motor. The wire is to
be positioned between stator and lower casing, approx. 1/3 from bottom of motor.
Figure 2 Lifting motor for installation
3. Lift the motor horizontally by 2 points.
4. Transport the motor horizontally to the installation or storage site.
5. Carefully lower the motor at the respective
site and place it on the floor.
If the motor is to be stored:
• Continue with Chapter 2.3 "Storage and shipping", Page 12.
If the motor is to be installed in a well:
• Continue with Chapter 4 "Installation",
Page 19.
2.2.4 Transport of the pump bowl assembly
NOTE Not all components or sub-
assemblies of a pumping unit are
necessarily supplied by Flowserve
or part of this delivery.
These user instructions apply only
to the components or subassemblies supplied by Flowserve
in this delivery, see Chapter 12.1
"Scope of delivery".
CAUTION Use care to prevent bumping, push-
ing, or scraping of pump bowl assembly parts, especially the shafts,
or other machined surfaces.
Take precautions to prevent foreign
materials or dirt from entering the
working parts of the pump bowl assembly.
NOTE The following description refers to
pumps without auxiliary carriers.
Should the pump be delivered on an
auxiliary carrier, refer to the pump
manual for transportation instructions.
1. Connect the pump
• directly to the hoists, or
• to the cross-beam
If the motor is to be maintained:
• Continue with Chapter 6 "Maintenance",
Page 50.
Page 11 of 68
of a portable crane.
2. By means of the crane, carefully lift the pump
and move it to the desired site.
If the pump bowl assembly is to be stored:
• Continue with Chapter 2.3 "Storage and shipping", Page 12.
If the pump bowl assembly is to be installed in a
well:
• Continue with Chapter 4 "Installation",
Page 19.
If the pump bowl assembly is to be maintained:
• Continue with Chapter 6 "Maintenance",
Page 50.
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
2.3 Storage and shipping
For the removal of the pump from the well see
Chapter 4.5 "Uninstallation", Page 45, if necessary.
Requirements for the storage area
• Safe
• Clea
• Away from extended p
n
eriods of direct sunlight
• Well ventilated
• Dry
Air humidity:
................................40 % to 60 %
• Cool
Air temperatur
e for motors
originally filled by Flowserve:...+50 °C to -5 °C
CAUTION Always s tore mot or and pump bowl
assembly
separately
.
Prepare motor for storage or shipping after removing the motor from the well
1. Arrange the motor horizontally.
2. If pump and coupling are to be stored or
shipped sep
nents on motor shaft.
3. Install power terminal shipping cap (112),
power te
shipping caps (112-1).
4. If the motor is to be stored in a vertical position, proceed
a. Remove the adapter bracket (808).
b. Drill a vent hole in the motor shipping cap
(112-1
If the motor is returned to factory at a
later time, se
plug.
5. If the motor is to be returned to the factory,
eed as follows:
c
pro
a. Remove motor half-coupling (529) or mo-
tor one-pie
b. Lubricate shaft with some form of pene-
trating oil.
c. Place coupling and components in motor
ship
minal gasket (744-6) and bolt cap securely in place.
arately: Install coupling compo-
nal gasket (744-6), and motor
rmi
as follo
ws:
).
al the vent hole by a pip
ce coupling (531).
ping cap
(112-1) with its power ter-
e
d. Elevate motor over a sump or drum to
nd
drain oil a
water from motor.
e. Remove lower casing drain plug (806)
from bottom of motor, then remove vent
plugs (806-4 and 806-5) at top of motor
and allow motor to fully drain.
f. Replace drain and vent plugs.
Prepare pump bowl assembly for storage or
shipping
NOTE Not all components or sub-
assemblies
of a pumping unit are
necessarily supplied by Flowserve
or part of this delivery.
These user instructions apply only
to the c
omponen
ts or subassemblies supplied by Flowserve
in this delivery, see Chapter 12.1
"Scope of delivery".
NOTE The following description refers to
w
pumps
ithout auxiliary carriers.
Should the pump be delivered on an
y
auxiliar
carrier, refer to the pump
manual for storage and shipping
instructions.
1. Install blocks in the strainer to restrain the
pump shaft.
This prevents shaft end float and possible in-
e during handling.
ternal da
mag
2. Make sure the bowl assembly is thoroughly
dry.
3. Install suitable covers to seal off all openings.
Page 12 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
Store pumping unit
NOTE The following description refers to
pumps without auxiliary carriers.
Should the pump be delivered on an
auxiliary carrier, refer to the pump
manual for storage and shipping
instructions.
Store the pumping unit as follows:
• Motor:
Preferably vertically
Filled with oil
• Pump bowl assembly with rubber bearing
bushes:
Vertically
• Pump bowl assembly with other than rubber
bearing bushes:
Preferably vertically
DANGER
Horizontally stored motors and
pump bowl assemblies must be secured against rolling.
ertically stored motors and pump
bowl assemblies must be secured
by appropriate means in this storage position to prevent tipping over.
• Power cable:
Leads protected from moisture
NOTE Do not bend power cable during
storage.
Maintenance during storage
• Storage up to four weeks
At the beginning and end of the storage pe-
riod: Carefully check the motor to be sure
there are no signs of oil leakage.
• Storage between 1 and 24 months
Maintenance of the motor, every 6 to 8 weeks:
1. Remove the motor shipping cap (112) at
the motor.
3. Mount the motor shipping cap (112) to
the motor.
Maintenance of the pump, every 6 to 8 weeks:
1. Remove the discharge housing and the
non-return valve for the pump shaft.
2. Turn the pump shaft several times by
means of a wrench.
4. Mount the discharge housing and nonreturn-valve to the pump.
• Storage for over 24 months
After a storage of more than 24 months, we
recommend a complete visual inspection at
our main factory or at your nearest Flowserve
representative.
Shipping
Ship motor and pump bowl assembly
• in non-airtight protection film
• in wooden box or similar transport packaging.
2.4 Recycling and end of product life
At the end of the service life of the pumping unit or
its parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and heeding local regulations.
If the product contains substances which are harmful to the environment, these should be removed
and disposed of in accordance with local regulations. This also includes the liquids and or gases in
the "seal system" or other utilities.
DANGER
Make sure that hazardous sub-
stances are disposed of safely and
that the correct personal protective
equipment is used.
The safety specifications must be in
accordance with the local regulations at all times.
Hazardous substances in the pumping unit are
• Motor oil
2. Turn the motor shaft several times by
means of a wrench.
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
3 DESCRIPTION
3.1 Configurations
3.1.1 General Description
The Flowserve submersible pumping unit is a
combination of
• a vertic
chanical seal
• a vertical pump bowl a
designed for sustained operation submerged in
water.
The
pump bowl assembly.
The rotating element of the pump bowl assembly is
driven from the bottom
connected to the motor shaft by a coupling.
Power is supplied to the motor through a submarine po
we
and extends to the starting equipment. Motor and
pump bowl assembly are connected to the riser
pipe. The riser pipe is threaded or flanged and
coupled in random lengths and the entire unit is
coupled to a wellhead assembly.
Each pumping unit has been individually manufac-
ccording to the special requirements of the
a
tured
customer. The technical data is given in Chapter
12.2 "Data sheet".
al, oil filled motor with double me-
ssembly
motor is positioned directly below the
where its extended shaft is
r cable which is fastened to the riser pipe
These user instructions apply only
to the componen
ts or subassemblies supplied by Flowserve
in this delivery, see Chapter 12.1
"Scope of delivery".
3.1.3 Motor serial number
The motor serial number is on the name plate on
the stator.
3.2 Design of major parts
The motor is filled with, lubricated and cooled by a
special mineral oil of high dielectric strength.
This oil
• allows high efficiency rotor-stator design,
• provides
qualities, and
• protects the motor from internal corrosion.
CAUTIO
excellent insulation and lubrication
N The oil used in this pumping unit is
specifie
d in Chap
ter 12.2 "Data
sheet".
Use of other oil
3.1.2 Main Components
A pumping unit consists of
• Motor
• Pump bowl assembly
• Non-return valve
• Power cable
• Riser pipe
(discharge column)
• Cable or bracket to fasten the motor power
cabl
e onto the riser pipe
• Wellhead (surface plate)
• Terminal box or jun
• Tools for inst
ction box
allation and maintenance.
NOTE Not all components or sub-
assemblies of a pumping unit are
necessarily supplied by Flowserve
or part of this delivery.
• ma
y cause damage to the
pumping unit
• renders Flo
wserve's warranty
void.
The motor does not require periodic oil changes.
The oil is circulated within the motor by pumping
action of the
thrust bearing disc. Separation between the motor oil and pump liquid at the shaft
exit is maintained by two mechanical seals.
The motor is pressure compensated.
The double mechanical seal system uses a pres-
balan
sure
ce process to equalize the pressure differential across the seals, minimizing leakage and
providing years of maintenance free service. The
inner seal diverts any pumped fluid leakage via a
communication line to a storage reservoir at the
bottom of the motor. The motor is vented to the
well by the balance line. As the oil expands, some
oil is pushed out of the motor through the balance
tube. As the oil cools down, pumped fluid is drawn
back into the lower casing at the bottom of the motor through the balance tube.
Page 14 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
3.3 Performance and operating limits
3.3.1 Normal operating conditions
Operating purpose
Submersible pumps serve to transport water under
the operating con
ditions described in the following.
tion
Opera
• Operation
wit
hin prescribed voltage tolerance,
see Chapter 12.2 "Data sheet"
• No operation against closed slide valve
• Permissible o
perational range: 50 % to 120 %
of the optimal delivery rate
CAUTION Other uses, operating purposes o
operating conditions must be
agreed upon by Flowserve.
Water characteristics
• Water temperature: .............
• Sand content:
......................Maximum 25 mg/l
Also see Chapter 3.4.3 "
well", Page 16, and Chapter 3.4.5 "Effect of
pumping sand", Page 16.
• No impuritie
s which could lead to deposits
and blockages within the pump or to deposits
on the motor surface.
Also see Chapter 3.4.6 "Effect of air or gas",
nd Chapter 3.4.7 "Oxidizing and
16 a
Page
corrosive effects of chemicals, air and gases",
Page 16.
• No occurrence of water hammer
CAUTIO
N At higher surrounding temperatures
and/or lo
er flow velocities on the
w
external motor surfaces, or if there
is risk of clogging, special measures for heat dissipation are required.
Inform Flowserve of the surrounding conditio
ns.
See Chapter 12.2
"Data sheet"
evelopment of the
D
• Observation of the
starting frequency
maximum permissible
Installation position
Take the following criteria into account when determinin
• Vertical installation in a
g the installatio
n position and depth:
well above the filter
line, so that a perfect flow is guaranteed along
the external motor wall.
• Sufficient water cover
• A static wat
er level at least 2 m above the
pump exit
• A dynamic water level above the suction
hou
sing, taking into account the required net
positive suction head for the pump (see Chapter 12.2 "Data sheet")
• Flow rate (see Cha
• Supply cond
pter 12.2 "Data sheet")
itions of the pumping medium
(dependent upon the installation conditions)
CAUTION The pumping unit should be in-
stalled above the
well filter.
If this is not possible, prevent direct
w
suction
ithin the filter line by suitable measures (e.g. blind tube in
the filter, outer pump mantle, pump
with sand protection jacket.
Flo
of the p
application and confirm its use, i
applicable.
Pumping unit
• Corre
ctly selected and adjusted motor protec-
tion
wserve will check the suitability
ump
ing unit for its planned
Page 15 of 68
3.3.2 Design changes
Alternation or addition of the pumping unit may
c
only take pla
• by Flowserve,
e
or
• after written consent by Flowserve.
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
3.4 Preconditions at the installation
site
3.4.1 Survey of well
Always sound the well to make sure it is deep
enough to permit install
consisting of pump bowl assembly and motor. If
the exact diameter and depth of the well casing is
not known, "cage" the well following the procedure
outlined in Chapter 3.4.2 "Crooked well", Page 16.
Experience indicates that many wells have more
stri
that one
ng of casing installed and frequently
the lower sections are smaller in diameter than the
surface casing. Be certain the submersible pumping unit will pass into the well freely and hang well
above of the well bottom.
3.4.2 Crooked well
A well that is known to be crooked and that has not
ly accommodated a pumping unit of com-
previou
s
parable size must be "caged" before the submersible pumping unit is installed.
1. Prepare a cage of the same length and di-
the combined motor and pump
ameter a
s
bowl assembly, with 12 m to 15 m (40 feet to
50 feet) of the proper size of riser pipe.
2. Lower the cage into the well to the point at
h the pumping unit is to be placed.
c
whi
3. If the cage can be lowered to this point with-
out touching
the inner wall of the well, the
submersible pumping unit can be installed.
3.4.3 Development of the well
Do not use a new pumping unit to develop the well.
Developing, surging and freeing the well of sand
s
are con
idered a part of the well drillers contract
and should be accomplished by the use of a test
pumping unit.
ation of the pumping unit
maximum well draw-down level, although some
installations may require more submergence.
3.4.5 Effect of pumping sand
Flowserve does not guarantee the pumping unit to
be resistant
against the erosive action of sand, silt
or other abrasive materials suspended in water.
Pumping sand will adversely affect the motor be-
e the vibration produced in a worn pump bowl
s
cau
assembly will be transmitted to the motor and
could result in a shortened motor life.
3.4.6 Effect of air or gas
The presence of gases in the water may reduce
a
city and head of the pumping unit, thus de-
cap
creasing the hydraulic performance. Further, air or
gas in the water will cause deterioration of materials of the pumping unit sooner than under normal
conditions.
3.4.7 Oxidizing and corrosiv e effects of
r and gases
chemicals, a
i
Even if the composition of the pumped water is
n due to chemical analysis, it is not always
know
possible to predict the corrosive action of water on
the metals of the pumping unit.
In addition to chemicals, water may also contain
entrain
ed air or ga
ses that have a definite oxidizing
or corrosive action of their own. This action is accentuated by high velocities within the pump.
Such conditions are not recognizable in the chemical analysis of the water.
Conforming with the Standards of the Hydraulic
Institute of th
e United States and the p
ractice of all
reliable pump manufacturers, Flowserve does not
guarantee its pumps and motors to be resistant
against corrosive or electrolytic action.
Should you require motors or pumps to perform
unde
r oxidizi
ng or corrosive conditions, contact
Flowserve for further information.
3.4.4 Suction and submergence requires
ment
Pumping th
unit br
e well at a rate at which the pumping
eaks suction will cause pump deterioration.
It is suggested that a method be provided for keeping a record of the water level above the suction
inlet.
The minimum submergence recommended is 3 m
(10
feet) of
riser pipe submergence below the
Page 16 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
3.5 Electrical requirements
3.5.1 General electrical requirements
The Byron Jackson submersible motor is designed
for across-line start, eliminating the need for reduced voltage starting equipment. Maximum current inrush when the motor is connected across the
line at full voltage will be limited to about 700 % of
the rated load current.
Because starting the motor at full voltage results in
high starting torque, the motor accelerates to operating speed very rapidly (within 0.8 seconds, typically), and current consumption correspondingly
drops to normal. The rated power requirements of
the motor are stated on the pump nameplate located on the wellhead.
Allowed combinations of voltage and frequency
variations during operation are classified according
IEC 60034 as being either Zone A or Zone B
(Figure 3) or according NEMA (see Figure 4).
Voltage and frequency limits
0,1
0,08
0,06
0,04
0,02
0
-0,05 -0,04 -0,03 -0,02 -0,01 0 0,01 0,02 0,03 0,04 0,05
-0,02
Voltage Variation p.u.
-0,04
-0,06
-0,08
-0,1
Frequency Variation p.u.
Figure 3 Voltage and frequency limits acc. IEC 60034
Figure 4 Voltage and frequency limits acc. NEMA
The motor is capable of performing its rated torque
continuously within Zone A, but need not comply
fully with its performance at rated voltage and frequency (see rated point in Figure 3), and may exhibit some deviations. Temperature rises may be
higher than at rated voltage and frequency. For
conditions at the extreme boundaries of Zone A,
the temperature rises and temperatures may exceed the specified limits of temperature rise and
temperature by approximately 10 K.
Operation outside Zone A (within Zone B) may exhibit greater deviations from its performance at
rated voltage and frequency than in Zone A. Temperature rises may be higher than at rated voltage
and frequency and most likely will be higher than
those in Zone A. Extended operation at the
perimeter of Zone B is not recommended.
Low voltage is a serious problem since the operating motor current is increased, resulting in additional motor heating. However, the motor is designed to operate continuously at 110 % of rated
current, so that some reduction in voltage can be
tolerated as long as it is not also accompanied by
an overload of the motor.
Page 17 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
With variations in voltage, the motor characteristics
will, in general, vary as given in Table 2.
Voltage 110 % 90 %
Speed Increase 1 % Decrease 1.5 %
Efficiency (full load) Increase 0.5 % Decrease 1 %
Power factor (full load) Decrease 3 % No change
Current (starting) Increase 11 % Decrease 11 %
Current (full load) Decrease 8 % Increase 11 %
Temperature Decrease 2 % Increase 5 %
Table 2 Motor characteristics at varying voltage
Rated or full load current refers to the amperage
drawn by the motor at nameplate output, frequency
and voltage at the motor terminals. The maximum
allowable current (except momentarily at start-up)
is 110 % of the rated value.
The voltage on all three phases should be evenly
balanced as closely as can be read on the usually
available commercial voltmeter, because the current unbalance will be in the order of 6 to 10 times
the voltage unbalance. Running the motor with the
unbalanced voltage will lead to increased temperature and decreased motor life time, and therefore
must be avoided.
The value given in Chapter 12.2 "Data sheet", is a
standard value for the operating point. If the actual
operational current in the operating point of the
pump bowl assembly lies under this given value,
the switch must be adjusted lower so that there is
effective protection and malfunctions can be indicated in time.
DANGER
Do not set the motor protection ad-
justment higher than the highest permissible value given in Chapter 12.2
"Data sheet".
Do not test the perfect functioning o
a motor protection switch by intentional single-phasing.
3.5.3 Short circuit protection
To prevent short circuiting of the power cable and
the motor, safety measures must be taken according to local ordinances.
Guide values for the safety fuse sizes can be taken
from Chapter 12.2 "Data sheet".
Poor voltage regulations of an engine-driven generator, if the power is derived from such a source,
can be very disadvantageous to the motor. Thus,
Flowserve assumes no responsibility for pumping
units operated on such equipment unless agreed
on in writing.
Also, because of the unpredictable characteristics
and past experiences associated with the use of
phase converters, Flowserve must void all guarantees for applications that incorporate these devices
as a means of obtaining three phase power.
3.5.2 Motor protection
To protect the motor against power overload, an
inverse time-lag overload relay must be provided,
sensitive to phase failure and which compensates
for temperature.
The over current relay for the switchgear and the
safety fuses can be adjusted or selected according
to Chapter 12.2 "Data sheet".
The adjustment of the motor protection switch
(thermally delayed over current relay) must be
done according to the value given in Chapter 12.2
"Data sheet".
Page 18 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
4 INSTALLATION AND UNINSTALLA-
TION
4.1 Fitter
It is recommended that the services of Flowserve
be employed for the installation and initial starting
of a Byron Jackson pump.
Such service will ensure the purchaser that the
properly installed, and will provide an
equipm
ent is
excellent opportunity for the plant operator to receive special instructions relative to the pumping
unit.
4.2 Equipment and personnel re-
quired
4.2.1 Equipment and tools supplied with mo-
tor
Equipment and tools supplied with motor and
half coupling
• Hex so
(806-2)
• Hex socket wrench for coupling set screw
(806
• Hex socket wren
• Hex socket wren
cket wrench for shaft button screw
-1)
ch for vent plug (806-4)
ch for vent plug (806-5)
4.2.2 Equipment and tools to be supplied by
opera
tor
Provide the followin
g equipment and tools:
• Lifting Equipment.
Must be of sufficient strength and rigidity to lift
the com
lete unit safely, see Table 3,
p
Page 20, and of sufficient height to allow
clearance between load hook and foundation.
For weight see Chapter 12.2 "Data sheet".
• Two pai
rs of corre
• One correc
• One correc
tly sized column U-plate
tly sized motor U-plate (see Figure
ctly sized pipe elevators
5, Page 21 and Table 4, Page 21)
• One 1.2 - 1.8 m (4 - 6 feet) section of column,
thread
ed and coupled, to be attached to the
top case and used for handling the pump bowl
assembly.
Deduct this length from total column length
specifications.
• Colum
n
A supply of pipe, in random lengths, threaded
and
pled, of correct size to handle the unit
cou
capacity and total weight and of adequate
length to set the unit at the correct pumping
level in the well. The threading is 8 threads
per 25 mm (1 inch) and 19 mm (0.75 inch) taper per foot.
• Aligning jig as
sembly, including the following
parts:
- Shim, shaft adjusting (262-6)
- Shim, shaft adjusting (262-7)
- Button, thrust (130)
- Screw, thrust Button (806-2)
- Washer, coupling lock screw (690-4)
- Screw, coupling lock (806-3)
- Aligning jig (265)
- Coupling, driver (529)
- Key, coupling (676-1)
- Screw, set, coupling (806-1)
• One pai
r of cable re
el stands, with axle
• One portable insulation resistance tester
("Megg
• One clamp
er"), 0 - 100 MΩ / 1000 Volts
-on ammeter
• One volt/ohmmeter
• Components for water level indicating system
• Special ba
nding tool ("Band-it") for cable
bands
• A length of 1.27
cm (0.5 inch) hemp rope and
a cable installation wheel. Diameter must be
at least 14 times cable outer diameter.
• Ordinary hand tools (mechanical and electrial) used in this kind of work
c
• Two sets of chain tongs
• Rubber mat and insulated gloves for electrical
work in da
mp conditions
Page 19 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
• An adequate supply of approved thread compounds, as follows
- For installation of the short section of col-
Motors
Nominal motor
size
umn pipe, next to top case or top case
flange, use only Loctite 277 (Red) &
Primer T or equal.
- For remaining column pipe threads, use a
8"
pipe thread compound that is capable of
lubricating and sealing.
Column
Size Weight per foot in kg (pounds)
Empty Full
2-1/2 2.6 (5.8) 3.6 (7.9)
3 3.4 (7.6) 4.9 (10.8)
4 4.9 (10.9) 7.4 (16.4)
5 6.7 (14.8) 10.7 (23.5)
6 8.7 (19.2) 14.4 (31.7)
8 11.3 (25.0) 21.4 (47.2)
10 14.5 (32.0) 30.2 (66.6)
12 20.4 (45.0) 42.6 (93.9)
Bowl Slumps
Size Weight in kg (pounds)
1
8MQ 36 (80) 7 (15)
10MQ 79 (175) 17 (37)
11MQ 132 (290) 32 (70)
12MQ 200 (440) 57 (125)
13MQ 284 (625) 79 (175)
15MQ 386 (850) 120 (265)
Cable
Volts Size Weight per foot
600
5000
st
Stage Additional Stage
in kg (pounds)
8 0.14 (0.30)
4 0.35 (0.77)
2 0.50 (1.10)
300MCM 2.00 (4.40)
500MCM 3.08 (6.80)
6 0.41 (0.90)
2 0.54 (1.20)
1/0 1.00 (2.20)
4/0 1.54 (3.40)
10"
12"
14"
17"
21"
Table 3 Component weight chart for calculating
foundation, derrick and hoist loads
Horsepower Weight
in kg (pounds)
7-1/2 211 (465)
10 211 (465)
20 227 (500)
25 249 (550)
30 249 (550)
40 431 (950)
50 431 (950)
60 458 (1 010)
75 458 (1 010)
100 490 (1 080)
125 553 (1 220)
125 915 (2 018)
150 953 (2 100)
175 1 002 (2 210)
200 1 027 (2 265)
125 1 170 (2 580)
150 1 288 (2 840)
200 1 424 (3 140)
250 1 485 (3 273)
300 1 485 (3 273)
300 1 690 (3 725)
350 1 860 (4 100)
400 1 928 (4 250)
450 1 996 (4 400)
500 1 996 (4 400)
600 2 087 (4 600)
600 1 950 (4 300)
800 2 359 (5 200)
1 000 2 767 (6 100)
1 200 3 221 (7 100)
1 500 3 720 (8 200)
Page 20 of 68
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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04
Figure 5 Motor U-plate
Nominal
motor
size
A B C D E
8" 38.10
10" 40.64
12" 45.72
14" 50.80
21" 91.44
Table 4 Motor U-plate chart
Dimensions in cm
(inches)
(15)
(16)
(18)
(20)
(36)
0.95 +
0.32
(0.375 +
0.125)
0.95 +
0.32
(0.375 +
0.125)
1.27 +
0.32
(0.500 +
0.125)
1.27 +
0.32
(0.500 +
0.125)
1.27 +
0.32
(0.500 +
0.125)
25.40
(10)
30.48
(12)
35.56
(14)
35.56
(14)
73.66
(29)
25.40
(10)
25.40
(10)
25.40
(10)
25.40
(10)
53.34
(21)
14.61 +
0.32
(5.750 +
0.125)
18.10 +
0.32
(7.125 +
0.125)
19.05 +
0.32
(7.500 +
0.125)
24.77 +
0.32
(9.750 +
0.125)
42.57 +
0.32
(16.760
+ 0.125)
4.2.3 Personnel required
Flowserve recommends that 2 persons plus 1
crane operator perform the installation or uninstallation procedure.
4.3 Hydraulic connection
Exemplary construction of a water supply system is
depicted in Figure 6, Page 22. As this shows a basic arrangement, the actual layout must be suited
to local and technical conditions.
DANGER
All work on the hydraulic connec-
tion may only be done by qualified
fitters.
Page 21 of 68
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