Flowserve Chemstar standard User Manual

USER INSTRUCTIONS

Chemstar standard and repeller
pumps

Frame mounted, heavy-duty, centrifugal chemical process
pumps

PCN=71569185 02-10 (E) (Based on ISO-30-E.)
Original instructions.

Installation

Operation

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

CONTENTS

Page

1 INTRODUCTION AND SAFETY............................ 3

1.1 General ...........................................................3

1.2 CE marking and approvals..............................3

1.3 Disclaimer .......................................................3

1.4 Copyright.........................................................3

1.5 Duty conditions................................................ 3

1.6 Safety..............................................................4

1.7 Nameplate and safety labels...........................7

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

1.9 Noise level.......................................................8

2 TRANSPORT AND STORAGE..............................9

2.1 Consignment receipt and unpacking...............9

2.2 Handling..........................................................9

2.3 Lifting...............................................................9

2.4 Storage............................................................9

2.5 Recycling and end of product life....................9

3 DESCRIPTION ......................................................9

3.1 Configurations.................................................9

3.2 Name nomenclature........................................9

3.3 Design of major parts....................................10

3.4 Performance and operating limits ................. 10

4 INSTALLATION....................................................10

4.1 Location.........................................................10

4.2 Part assemblies.............................................10

4.3 Foundation .................................................... 11

4.4 Grouting ........................................................ 11

4.5 Initial alignment ............................................. 11

4.6 Piping ............................................................12

4.7 Final shaft alignment check ..........................15

4.8 Electrical connections ...................................15

4.9 Protection systems........................................15

5 COMMISSIONING, START-UP, OPERATION

AND SHUTDOWN ...........................................15

5.1 Pre-commissioning procedure ......................15

5.2 Pump lubricants ............................................16

5.3 Impeller clearance.........................................17

5.4 Direction of rotation.......................................17

5.5 Guarding .......................................................18

5.6 Priming and auxiliary supplies ...................... 18

5.7 Starting the pump..........................................18

5.8 Running the pump.........................................18

5.9 Stopping and shutdown (all series)...............19

5.10 Hydraulic, mechanical and electrical duty...20

6 MAINTENANCE ...................................................20

6.1 General..........................................................20

6.2 Maintenance schedule...................................21

6.3 Spare parts.....................................................22

6.4 Recommended spares...................................23

6.5 Tools required ................................................23

6.6 Fastener torques............................................24

6.7 Setting impeller clearance .............................24

6.8 Disassembly ..................................................25

6.9 Examination of parts......................................27

6.10 Assembly .....................................................27

6.11 Sealing arrangements..................................32

7 FAULTS; CAUSES AND REMEDIES...................33

8 PARTS LISTS AND DRAWINGS .........................35

8.1 Chemstar – Groups A, B and C.....................35

8.2 Chemstar – Group D......................................36

8.3 Chemstar repeller pump – Group B and C

9 CERTIFICATION..................................................40

10 OTHER RELEVANT DOCUMENTATION

– large bore repeller cover

– bolt-on stuffing box ...................................37

8.4 Chemstar repeller pump – Group B and C

– small bore repeller cover

– integral stuffing box ..................................38

8.5 Chemstar repeller pump – Group B and C

with bolt-on stuffing box – exploded view....39

8.6 General arrangement drawing.......................40

AND MANUALS................................................40

10.1 Supplementary User Instruction manuals....40

10.2 Change notes ..............................................40

10.3 Additional sources of information.................40

Page

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CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

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 and regulations.

These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow and
apply the present user instructions is considered
to be misuse. Personal injury, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.

1.2 CE marking and approvals

It is a legal requirement that machinery and equipment
put into service within 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,
temperature or duty) it is requested that the user seeks
the written agreement of Flowserve before start up.

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CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

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 products used
in potentially explosive atmospheres section 1.6.4
also applies.

NEVER DO MAINTENANCE WORK

WHEN THE UNIT IS CONNECTED TO POWER

GUARDS MUST NOT BE REMOVED WHILE

THE PUMP IS OPERATIONAL

DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.

FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoro­elastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
contact must be avoided.

HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.

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 (175 ºF) or
below -5 ºC (20 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.

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CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

1.6.4 Products used in potentially explosive

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, unless allowed by Flowserve in writing,
so that their force, due to internal pressure, acts on the
pump flange.

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

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

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.)

NEVER RUN THE PUMP DRY

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.

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 eg Ex electrical items outside the EU may
be required certified to other than ATEX eg 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 drive (VFD) can
cause additional heating effects in the motor and so,
for pump 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.

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.

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CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

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 ATEX temperature class and must not exceed the
values in the table that follows:

Temperature class

to EN13463-1

T6
T5
T4
T3
T2
T1

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

Maximum surface

temperature permitted

85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)

Temperature limit of

liquid handled *

Consult Flowserve
Consult Flowserve

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

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

The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.

Temperature classification “Tx” is used when the liquid
temperature varies and 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.

If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
contact between rotating and stationary components.

Where there is any risk of the pump being run against
a closed valve generating high liquid and casing
external surface temperatures, fit an external surface
temperature protection device.

Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, a temperature or power
monitor and make routine vibration monitoring checks.

In dirty or dusty environments, make regular checks
and remove dirt from areas around close clearances,
bearing housings and motors.

1.6.4.4 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, fit an appropriate dry run protection device
(for example liquid detection or a power monitor).

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

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CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking
and anti-static for Category 2.

To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.

Avoid electrostatic charge: do not rub non-metallic

surfaces with a dry cloth; ensure cloth is damp.
The coupling must be selected to comply with 94/9/EC

and 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

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, install a liquid detection device

1.6.4.7 Maintenance to avoid the hazard

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

For details of nameplate, see the Declaration of
Conformity, or separate documentation included with

these User Instructions.

1.7.2 Safety labels

Oil lubricated units only:

CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION

Seal Guard units only:

The responsibility for compliance with maintenance
instructions is with the plant operator.

To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions.

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CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

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.

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

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 LpA at 1 m
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.

For estimating sound power level LWA (re 1 pW) then
add 14 dBA to the sound pressure value.

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.

Motor size
and speed

kW (hp)

<0.55(<0.75) 72 72 64 65 62 64 62 64

0.75 (1) 72 72 64 66 62 64 62 64

1.1 (1.5) 74 74 66 67 64 64 62 63

1.5 (2) 74 74 66 71 64 64 62 63

2.2 (3) 75 76 68 72 65 66 63 64
3 (4) 75 76 70 73 65 66 63 64
4 (5) 75 76 71 73 65 66 63 64

5.5 (7.5) 76 77 72 75 66 67 64 65

7.5 (10) 76 77 72 75 66 67 64 65
11(15) 80 81 76 78 70 71 68 69

15 (20) 80 81 76 78 70 71 68 69

18.5 (25) 81 81 77 78 71 71 69 71
22 (30) 81 81 77 79 71 71 69 71
30 (40) 83 83 79 81 73 73 71 73
37 (50) 83 83 79 81 73 73 71 73
45 (60) 86 86 82 84 76 76 74 76
55 (75) 86 86 82 84 76 76 74 76

75 (100) 87 87 83 85 77 77 75 77

90 (120) 87 88 83 85 77 78 75 78
110 (150) 89 90 85 87 79 80 77 80
150 (200) 89 90 85 87 79 80 77 80

Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.

3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min

Pump

only

Pump and

Typical sound pressure level LpA at 1 m reference 20 µPa, dBA

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Page 8 of 44 flowserve.com

CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

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 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

To avoid distortion, the pump unit

should be lifted as shown:

A crane must be used for all pump sets in
excess of 25 kg (55 lb). Fully trained personnel must
carry out lifting, in accordance with local regulations.

The driver weight is recorded on its nameplate.

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.

3 DESCRIPTION

3.1 Configurations

The Chemstar pump is a heavy-duty chemical service
centrifugal pump that can be built to achieve many
chemical liquid pumping requirements. (See 3.2 and

3.3 below.) The exclusive external micrometer shaft
adjustment provides accurate and fast setting of
impeller clearance.

3.2 Name nomenclature

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

125X100-315

Nominal suction branch size in mm
Nominal discharge branch size in mm
Nominal maximum impeller diameter in mm
The typical nomenclature above is the general guide

to the Chemstar configuration description.

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CHEMSTAR USER INSTRUCTIONS ENGLISH 71569185 02-10

Identify the actual pump size and serial number from
the pump nameplate. Check that this agrees with the
applicable certification provided.

If it is a Chemstar pump with hydrodynamic sealing or
repeller then the pump size will be engraved on the
nameplate typically as below:

125X100M-315

M = repeller pump

3.3 Design of major parts

3.3.1 Pump casing

The pump casing is designed with a horizontal
centreline end inlet and a vertical centreline top outlet,
which makes it self venting. For ease of maintenance,
the pump is constructed so that pipe connections do not
have to be disturbed when internal maintenance is
required.

3.3.2 Impeller

An exclusive reverse vane impeller is fitted giving
important maintenance-reducing advantages. The
reverse vane impeller is set against the rear cover.
(On the hard-chrome iron material option the design
of the impeller is front open and is set against the
front of the casing.)

3.3.3 Shaft

The large diameter stiff shaft, mounted on bearings,
has a keyed drive end.

3.3.4 Bearing housing

The exclusive external micrometer shaft adjustment
bearing housing design enables quick and accurate
adjustment of impeller face clearance.

3.3.5 Pump bearings and lubrication

The pump is fitted with ball type bearings which may
be configured differently dependent on use. The
bearings may be oil or grease lubricated depending
upon the arrangement specified.

3.3.6 Rear cover

The rear cover has spigots between the pump casing
and bearing housing for optimum concentricity.

A fully confined gasket forms the seal between the
pump casing and the seal housing.

The rear cover designs provide improved performance
of mechanical seals. The design enables the optimum
sealing solution for each application to be fitted.

3.3.7 Shaft seal

The mechanical seal(s) attached to the pump shaft
seals the pumped liquid from the environment. Gland
packing may be fitted as an option.

3.3.8 Driver

The driver is normally an electric motor. Different drive
configurations may be fitted such as internal combustion
engines, turbines, hydraulic motors etc driving via
couplings, belts, gearboxes, drive shafts etc.

3.3.9 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 ambient temperature
Maximum pump speed refer to the nameplate

- 20 to + 40 ºC
(- 4 to +104 ºF)

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 located to allow room for access,
ventilation, maintenance and inspection with ample
headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped. Refer
to the general arrangement drawing for the pump set.

4.2 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.

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4.3 Foundation

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) Adjustable baseplates having stilt mount feet

have no foundation bolts securing it to the floor.
The feet are adjusted to maintain the top surface
of the baseplate level.

c) The pump and driver have been aligned before

dispatch within the permissible misalignment limits
defined in section 4.5.2, Alignment methods.

d) Where the baseplate does not have stilt mount

feet, install the baseplate onto packing pieces
evenly spaced and adjacent to foundation bolts.

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

Foundation bolts should only be fully tightened when
the grout has cured.

4.5 Initial alignment

4.5.1 Thermal expansion

The pump and motor will normally
have to be aligned at ambient temperature with an
allowance for thermal expansion at operating
temperature. (See chart.) In pump installations
involving high liquid temperatures, the unit should be
run at the actual operating temperature, shut down
and the alignment checked immediately.

Motor and pump centre line height adjustment:

e) Level with shims between baseplate and packing

pieces.

f) Check alignment of pump and motor half

coupling. If this is not correct, it indicates that the
baseplate has become twisted and should be
corrected by re-shimming.

4.4 Grouting

Where applicable, grout in the foundation bolts.
After adding pipework connections and rechecking the

coupling alignment, the baseplate should then be
grouted in accordance with good engineering practice.
Fabricated steel and cast iron baseplates can be filled
with grout. Folded steel baseplates should be grouted
to locate their packing pieces. If in any doubt, please
contact your nearest service centre for advice.

Graph based on the assumptions that:

1. Operating temperature rise of the motor frame is 50 °C (90 °F).

2. Packing piece/motor stool is not affected.

Operation

1. Enter graph at base to shaft centre line height.

2. Read line for frame material.

3. Set motor shaft and coupling LOW by figure on left-hand side.

4.5.2 Alignment methods

Pump and driver must be isolated

electrically and the half couplings disconnected.

The alignment MUST be checked.

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Angular

Although the pump will have been aligned at the factory
it is most likely that this alignment will have been
disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump to
the motor.

Alignment is achieved by adding or removing shims
under the motor feet and also moving the motor
horizontally as required. In some cases where the
alignment cannot be achieved it will be necessary to
move the pump before recommencing the above
procedure.

For couplings with narrow flanges use a dial indicator as
shown. Rotate both shafts together so that the dial
indicator probe keeps the same contact point onto the
flange during 360 degree rotation. The alignment
values are maximums for continuous service.

Parallel

Set a dial indicator as shown in sketch and loosen off
the holding down bolt while noting any deflection
reading on the dial test Indicator - a maximum of

0.05 mm (0.002 in.) is considered acceptable but any
more will have to be corrected by adding shims. For
example, if the dial test indicator shows the foot lifting

0.15 mm (0.006 in.) then this is the thickness of shim
to be placed under that foot. Tighten down and
repeat the same procedure on all other feet until all
are within tolerance

Permissible misalignment limits at working
temperature:

• Parallel alignment

- 0.25 mm (0.010 in.) TIR maximum

• Angular alignment

- 0.3 mm (0.012 in.) TIR maximum for couplings
not exceeding 100 mm (4 in.) flange diameter

- 0.5 mm (0.020 in.) TIR maximum for couplings
over 100 mm (4 in.) diameter

When checking parallel alignment, the total indicator
read-out (TIR) shown is twice the value of the actual
shaft displacement.

Align in the vertical plane first, then horizontally by
moving motor. Maximum pump reliability is obtained by
near perfect alignment of 0.05 - 0.075 mm (0.002 -

0.003 in.) parallel and 0.05 mm (0.002 in.) per 100 mm
(4 in.) of coupling flange diameter as angular
misalignment.

4.5.3 Check for soft foot

This is a check to ensure that there is no undue
stress on the driver holding down bolts; due to non­level baseplate or twisting. To check, remove all
shims and clean surfaces and tighten down driver to
the baseplate.

Complete piping as below and see section 4.7,
Final shaft alignment check up to and including section
5, Commissioning, startup, operation and shutdown,
before connecting driver and checking actual rotation.

4.6 Piping

Protective covers are fitted to the pipe
connections to prevent foreign bodies entering during
transportation and installation. Ensure that these
covers are removed from the pump before connecting
any pipes.

4.6.1 Suction and discharge pipework

In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose
pipework that is one or two sizes larger than the
pump suction and discharge. Typically main
pipework velocities should not exceed 2 m/s (6 ft/sec)
suction and 3 m/s (9 ft/sec) on the discharge.

Take into account the available NPSH which must be
higher than the required NPSH of the pump.

Never use pump as a support for
piping.

Maximum forces and moments allowed on the pump
flanges vary with the pump size and type. To minimize
these forces and moments that may, if excessive, cause
misalignment, hot bearings, worn couplings, vibration
and the possible failure of the pump casing, the
following points should be strictly followed:

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• Prevent excessive external pipe load

• Never draw piping into place by applying force to

pump flange connections

• Do not mount expansion joints so that their force,
due to internal pressure, acts on the pump flange

Ensure piping and fittings are flushed

before use.

Ensure piping for hazardous liquids is arranged

to allow pump flushing before removal of the pump.

4.6.2 Suction piping

a) The inlet pipe should be one or two sizes larger

than the pump inlet bore and pipe bends should
be as large a radius as possible.

b) On suction lift the piping should be inclined up

towards the pump inlet with eccentric reducers
incorporated to prevent air locks.

c) On positive suction, the inlet piping must have a

constant fall towards the pump.

d) The pipe next to the pump should be the same

diameter as the pump suction and have a minimum
of two pipe diameters of straight section between
the elbow and the pump inlet flange. Where the
NPSH margin is not large, it is recommended that
the straight pipe is 5 to 10 times the pipe diameter.
(See section 10.3, Reference 1.) Inlet strainers,
when used, should have a net 'free area' of at least
three times the inlet pipe area.

e) Fitting isolation and non-return valves will allow

easier maintenance.

f) Never throttle pump on suction side and never

place a valve directly on the pump inlet nozzle.

4.6.3 Discharge piping

A non-return valve should be located in the discharge
pipework to protect the pump from excessive back
pressure and hence reverse rotation when the unit is
stopped.

Fitting an isolation valve will allow easier maintenance.

4.6.4 Auxiliary piping

c) Always stagger the end gaps of the packing by

90 degrees apart to ensure the best seal.

d) To speed installation of each ring, have an

assistant turn the pump shaft in the correct
direction. This movement will tend to draw the

rings into the stuffing box.
e) Lightly tighten the gland.
f) Final adjustments are covered in section 5.8,

Running the pump.
g) When suction pressure is below ambient

pressure and stuffing box head over total suction

head is less than 10 m (33 ft), it may be

necessary to feed gland packing with compatible

liquid to the pumpage to provide lubrication and

prevent the ingress of air. This is to be added

through tap V shown above. The pressure of the

feed liquid should be at least 1 bar (14.5 psi)

above the stuffing box pressure, regulated to a

flow rate of 0.25 to 0.5 m3/h (1 to 2 USgpm). At

lower speeds, grease lubrication may be used

when compatible with the pumpage. In non-

abrasive applications, where the pumpage itself

is sufficient to lubricate the packing without an

external pipeline, tap V should be plugged.
h) When a special abrasive liquid packing

arrangement is specified, the installation

procedures are the same as the standard packing

with the following exceptions. The special lip seal

is installed first, followed by two seal cage

assemblies, then two of the packing rings provided

as shown below. An external compatible liquid

source line should be connected to tap V, in the top

of the stuffing box.

The connections that are to be piped
up will have been fitted with protective metal or
plastic plugs which will need to be removed.

4.6.4.1 Pumps fitted with packed glands

a) Packing is to be fitted before use.
b) A temporary PTFE lip seal may have been

installed against the face of the stuffing box for
shipping. If so, discard this lip seal and slide the
packing rings [4130] and lantern ring [4134] into
the stuffing box in the order shown.

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Chemstar repeller pump only

In Chemstar pumps fitted with a repeller and with
dry running gland packing as secondary sealing
the packing is factory installed.

In some applications to limit the gland packing
fouling, Chemstar repeller pumps could possibly
have a 0.25 to 0.5 m³/h external clean compatible
liquid flush injected into the stuffing box at 5 to 10 m
head above ambient pressure prior to start up and
prior to shut down.

4.6.4.2 Pumps fitted with mechanical seals

The Seal Sentry design of the anti-vortex single
internal rear cover provides excellent liquid circulation
around the seal and will not normally require a
separate flush.

Single seals requiring flush by re-circulation of pumped
liquid will normally be provided with the auxiliary piping
from pump casing already fitted. (Where an external
compatible flush is specified, the piping to the pump is
the responsibility of the pump installer.)

Rear covers with an auxiliary quench connection
require connection to a suitable source of liquid, low
pressure steam or static pressure from a header tank.
Recommended pressure is 0.35 bar (5 psi) or less.

Double seals require a barrier liquid between the
seals, compatible with the pumped liquid.

With back-to-back double seals, the barrier liquid should
be at a minimum pressure of 1 bar (15 psi) above the
maximum pressure on the pump side of the inner seal
and at least 1 bar (15 psi) above ambient external
pressure. The barrier liquid pressure must not exceed
limitations of the seal on the atmospheric side.

For toxic service the barrier liquid supply and
discharge must be handled safely and in line with
local legislation.

Seal chamber pressure:

Mechanical

seal

Gland

packing

Use seal manufacturer's limits or ask seal

manufacturer to verify seal pressure

Maximum stuffing box pressure =

5 bar (3 500 r/min), 7 bar (2 900 r/min)

and 10 bar (1 450 and 1 750 r/min)

Special seals may require different auxiliary piping to
that described above. Consult separate User
Instructions and/or Flowserve if unsure of correct
method or arrangement.

For pumping hot liquids, to avoid seal damage, it is
recommended that any external flush/cooling supply
be continued after stopping the pump.

4.6.4.3 External recirculation and flush for
pumps fitted with repeller

Only dry running single mechanical seals or packing
arrangement approved by Flowserve must be used.
(Refer to section 8.3.) In some applications, to keep
seal faces clean, pumps could possibly have a 0.25
to 0.5 m3/h external clean compatible liquid flush
injected into the seal cavity at 5 to 10 m head above
atmospheric pressure prior to start up and prior to
shut down. The Chemstar repeller chamber can
have an auxiliary recirculation connection back to the
suction side pipe.

Customers should always seek instructions from
Flowserve if the pump is not supplied with the
optional recirculation line or external flush and if it is
planned to install these later.

4.6.4.4 Pumps fitted with heating/cooling jackets

Connect the heating/cooling pipes from the site
supply. The top connection should be used as the
outlet to ensure complete filling/venting of the jacket
unless the heating medium is steam, when the
bottom connection should be used as the outlet.

4.6.5 Final checks

Check the tightness of all bolts in the suction and
discharge pipework. Check also the tightness of all
foundation bolts.

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