Experience In Motion
Flowserve Circulator
Instruction,Operation and
Maintenance Manual
Table of Contents
Section
A Installation, Start-up and Maintenance
1. Introduction
2. Installation
3. Start-up
3.4 Pressure control valve adjustment
3.5 Pressure relief valve reset procedure
4. Maintenance
5. Troubleshooting
B Piping and Instrumentation Diagram
C Kit Installation Instruction
1. Pressure switch
2. Accumulator
3. Level switch
4. Heat exchanger
5. Pressure gauge
D Customer Drawings
Section A: Installation, Start-up and Maintenance
2.3 Foundation/placement
1 Introduction
1.1 This manual is a valuable tool covering the circulator
you have purchased.
1.2 Do not proceed with installation or operation until you
have read and understand this manual.
1.3 Following is a step-by-step approach covering installation, start-up, operation and maintenance of the
circulator.
1.4 Familiarize yourself with and refer to the circulator
drawing (Section B). Item numbers referred to in this
manual can be found on this drawing. Order specic
drawings can be found in Appendix 1.
1.5 The circulator purchased includes only the kit options
shown on these drawings. Additional kits are available
as described in Section C.
2.3.1 The foundation (customer steel base or con-
crete pad) for the circulator should be at and
level, with anchor bolts set rmly in place.
A foundation weight of not less than 3 times
the weight of the circulator (when lled with
barrier uid) is recommended as a minimum
for concrete foundations. Steel baseplates
shall have sufcient rigidity to prevent distort-
ing the circulator after bolt down.
2.3.2 The foundation must be free of all debris prior
to placement of the circulator.
2.3.3 The circulator reservoir is fabricated such that
the top is level. Gently lower the circulator
onto the foundation and check to see if the
level is maintained. If required, shim mounting
feet level before bolting the circulator down.
Mounting bolts should be torqued per manu-
facturer’s specications.
2.4 Interconnecting piping/tubing
2 Installation
2.1 Location
2.1.1 Circulator location and ambient temperature
extremes must be taken into account. All inter connecting piping/tubing must be thermally
protected to insure a continuous ow of barrier
uid.
2.1.2 Shading the circulator from direct sunlight is
recommended.
2.1.3 Installation must take place during a time when
ambient temperatures are above freezing or
with all uid lines protected from damage.
2.1.4 Follow notes listed on the circulator order
drawings, in Appendix 1, covering utility require ments and control component points.
2.2 Lifting/uncrating
2.2.1 Remove the crating carefully to avoid damag ing components.
2.2.2 The circulator must be lifted only from the bottom
or by the lifting lugs when provided. Lift carefully
2
to avoid damaging circulator components.
2.4.1 Definition: Interconnecting piping/tubing is all
uid piping/tubing between the circulator and
the process equipment.
2.4.2 Piping/tubing should be installed to meet local
codes or other applicable standards.
2.4.3 The interconnecting piping/tubing system
should be sized and constructed to minimize
pressure losses and should not be less
than the corresponding pipe/tube size and
schedule as contained in the circulator (refer
to the piping and instrumentation diagram of
pipe size, schedule and material).
2.4.4 The interconnecting piping/tubing system,
both to and from the seal, should be construct ed of similar material as the circulator.
2.4.5 Piping/tubing must not be supported by the
circulator.
2.4.6 Before installing, the piping/tubing system
should be checked for freedom from contami nation. If not completely free of contaminants,
clean and ush the entire interconnecting
piping/tubing system before connecting the cir culator. Once you are sure the piping/tubing
system is free of contamination, drain the
ushing media and air blow dry.
Do not, under any circumstances, use the circulator to
flush the interconnecting piping/tubing. Using the circulator to flush the interconnecting piping/tubing will
void the warranty. The circulator is flushed clean and
sealed at the factory.
It is the customer’s responsibility to familiarize them-
selves with the instrumentation and controls mounted
on the circulator. The customer’s supplied control
panel shall at minimum provide the functions listed
and as described on the circulator drawings.
2.4.7 Connections to circulator: A teon paste pipe
sealant is recommended and should be applied
no closer than two threads from the end of the
tting to avoid contamination.
2.4.7.1 Do not remove plugs from ports until
you are ready to make a nal connec-
tion.
2.4.7.2 Refer to the circulator drawings in
Section B for connections to be made.
3 Start-up Operation
3.1 Initial start-up
3.1.1 Check all eld connections in piping/tubing to
see that the joints are tight. Also check and
tighten circulator fasteners, which may have
become loose during transit.
3.1.2 Verify the correct barrier uid type with the seal
manufacturer before lling. Fill the reservoir to
the top of the level gauge through the ller port
provided.
3.1.3 The pump/motor assembly does not require
alignment.
3.1.4 Before connecting the motor power source.
Disengage the pump/motor coupling. Connect
the motor power source. Jog the motor (3-5
seconds) to check rotation against the rotation
arrows. Reconnect the pump/motor coupling.
Replace the coupling guard cover plate.
3.2 All instruments must be tied into the customer’s
control panel to operate the main process equipment. Functions listed on the circulator drawings
are the minimum requirements necessary to insure
proper operation. The manufacturer may place more
stringent requirements on sequencing of the main
process equipment. It is recommended the customer
contact the seal manufacturer to obtain a list of all
operational sequences and interlocks to insure safe
and efcient operation.
3.3 This circulator is equipped with a Pressure Relief
Valve (PRV-1) and a Pressure Control Valve (PCV-1).
The pressure relief valve on the right end of the manifold is factory set at and should never be adjusted.
The pressure contol valve on the left end of the manifold is factory set and will need adjustment to meet the
requirements of the application. The pressure control
valve can be adjusted using the following procedure
and referring to the manufacturers service manual in
Appendix 2 of this manual.
3.4 Pressure control valve adjustment
The pressure control valve located on the left end of the
manifold is factory set at 200 psig (1379 kPa) and will need
adjustment to meet the requirements of the application.
Follow these steps to adjust the pressure control valve.
3.4.1 The uid temperature in the circulator must be
at the normal operating temperature to achieve
the correct pressure setting.
3.4.2 To prevent accidental over pressurization of the
seal, connect the seal supply port directly to
the seal return port, bypassing the seal. This
will protect the seal from high pressures during
valve adjustment.
3.4.3 Completely open the pressure control valve
on the left end of the manifold.
3.4.4 Start the circulator and allow to run long
enough to remove any air from the system. All
uid ow should be through the pressure con-
trol valve, through the heat exchanger and
back into the reservoir.
3.4.5 Slowly close the pressure control valve on
the left end of the manifold until the desired
system pressure is achieved.
3.4.6 Shut down the circulator and return any piping
to its original, normal operating conguration.
The pressure control valve is now set to the
proper pressure.
3
3.5 Pressure relief valve reset procedure
4.2 Service of suction strainers
The pressure relief valve on the right end of the manifold is factory set at 450 psig (3103 kPa) and should
not require adjustment. If however, the relief valve setting
has become suspect or the seal requires a lower setting,
follow these steps to reset the pressure relief valve. Do not
exceed 450 psig (3103 kPa).
3.5.1 To prevent accidental over pressurization of
the seal, connect the seal supply port directly
to the seal return port. This will protect the
seal from high pressures during valve adjust ment.
3.5.2 Completely close the pressure control
valve on the left end of the manifold.
3.5.3 Completely open the pressure relief valve on
the right end of the manifold.
3.5.4 Start the circulator and allow to run long
enough to remove any air from the system. All
uid ow should be through the pressure relief
valve and into the reservoir.
To service the suction strainer, the circulator pump must
be shut off. Make sure the circulator motor cannot be auto
started. Remove top plate of reservoir. Strainers should be
checked and cleaned every 12 months.
4.3 Customer electrical
It is the customer’s responsibility to provide a control panel
to properly operate the circulator.
4.4 Pressure lter
4.4.1 Caution: Do not attempt to open any lines,
loosen ttings or remove lter canister unless
all pressure gauges read zero pressure.
Be sure that instrument isolation valves are
open to gauges. Always wear safety goggles
with side shields when performing mainte-
nance or making adjustments to the system.
4.4.2 After 8 hours of initial start-up or sooner
per clogging indicator, the lter element
should be changed.
3.5.5 Carefully close the pressure relief valve on the
right end of the manifold until the desired pres sure is maintained in the system.
3.5.6 Shut down the circulator. The pressure relief
valve is now set at and will not need further
adjustment. Higher adjustment of the pressure
relief valve may cause damage to the pump.
3.5.7 Once the pressure relief valve is set, reset the
pressure control valve setting. Refer to the
previous section of this document.
4 Maintenance
Caution: Do not attempt to work on this system unless
you have on safety glasses with side shields
and you have completely read and understand
this service manual.
4.4.3 Change element every time the clogging indi-
cator on the lter is in the red service lter
position.
4.5 Questions
Do not hesitate to contact your Flowserve representative
with any questions you have concerning the installation,
operation or maintenance of the circulator.
4.1 Electrical/power input
Shut down all electrical power to the circulator prior to
attempting maintenance.
4
5 Troubleshooting
Problem Probable Cause
Unable to maintain Pressure Low pressure control valve setting: Follow the procedure in this document to
(Low Pressure) adjust the valve as required.
Low pressure relief vale setting: Fluid is bypassing the through the valve and
returning to the tank. Follow the procedure in this document to adjust the
valve as required.
Unable to maintain Pressure High pressure control valve setting: Follow the procedure in this document to
(High Pressure) adjust the valve as required.
Low Temperature/High Viscosity: Low temperature can cause the barrier uid
to have a too high of viscosity, creating high pressure loss on the seal supply
and return lines. Insulate line to maintain temperature.
Poor supply and return line piping: The supply and return line piping should be
sized and constructed to eliminate as much pressure loss as practical.
Unable to maintain Flow Low pressure relief vale setting: Follow the procedure in this document to adjust
the valve as required.
Worn Pump: If the circulator pump wears the discharge ow rate will decrease.
This will be more apparent at higher pressures. Measure the ow rate at normal
operating pressure and again at 1/2 normal operating pressure. If the
ow increases more than 20% then the pump may need to be replaced.
Note: pump wear can be accelerated by poor quality barrier uid and/or failure
to maintain system ltration, and prevent ingression.
5
Section B: Piping and Instrumentation Diagram
Customer specific drawings can be found in Appendix 1.
Key
Optional pressure switch kit
(UKDPU9802)
Optional accumulator kit
(UKDPU9806)
Test Port
RV-1 Factory set at 450 psig (3103 kPa)
PCV-1 Factory set at 200 psig (1379 kPa)
Reset PCV-1 as required
PS
1
PS-1
A
1-1/4"
CV-1
B
1/4"
C
1/2"
1
Supply
RV-1
P
CV-2
2
Return
Pl
1
PCV-1
PI-1
contained in
manifold block
contained in
optional kit
Optional heat exchanger kit
(UKDPU9806)
H
5/8"
1/2"
6
7
Pl
2
Optional level switch kit
(UKDPU9805)
LS
1
LG
1
Tl
1
3/4"
5/8"
1"
1/2"
4
1/2"
5
3/4"
3
Schedule of connections
connection size service
1
2
3 3/4" NPT drain (plugged)
4
5
6
7
1
/
2" NPT seal supply
1
/
2" NPT seal return
1
/
2" NPT cooling water supply (plugged)
1/2
"
NPT cooling water return (plugged)
3
/
8" NPT cooling water supply (option)
3
/
8" NPT cooling water return (option)
6
Section C: Kit Installation Instructions
Seal Support System
Part No.
Part No.
PSI
to
to
Xxxxxxx
Xxxxxxx Xxxxx Xxxx Xx
Xxxxx xx xxxxxxxxx
Xxxxx xx xxxxxxxxxxx
Xxxxxx
Xxxx Xx.
Xxxx xxxxxx xxxx
xxxxxxxx xx xxxx
xxxxxx xxxxxxxxx
xxxxxx xxxxxxxxx
Available kit options
Option 1: Pressure switch
Part code UKDPU9802
Option 2: Safety feature (accumulator)
Part code UKDPU9803
Option 3: Level switch
Part code UKDPU9805
Option 4: External heat exchanger
Part code UKDPU9806
3. Thread 1/2” side of adapter into pressure switch nger
tight.
4. Place an open end wrench on the ball valve and an
open end wrench on the pressure switch connection
nut. Tighten connection until ball valve handle is facing
the pressure switch adjustment cover. Do not over
tighten.
5. Apply Teon tape and/or Jomar pipe dope or equal
to the ball valve threads. Start no closer to the end of
the treads than the 2nd thread.
6. Clean any dirt or debris from the 1/4” NPT connection
on the bottom of the manifold block. Remove the 1/4”
NPT plug from the bottom of the manifold block.
Before installing any kit to the circulator, it must be shut
down and disconnected from the main power source. Safety glasses with side shields must be worn when working
on the unit. Clean the unit of all debris. Familiarize yourself
with these instructions and the components for each kit
before beginning any installation.
Option 1
The pressure switch kit includes:
• 1/4” NPT ball valve
• 1/4” x 1/2” NPT adapter
• Pressure switch, 1/2” NPT
Kit installation instructions
1. Apply Teon tape and/or Jomar pipe dope or equal to
adapter threads. Start no closer to the end of the
threads than the 2nd thread.
2. Thread 1/4” side of adapter into ball valve nger tight.
7. Thread the pressure switch assembly into the mani-
fold block nger tight.
8. Place an open end wrench on the ball valve and
tighten into the manifold block. Tighten connections
until ball valve handle is facing away from the
circulator. Do not over tighten. See Figure 1.
9. Rotate the ball valve handle to the off position. Ball
valve is off when handle is rotated 90° to the ball valve
ports.
10. Installation is complete.
11. It is the responsibility of the customer to wire and set
the pressure switch.
12. The pressure switch can be put into service once the
unit is restarted and the customer has veried the
circulator is running normal. Rotate the ball valve
handle 90° to allow ow to the switch.
Figure 1
ball valve
adapter
pressure
switch
7
Option 2
Seal Support System
Part No.
Part No.
PSI
to
to
Xxxxxxx
Xxxxxxx Xxxxx Xxxx Xx
Xxxxx xx xxxxxxxxx
Xxxxx xx xxxxxxxxxxx
Xxxxxx
Xxxx Xx.
Xxxx xxxxxx xxxx
xxxxxxxx xx xxxx
xxxxxx xxxxxxxxx
xxxxxx xxxxxxxxx
The safety feature kit includes:
• Accumulator, 1-1/4” NPT
• 1-1/4” NPT pipe nipple
• 1/4” tubing and tube ttings
Kit Installation Instructions:
1. Apply Teon tape and/or Jomar pipe dope or equal to
1-1/4” pipe nipple threads. Start no closer to the end
of the threads than the 2nd thread.
2. Thread pipe nipple into the accumulator nger tight.
3. Clean any dirt or debris from the 1-1/4” NPT connec-
tion on the top of the manifold block. Remove the
1-1/4” NPT plug from the top of the manifold block.
4. Thread the nipple/accumulator assembly into the
manifold block. Tighten assembly until the 1/4” NPT
connection in the accumulator is facing the front of the
manifold block. With wrench placed on the connection
end of the accumulator tighten assembly. Do not over
tighten. See gure 2.
13. Hold tubing into position and tighten each nut with a
wrench until tight. Do not over tighten.
14. Clean any dirt or debris from cartridge connections.
Remove cartridge plugs from manifold block.
See Figure 2.
15. Do not use Telfon tape or pipe dope on cartridge
valves.
16. Insert and nger tighten the needle valve cartridge
into the cavity on the front of the manifold block.
17. Insert and nger tighten the check valve cartridge into
the bottom of the manifold block.
18. Insert and nger tighten the check valve cartridge into
the top of the manifold block.
19. Tighten valves with open-end wrench or socket
wrench. Do not over tighten.
20. Installation is complete.
5. Clean any dirt or debris from the 1/4” NPT connection
on the top of the manifold block. Remove the 1/4” NPT
plugs from the and accumulator and the top of the
manifold block.
6. Apply Teon tape and/or Jomar pipe dope or equal to
tube tting NPT threads. Start no closer to the end of
the threads than the 2nd thread.
7. Thread tube ttings into the accumulator and manifold
block. Tighten into accumulator and manifold block.
Do not over tighten. See Figure 2.
8. Remove tube tting nut and ferrule.
9. Insert tubing into ttings on accumulator and manifold
block. Verify tubing ends are the correct length. Cut to
t if required. Proceed to the next step once tubing is
the correct length.
10. Slide tube tting nut and ferrule onto each end of
tubing.
11. Insert tubing into ttings on accumulator and block
manifold.
12. Slide tting nuts into place and nger tighten.
21. It is the customer’s responsibility to pre-charge the
accumulator.
Figure 2
accumulator
tubing and
ttings
nipple
needle
valve
check
valve
pilot to
open
check
valve
8
Option 3
Seal Support System
Part No.
Part No.
PSI
to
to
Xxxxxxx
Xxxxxxx Xxxxx Xxxx Xx
Xxxxx xx xxxxxxxxx
Xxxxx xx xxxxxxxxxxx
Xxxxxx
Xxxx Xx.
Xxxx xxxxxx xxxx
xxxxxxxx xx xxxx
xxxxxx xxxxxxxxx
xxxxxx xxxxxxxxx
xxxxx
The level switch kit includes:
• Level switch, 3/4” NPT
Kit Installation Instructions
1. Apply Teon tape and/or Jomar pipe dope or equal
to level switch threads. Start no closer to the end of the
threads than the 2nd thread.
Option 4
The heat exchanger kit includes:
• Heat exchanger
• Heat exchanger mounting brackets
• U-bolts with nuts and mounting pad (quantity 2)
• Tube ttings (quantity 3)
• Tubing (quantity 3)
Kit Installation Instructions
2. Clean any dirt or debris from the reservoir connection.
Remove 3/4” plug from reservoir coupling next to the
level gauge.
3. Thread in level switch. Tighten with ats on the shaft in
the vertical position. See gure 3.
4. Installation is complete.
5. It is the responsibility of the customer to wire the level
switch.
Figure 3
1. Apply Teon tape and/or Jomar pipe dope or equal to
the 4 tube ttings threads. Start no closer to the end of
the threads than the 2nd thread.
2. Remove tubing from the manifold block to the lter
and discard.
3. Attach heat exchanger mounting brackets with two (2)
1/2” 13 mounting bolts through the holes provided in
the top of the manifold block and nger tighten bolts.
See Figure 4.
4. Place a mounting pad on each mounting bracket
between the mounting holes.
5. Place the heat exchanger on the mounting pads. Shell
connection should be facing up with the cooling media
connections facing the drain side of the reservoir. See
Figures 4 and 5.
6. Install the U-bolts over the heat exchanger and
through the mounting pads and brackets and nger
tighten nuts.
level switch shaft position
7. Install and tighten tube ttings into the heat exchanger
shell connections. Do not over tighten.
8. While facing the unit from the block side, position the
heat exchanger approximately 4-1/2 inches (114 mm)
from the right side of the reservoir. See Figure 4.
9. Level the heat exchanger across the cooling media
ports. See gure 5.
10. Remove the tting nuts and ferrules from the ttings
on the left side of the heat exchanger and the mani-
fold block. Assemble the short piece of tubing, 90°
union tube tting and the short 90° bent tube into the
heat exchanger and the manifold block.
11. Verify tubing ends are the correct length. Cut to t if
required. Proceed to the next step once tubing is the
correct length.
9
12. Slide tting nuts into place and nger tighten.
13. Remove the tting nuts and ferrules from the ttings
on the right side of the heat exchanger and the lter.
Slide them onto the “L” shaped tubing.
19. Hold tubing into position and tighten each nut with a
wrench until tight. Do not over tighten.
20. Disconnect the existing cooling media lines from the
reservoir’s internal heat exchanger.
14. Insert the “L” shaped tube into the right side of the heat
exchanger and the lter. Verify tubing ends are the
correct length. Cut to t if required. Proceed to the next
step once the tubing is the correct length.
15. Slide tube tting nut and ferrule onto each end of the
tubing.
16. Insert tubing into the ttings on the heat exchanger
and lter.
17. Slide tting nuts into place and nger tighten.
18. Square the mounting brackets with the manifold block.
See Figure 4. Tighten the mounting bolts and the U-
bolt nuts. Do not over tighten.
Figure 4
21. Apply Teon tape and/or Jomar pipe dope or equal to
the 1/2” NPT plug threads. Start no closer to the end
of the threads than the 2nd thread.
22. Thread the plugs into the reservoir’s internal heat
exchanger and tighten. Do not over tighten.
23. Installation is complete.
24. It is the responsibility of the customer to connect to the
heat exchanger cooling media ports.
Note: For additional cooling capacity run cooling media
through both the internal and external cooling coils
in series.
Figure 5
mounting
bracket
heat
exchanger
10
cooling port
orientation
mounting
bracket
4.50"
tubing and
ttings
Section D: Customer Drawings
Note: The following documents are typically provided as
part of the order documentation package along with
this IOM.
Appendix 1: Order Drawings
- Piping and Instrumentation Diagram
- General Arragement
- Bill of Material
- Electrical
Appendix 2: Component Information
- Catalog
- Component IOMs
11
TO REORDER REFER TO
flowserve. co m
USA and Canada
Tulsa, Oklahoma, USA
Telephone: 1 918 599 6062
Telefax: 1 918 583 1071
Europe, Middle East, Africa
Roosendaal, the Netherlands
Telephone: 31 165 581400
Telefax: 31 165 554590
Asia Pacific
Singapore
Telephone: 65 6544 6800
Telefax: 65 6214 0541
Latin America
Mexico City
Telephone: 52 55 5567 7170
Telefax: 52 55 5567 4224
B/M #
F.O
.
FIS187eng ORG 4/10 Printed in USA
To find your local Flowserve representative
and find out more about Flowserve Corporation,
visit www.flowserve.com
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When
properly selected, this Flowserve product is designed to perform its intended function safely during its useful life.
However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used
in numerous applications under a wide variety of industrial service conditions. Although Flowserve can provide
general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user
must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and
maintenance of Flowserve products. The purchaser/user should read and understand the Installation Instructions
included with the product, and train its employees and contractors in the safe use of Flowserve products in connection
with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for
informative purposes only and should not be considered certified or as a guarantee of satisfactory results by reliance
thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any
matter with respect to this product. Because Flowserve is continually improving and upgrading its product design,
the specifications, dimensions and information contained herein are subject to change without notice. Should any
question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of
its worldwide operations or offices.
© Copyright 2010 Flowserve Corporation
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