Flowserve Circulator User Manual
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
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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.
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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.
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