Flowserve CPXS User Manual
USER INSTRUCTIONS
CPXS, CPXNS and CPXPS
Installation
Operation
Frame mounted, modular design, centrifugal, chemical
process pumps with magnetic drive
PCN=71569250 07-11 (E) (Based on C957KH025 and
C957KH049.) Original instructions.
Maintenance
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
CONTENTS
Page
1 INTRODUCTION AND SAFETY........................4
1.1 General .........................................................4
1.2 CE marking and approvals ...........................4
1.3 Disclaimer .....................................................4
1.4 Copyright.......................................................4
1.5 Duty conditions .............................................4
1.6 Safety............................................................5
1.7 Nameplate and safety labels ........................ 9
1.8 Specific machine performance......................9
1.9 Noise level ....................................................9
2 TRANSPORT AND STORAGE........................10
2.1 Consignment receipt and unpacking .......... 10
2.2 Handling......................................................10
2.3 Lifting...........................................................10
2.4 Storage........................................................ 11
2.5 Recycling and end of product life................ 11
3 DESCRIPTION ................................................11
3.1 Configurations.............................................12
3.2 Name nomenclature....................................12
3.3 Design of major parts..................................12
3.4 Performance and operating limits...............12
4 INSTALLATION................................................ 13
4.1 Location ......................................................13
4.2 Part assemblies ..........................................13
4.3 Foundation..................................................13
4.4 Grouting ......................................................13
4.5 Initial alignment...........................................13
4.6 Piping..........................................................14
4.7 Electrical connections .................................18
4.8 Final shaft alignment check ........................18
4.9 Protection systems......................................18
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN ...........................................19
5.1 Pre-commissioning procedure....................19
5.2 Pump lubricants ..........................................20
5.3 Open impeller clearance.............................21
5.4 Direction of rotation.....................................21
5.5 Guarding .....................................................21
5.6 Priming and auxiliary supplies....................21
5.7 Starting the pump........................................21
5.8 Running the pump.......................................22
5.9 Stopping and shutdown ..............................23
5.10 Hydraulic, mechanical and electrical duty ..23
6 MAINTENANCE............................................... 23
6.1 General.......................................................23
6.2 Maintenance schedule................................ 24
6.3 Spare parts.................................................. 25
6.4 Recommended spares................................ 25
6.5 Tools required ............................................. 25
6.6 Fastener torques......................................... 26
6.7 Setting impeller clearance .......................... 26
6.8 Disassembly ............................................... 26
6.9 Examination of parts...................................28
6.10 Magnets......................................................29
6.11 Assembly .................................................... 29
7 FAULTS; CAUSES AND REMEDIES .............. 32
8 PARTS LISTS AND DRAWINGS..................... 34
8.1 CPXS – frame mounted – coated shaft –
PEEK shell.................................................. 34
8.2 CPXS – frame mounted – sleeved shaft –
PEEK shell.................................................. 35
8.3 CPXS – frame mounted – coated shaft –
dual containment ........................................ 36
8.4 CPXS – frame mounted – sleeved shaft –
dual containment ........................................ 37
8.5 CPXS – frame mounted – coated shaft –
metal shell................................................... 38
8.6 CPXS – frame mounted – sleeved shaft –
metal shell................................................... 39
8.7 CPXPS – frame mounted – coated shaft –
PEEK shell.................................................. 40
8.8 CPXPS – frame mounted – sleeved shaft –
PEEK shell.................................................. 41
8.9 CPXPS - auxiliary connection points..........42
8.10 CPXS - parts interchangeability.................. 43
8.11 General arrangement drawing.................... 44
9 CERTIFICATION ............................................. 44
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ....................................................... 44
10.1 Supplementary User Instruction manuals... 44
10.2 Change notes ............................................. 44
10.3 Additional sources of information ............... 44
Page
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
INDEX
Page
Additional sources (10.3).........................................44
Alignment of shafting (4.3, 4.5 and 4.7)
Assembly (6.11).......................................................29
ATEX marking (1.6.4.2) .............................................7
Bearing sizes and capacities (5.2)...........................20
CE marking and approvals (1.2)................................4
Certification (9) ........................................................44
Change notes (10.2)................................................44
Clearances, impeller (6.7) .......................................26
Commissioning and operation (5)............................19
Compliance, ATEX (1.6.4.1)......................................6
Configurations (3.1) .................................................12
Copyright (1.4)...........................................................4
Design of major parts (3.3)......................................12
Direction of rotation (5.4) .........................................21
Disassembly (6.8)....................................................26
Disclaimer (1.3).......................................................... 4
Dismantling (6.8, Disassembly)...............................26
Drawings (8) ............................................................34
Duty conditions (1.5)..................................................4
Electrical connections (4.7) .....................................18
End of product life (2.5) ...........................................11
Examination of parts (6.9) .......................................28
Fastener torques (6.6) .............................................26
Faults; causes and remedies (7).............................32
Foundation (4.3) ......................................................13
General arrangement drawing (8.11) ...................... 44
General assembly drawings (8)...............................34
Grouting (4.4)........................................................... 13
Guarding (5.5).......................................................... 21
Handling (2.2) ..........................................................10
Hydraulic, mechanical and electrical duty (5.10).....23
Impeller clearance (5.3 and 6.7)
Inspection (6.2.1 and 6.2.2).....................................24
Installation (4) ..........................................................13
Lifting (2.3)...............................................................10
Location (4.1)...........................................................13
Lubrication (5.1.1, 5.2 and 6.2.3)
Lubrication schedule (5.2.3)....................................20
Magnets (6.10)......................................................... 29
Maintenance (6).......................................................23
Maintenance schedule (6.2)....................................24
Name nomenclature (3.2)........................................12
Nameplate (1.7.1)......................................................9
Operating limits (3.4.1) ............................................12
Ordering spare parts (6.3.1)....................................25
Page
Part assemblies (4.2)............................................... 13
Parts lists (8)............................................................ 34
Performance (3.4).................................................... 12
Piping (4.6) .............................................................. 14
Pre-commissioning (5.1) ......................................... 19
Priming and auxiliary supplies (5.6) ........................ 21
Protection systems (4.9).......................................... 18
Reassembly (6.11, Assembly)................................. 29
Receipt and unpacking (2.1) ................................... 10
Recommended fill quantities (5.2.2)........................ 20
Recommended oil lubricants (5.2.1)........................ 20
Recommended spares (6.4).................................... 25
Recycling (2.5)......................................................... 11
Replacement parts (6.3 and 6.4)............................. 25
Running the pump (5.8)........................................... 22
Safety action (1.6.3) .................................................. 5
Safety markings (1.6.1) ............................................. 5
Safety, protection systems (1.6 and 4.9)
Sectional drawings (8).............................................34
Setting impeller clearance (6.7)............................... 26
Sound pressure level (1.9, Noise level)..................... 9
Sources, additional information (10.3)..................... 44
Spare parts (6.3)...................................................... 25
Specific machine performance (1.8).......................... 9
Starting the pump (5.7)............................................ 21
Stop/start frequency (5.8.3).....................................22
Stopping and shutdown (5.9) .................................. 23
Storage, pump (2.4)................................................. 11
Storage, spare parts (6.3.2) .................................... 25
Supplementary manuals or information sources.....44
Supplementary User Instructions (10.1).................. 44
Thermal expansion (4.5.1) ...................................... 13
Tools required (6.5) ................................................. 25
Torques for fasteners (6.6)......................................26
Trouble-shooting (7) ................................................ 32
Vibration (5.8.2).......................................................22
Safety labels (1.7.2)................................................... 9
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
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,
utilisng 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 mustread 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 complete and reliable. However, in spite of
all of the efforts of Flowserve Corporation to
provide comprehensive instructions, good
engineering and safety practice should always be
used.
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.
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
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 seek
written agreement of Flowserve before start up.
1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction would
cause hazards. The specific safety markings are:
This symbol indicates electrical safety
instructions where non-compliance will involve a high
risk to personal safety or the loss of life.
This symbol indicates safety instructions where
non-compliance would affect personal safety and could
result in loss of life.
This symbol indicates “hazardous and toxic fluid”
safety instructions where non-compliance would affect
personal safety and could result in loss of life.
This symbol indicates safety
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
This symbol indicates “strong magnetic
field” safety instructions where non-compliance would
affect personal safety, pacemakers, instruments, or
stored data sensitive to magnetic fields.
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
NEVER OPERATE THE PUMP WITHOUT
THE COUPLING GUARD AND ALL OTHER
SAFETY DEVICES CORRECTLY INSTALLED
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.
HIGH MAGNETIC FIELDS
Great care should be taken when assembling/
dismantling magnetic rotors, where fitted, because
of the very high forces which can be created by the
magnets.
Persons with pacemakers and any instrumentation
etc sensitive to magnetic fields should be kept well
away from the magnetic drive unit during
dismantling.
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
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.
bearing housings must not be insulated and
drive motors and bearings may be hot.
If the temperature is greater than 80 ºC (175ºF) or
below -5 ºC (23 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
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.
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.
NEVER RUN THE PUMP DRY
ENSURE CORRECT
LUBRICATION (See section 5, Commissioning,
startup, operation and shutdown.)
ONLY CHECK DIRECTION OF
MOTOR ROTATION WITH COUPLING SPACER
PIECE REMOVED
Starting in reverse direction of rotation will damage the
pump.
NEVER EXCEED THE MAXIMUM
DESIGN PRESSURE (MDP) AT THE WORKING
TEMPERATURE OF THE PUMP NAMEPLATE
START THE PUMP WITH OUTLET
VALVE PART OPENED
(Unless otherwise instructed at a specific point in the
User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump or motor at full or
zero flow. Pumps may be started with the valve further
open only on installations where this situation cannot
occur. The pump outlet control valve may need to be
adjusted to comply with the duty following the run-up
process. (See section 5, Commissioning start-up,
operation and shutdown.)
INLET VALVES TO BE FULLY
OPEN WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the pump.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow
rate with no back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/vibration.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
• Avoid excess temperature
• Prevent build up of explosive mixtures
• Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
For ATEX, both electrical and non-electrical equipment
must meet the requirements of European Directive
94/9/EC. Always observe the regional legal Ex
requirements 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.
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
Temperature class
Temperature class
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The party
responsible for assembling the ATEX 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. On
pumps sets controlled by 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.
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
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface
temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 ºC (104 ºF); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends
on the temperature class and must not exceed the
values in the table that follows.
The temperature rise at the bearings and due to the
minimum permitted flow rate is taken into account in
the temperatures stated.
to EN13463-1
T6
T5
T4
T3
T2
Maximum surface
temperature permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
Temperature limit of
liquid handled
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
Maximum permitted liquid temperature for
pumps with self priming casing
to EN13463-1
T6
T5
T4
T3
T2
* 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)
Temperature limit of
liquid handled
Consult Flowserve
Consult Flowserve
110 °C (230 °F) *
175 °C (347 °F) *
270 °C (518 °F) *
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
Temperature classification “Tx” is used when the liquid
temperature varies and when the pump is required to
be used in differently classified potentially explosive
atmospheres. In this case the user is responsible for
ensuring that the pump surface temperature does not
exceed that permitted in its actual installed location.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitors or
a 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.
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.
Do not attempt to check the direction of rotation with
the coupling spacer fitted due to the risk of severe
contact between rotating and stationary components.
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
Additional requirements for CPXPS pumps only
Where the system operation does not ensure control of
priming, as defined in the User Instructions, and the
maximum permitted surface temperature of the T Class
could be exceeded, the user shall fit an external surface
temperature protection device.
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 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.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking fro
category 2 equipment.
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.
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 an
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
CORRECT MAINTENANCE IS REQUIRED
TO AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with
maintenance instructions is with the plant
operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where
there is a risk from such tools or materials,
maintenance must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
For ATEX the coupling must be selected to comply
with 94/9/EC. Correct coupling 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.
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
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
The usual approach is to control the exposure time
to the noise or to enclose the machine to reduce
emitted sound. You may have already specified a
limiting noise level when the equipment was
ordered, however if no noise requirements were
defined, then attention is drawn to the following table
to give an indication of equipment noise level so that
you can take the appropriate action in your plant.
Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.
Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected from standard
and high efficiency motors when on load directly
driving the pump. Note that a motor driven by an
inverter may show an increased noise at some
speeds.
If a pump unit only has been purchased for fitting with
your own driver then the “pump only” noise levels in
the table should be combined with the level for the
driver obtained from the supplier. Consult Flowserve
or a noise specialist if assistance is required in
combining the values.
Oil lubricated units only:
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.
For units driven by equipment other than
electric motors or units contained within enclosures,
see the accompanying information sheets and
manuals.
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.
Page 9 of 48 flowserve.com
CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
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
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
2 TRANSPORT AND STORAGE
Typical sound pressure level LpA at 1 m reference 20 µPa, dBA
motor
Pump
only
Pump and
motor
Pump
only
Pump and
2.3 Lifting
motor
Pump
only
2.1 Consignment receipt and
unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve Pump Division
and must be received in writing within one month of
receipt of the equipment. Later claims cannot be
accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
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.
Slings, ropes and other lifting gear should be
positioned where they cannot slip and where a
balanced lift is obtained. The angle between two
load carrying slings or ropes must not exceed 60°
2.3.1 Bare pump
The bare pump should be lifted as shown:
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.
Pump and
motor
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
2.3.2 Pump and folded steel, or polycrete
baseplate set
Where the baseplate is folded steel or polycrete
there are no specific lifting points provided for the
complete machine set. Any lifting points that can be
seen are provided only for dismantling parts for
servicing.
The pump and folded steel, or polycrete, baseplate
set should be lifted as shown. With a sling around
the pump discharge nozzle, and around the
outboard end of the motor frame using choker
hitches pulled tight. The sling should be positioned
so the weight is not carried through the motor fan
housing. Make sure the completion of the choker
hitch on the discharge nozzle is toward the
coupling end of the pump.
2.3.3 Pump and cast iron, or fabricated,
baseplate set
The pump and cast iron, or fabricated, baseplate
set which has specific lifting points, should be lifted
as shown:
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.
Before lifting the driver alone, refer to the
manufacturer’s instructions.
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
3 DESCRIPTION
3.1 Configurations
The pump is a modular designed centrifugal pump
that can be built to achieve almost all chemical
liquid pumping requirements. For ultimate safety
the pump has been fitted with a magnetic drive.
(See 3.2 and 3.3 below.)
3.2 Name nomenclature
The pump size will be engraved on the nameplate
typically as below:
80-50CPXS200
Nominal suction size in mm
Nominal discharge size in mm
Configuration – see 3.3.1
Nominal ISO maximum impeller diameter
The typical nomenclature above is the general
guide to the CPXS configuration description.
Identify the actual pump size and serial number
from the pump nameplate. Check that this agrees
with the applicable certification provided.
3.3 Design of major parts
3.3.1 Pump casing
The pump casing [1100] 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 connectors do not have to be disturbed
when internal maintenance is required.
On the CPXS and CPXPS the casing feet pads are
underneath the casing. On the CPXNS they are on
the shaft centreline.
In addition, the CPXPS pump casing [1100] is
designed with a self priming action which works on
the reflux principle for suction lifts up to 7 m (23 ft).
3.3.2 Impeller
An open impeller is fitted.
3.3.3 Shaft
The large diameter stiff shaft, mounted on
bearings, has a keyed drive end. The pump shaft
is fitted with a magnetic rotor and product
lubricated bearings.
3.3.4 Bearing housing
For oil lubricated bearings, a sight glass enables
the oil level to be viewed. Additional lubrication and
cooling options may be fitted.
3.3.5 Pump bearings and lubrication
The ball bearings fitted in the bearing housing may
be oil or grease lubricated. The magnetic drive
journal bearings may be lubricated by product or
from an external source.
3.3.6 Shaft seal
The magnetic drive design utilizes the shell
between the magnets to prevent leakage of the
pumped fluid.
3.3.7 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.
3.3.8 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 and
materials may influence this data. If required, a
definitive statement for your particular application
can be obtained from Flowserve.
3.4.1 Temperature limits
The pump materials and construction have been
selected for your application, however, the following
fundamental limits should not be exceeded:
Neodymium magnets -40 to +120 ºC
(-40 to +248 ºF)
Samarium cobalt magnets -40 to +250 ºC
(-40 to +482 ºF)
PEEK shell (depending on pressure)-40 to +120 ºC
(-40 to +248 ºF)
3.4.2 Ambient temperature
These pumps are generally fitted with TEFC motors
with an ambient temperature limit of +40 ºC
(104 ºF).
Specific pumps may be fitted with motors to suit
client's requirements with other ambient
temperature limits - see motor nameplate for
details.
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CPXS, CPXNS and CPXPS USER INSTRUCTIONS ENGLISH 71569250 07-11
3.4.3 Operating limits
Maximum pump speed: refer to the nameplate.
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.
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) Install the baseplate onto packing pieces
evenly spaced and adjacent to foundation
bolts.
c) Level with shims between baseplate and
packing pieces.
d) The pump and driver have been aligned before
dispatch however the alignment of pump and
motor half coupling must be checked. If this is
incorrect, it indicates that the baseplate has
become twisted and should be corrected by reshimming.
e) If not supplied, guarding shall be fitted as
necessary to meet the requirements of ISO
12100 and EN953.
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, folded steel and cast iron
baseplates can be filled with grout. Polycrete
baseplates can not be grouted,see their User
Instructions 71569284 (E) for installation and use. If
in any doubt, please contact your nearest service
centre for advice.
Grouting provides solid contact between the pump
unit and foundation, prevents lateral movement of
vibrating 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. In pump installations involving high liquid
temperatures, the unit should be run at the actual
operating temperature, shut down and the alignment
checked immediately.
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Angular
4.5.2 Alignment methods
Pump and driver must be isolated
electrically and the half couplings disconnected.
The alignment MUST be checked.
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. The alignment values are
maximums for continuous service.
Parallel
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.
When the electric motor has sleeve bearings it is
necessary to ensure that the motor is aligned to run
on its magnetic centreline. Refer to the motor
manual for details. A button (screwed into one of
the shaft ends) is normally fitted between the motor
and pump shaft ends to fix the axial position.
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. 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.
Complete piping as below and see sections 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
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
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excessive, cause misalignment, hot bearings, worn
couplings, vibration and the possible failure of the
pump casing, the following points should be strictly
followed:
• 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.
4.6.1.1 CPXS and CPXNS only
Take the suction lift into account in the available
NPSH which must be higher than the required
NPSH of the pump.
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.
4.6.1.2 CPXPS self primer only
The delivery pipework must permit priming air to
escape unhindered from the pump during the
priming cycle, without back pressure and prevent
excessive run-back of liquid on shutdown to
minimise syphoning.
Priming air may be vented in one of the following
ways:
1. The discharge pipework regulating valve, if
fitted, may be partly opened during the priming
cycle to freely vent the air.
2. An automatic air release valve may be fitted to
the discharge pipework, between the pump and
any valves, providing that gases and vapours
given off are environmentally safe and
acceptable for release into the atmosphere.
3. An air bleed pipe may be run from the discharge
pipework, between the pump and any valves,
back to the suction tank or sump. This
arrangement has a disadvantage in that manual/
automatic control will be necessary during
operation to prevent continuous re-circulation of
the pumped liquid.
4.6.2 Suction piping
4.6.2.1 CPXS and CPXNS 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 pipe straight is 5 to 10
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.
g) The pump is fitted with silicon carbide bearings
therefore small non-abrasive solids less than
0.3 mm (0.012 in.) in diameter can be handled
providing they constitute no more than 2.5% by
volume of liquid handled.
h) Solids must be non-magnetic, must not have a
tendency to coagulate and must not be fibrous.
They should also be non-abrasive and must
not scale wetted surfaces. For services other
than above you are recommended to contact
Flowserve for advice.
4.6.2.2 CPXPS suction piping
a) The inlet pipe should be as short as possible,
airtight and the smallest volume as practical for
the pump flow rate so as to be able to prime in
quickly. Where inlet pipe volume is large an inlet
ball-foot valve or flap valve will be required.
b) It is recommended that the pump inlet pipe is no
larger than the pump inlet bore or such that the
suction velocity is in the range of 3 to 5 m/sec
(10 to 16 ft/sec). The piping should slope down
towards the pump casing suction flange.
c) Take the suction lift into account in the available
NPSH, which must be higher than the required
NPSH of the pump.
d) Allow a minimum of two pipe diameters of
straight section between the elbow and inlet
flange.
e) Fitting an isolation valve will allow easier
maintenance.
Page 15 of 48 flowserve.com
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