Flowserve CPXV fitted with WW User Manual

USER INSTRUCTIONS

CPXV fitted with WW/CW hydraulics

Installation

Operation

Centrifugal, modular design, vertical sump pumps

PCN=85392698 10-09 (E) Original instructions.

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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.............................9

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

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...............................................11

3.2 Name nomenclature......................................11

3.3 Design of major parts....................................11

3.4 Performance and operating limits.................12

4 INSTALLATION....................................................12

4.1 Location......................................................... 12

4.2 Part assemblies............................................. 12

4.3 Foundation .................................................... 12

4.4 Grouting ........................................................12

4.5 Piping ............................................................ 13

4.6 Electrical connections ...................................14

4.7 Protection systems........................................15

6 MAINTENANCE ...................................................19

6.1 General..........................................................19

6.2 Maintenance schedule...................................20

6.3 Spare parts.....................................................21

6.4 Recommended spares ..................................21

6.5 Tools required ................................................21

6.6 Casing, seal housing and fastener torques...22

6.7 Setting impeller clearance.............................22

6.8 Renewal clearances ......................................22

6.9 Disassembly ..................................................23

6.10 Examination of parts....................................24

6.11 Assembly .....................................................24

7 FAULTS; CAUSES AND REMEDIES ..................27

8 PARTS LISTS AND DRAWINGS.........................29

8.1 CPXV – WW/CW...........................................29

8.2 CPXV – WW/CW bearing options .................31

8.3 CPXV – WW/CW sealing options..................32

8.4 Parts interchangeability.................................33

8.5 General arrangement drawing.......................33

9 CERTIFICATION..................................................33

10 OTHER RELEVANT DOCUMENTATION

AND MANUALS .................................................33

10.1 Supplementary User Instruction manuals....33

10.2 Change notes ..............................................33

10.3 Additional sources of information.................33

Page

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 .......................................................17

5.6 Priming and auxiliary supplies ......................17

5.7 Starting the pump..........................................17

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

5.9 Stopping and shutdown................................. 19

5.10 Hydraulic, mechanical and electrical duty...19

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CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

INDEX

Page

Additional sources (10.3).........................................33

Assembly (6.11).......................................................24

ATEX marking (1.6.4.2) ............................................. 7

Bearing sizes and capacities (5.2.2)........................16

CE marking and approvals (1.2)................................4

Certification (9) ........................................................33

Change notes (10.2)................................................33

Clearances, impeller (6.7) .......................................22

Commissioning and operation (5)............................15

Compliance, ATEX (1.6.4.1)......................................6

Configurations (3.1) ................................................. 11

Copyright (1.4)...........................................................4

Design of major parts (3.3)......................................11

Direction of rotation (5.4) ......................................... 17

Disassembly (6.9)....................................................23

Disclaimer (1.3).......................................................... 4

Dismantling (6.9, Disassembly)...............................23

Drawings (8) ............................................................29

Duty conditions (1.5)..................................................4

Electrical connections (4.6) .....................................14

End of product life (2.5) ...........................................11

Examination of parts (6.10) .....................................24

Fastener torques (6.6) ............................................. 22

Faults; causes and remedies (7).............................27

Foundation (4.3) ......................................................12

General arrangement drawing (8.5) ........................33

General assembly drawings (8)...............................29

Grouting (4.4)........................................................... 12

Guarding (5.5).......................................................... 17

Handling (2.2) .......................................................... 10

Hydraulic, mechanical and electrical duty (5.10)..... 19

Impeller clearance (5.3 and 6.7)

Inspection (6.2.1 and 6.2.2).....................................20

Installation (4) .......................................................... 12

Lifting (2.3)...............................................................10

Location (4.1)...........................................................12

Lubrication (5.1.1, 5.2 and 6.2.3)

Lubrication schedule (5.2.5)....................................16

Maintenance (6).......................................................19

Maintenance schedule (6.2)....................................20

Name nomenclature (3.2)........................................11

Nameplate (1.7.1)......................................................9

Operating limits (3.4.1) ............................................12

Ordering spare parts (6.3.1)....................................21

Part assemblies (4.2)...............................................12

Parts interchangeability (8.4)...................................33

Parts lists (8)............................................................29

Performance (3.4)....................................................12

Piping (4.5) ..............................................................13

Pre-commissioning (5.1)..........................................15

Priming and auxiliary supplies (5.6).........................17

Protection systems (4.7)..........................................15

Page

Reassembly (6.11, Assembly) .................................24

Receipt and unpacking (2.1)......................................9

Recommended fill quantities (see 5.2.2)..................16

Recommended grease lubricants (5.2.3).................16

Recommended oil lubricants (5.2.1) ........................16

Recommended spares (6.4).....................................21

Recycling (2.5) .........................................................11

Replacement parts (6.3 and 6.4)..............................21

Running the pump (5.8) ...........................................18

Safety action (1.6.3) ...................................................5

Safety labels (1.7.2) ...................................................9

Safety markings (1.6.1) ..............................................5

Safety, protection systems (1.6 and 4.7)

Sectional drawings (8)..............................................29

Setting impeller clearance (6.7) ...............................22

Sound pressure level (1.9, Noise level) .....................9

Sources, additional information (10.3) .....................33

Spare parts (6.3) ......................................................21

Specific machine performance (1.8) ..........................9

Starting the pump (5.7).............................................17

Stop/start frequency (5.8.5)......................................18

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

Storage, pump (2.4) .................................................11

Storage, spare parts (6.3.2) .....................................21

Supplementary manuals or information sources......33

Supplementary User Instructions (10.1)...................33

Tools required (6.5)..................................................21

Torques for fasteners (6.6).......................................22

Trouble-shooting (see 7) ..........................................27

Vibration (5.8.4)........................................................18

Page 3 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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/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.

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.

Page 4 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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.

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.

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.

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

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 vapor 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.

Page 5 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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.

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.

NEVER RUN THE PUMP DRY
Liquid level controls are recommended to avoid the risk
of dry running.

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

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

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.)

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.

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 motor, coupling, pump thrust bearing and seal
can be made compliant with 94/9/EC ATEX Directive
for Equipment Categories 2 and 3 as required by the
duty conditions.

See the pump nameplate and Declaration of Conformity
for the pump classification. The pump column below
soleplate will also generally be to the same category
however in some applications the section of the pump
below soleplate and above liquid will have been
designed to Category 1, whereas above soleplate
Category 2 or 3 will apply. (See section 1.6.4.2.)

The pump will then be supplied with a copy of the
Certificate of Approval by a Notified Body and marked
with both categories. Users must pay particular
attention to pump operation and maintenance
instructions because of the hazard of the explosive
atmosphere.

Page 6 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

The output from a variable frequency drive (VFD) can
cause additional heating effects in the motor and so, for
pumps 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.

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 or in the case of
Category 1, below the soleplate on a special ATEX
marking plate.

1.6.4.3 Avoiding excessive surface temperatures

0518 II 1/2 GD c IIC 135 ºC (T4)

External examination
body *

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 Group II only)
IIA – Propane (Typical)
IIB – Ethylene (Typical)
IIC – Hydrogen (Typical)

Maximum surface temperature (Temperature Class)
(see section 1.6.4.3.)

* The external ATEX examination body
reference is included in the pump marking when the
Category is 1/2 or 1/3. In that situation, the 1 before
the /2 or /3 identifies the special case where the
pump is Category 1 below the soleplate and 2 or 3
above the soleplate.

For ATEX Group II Category 1 below the soleplate a
special ATEX marking plate is used. An example of
this is shown below.

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 an ambient in the range of –80 to +55 ºC (-112 to
131 ºF); refer to Flowserve for ambient temperatures
outside this range for this product.

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

Temperature

class to

EN 13463-1

T6
T5
T4
T3
T2
T1

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 (* depending on

material and construction

variant - check which is lower)

Consult Flowserve
Consult Flowserve

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

Do not attempt to check the direction of rotation with the
coupling element/pins fitted due to the risk of severe
contact between rotating and stationary components.

Page 7 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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

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

In dirty or dusty environments, regular checks must
be made and dirt removed from areas around close
clearances, bearing housings and motors.

The equipment utilises polymer based seals and
bearing surfaces that could be corroded if they
are in contact with unsuitable liquids or gases.
These surfaces are important for the operation of
the pump. Contact Flowserve if you are uncertain
about the performance of these materials with
respect to aggressive substances that may be
present in the hazardous area.

The pump casing must be flooded with liquid to the
minimum level on the dimensional General
Arrangement (GA) drawing, at any time that the pump
is operated. On pumps furnished to Group II
Category 1 below the soleplate, monitoring of the
level with a pump cut out on low level is required.

For pumps furnished to Category 1/2 and 1/3, if the
pump is operating remotely without regular checking,
it must be installed with continuous monitoring of
vibration level, set to shut down the pump at high
vibration levels, see also section 5.8.4.

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 the fitting of an appropriate dry run
protection device is recommended (for example liquid
detection or a power monitor).

To avoid potential hazards from fugitive emissions of
vapor 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
and anti-static for Category 2.

To avoid the potential hazard from random induced
current generating a spark, the earth contact on the
baseplate must be used.

Avoid electrostatic charge: do not rub non­metallic 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.

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, the installation of a liquid detection device is
recommended.

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.

Page 8 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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.)

1.7 Nameplate and safety labels

1.7.1 Nameplate

For details of nameplate, see the Declaration of
Conformity. Where a unit is ATEX Group II Category

1 below the soleplate there is an additional ATEX
marking plate (see section 1.6.4.2 Marking).

1.7.2 Safety labels

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.

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.

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.

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 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
separately with the equipment or attached to side
walls of the box or equipment.

Page 9 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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
200 (270)
300 (400) – 87

1

The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are inappropriate.

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

1 1

Pump and

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

motor

Pump

only

1

Pump and

motor

1

Pump

only

85

Pump and

motor

87 83
90 85

Pump

only

Pump and

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.
Pumps with drivers over approximately 7.5 kW, are

supplied with the pump packed as a separate item
from the driver. These and should be lifted
separately into their installed position, using lifting
points on the pump soleplate, and on the motor.

When lifting pumps with drivers fitted,
the resulting center of gravity may be above the lifting
points, and the method of slinging must prevent the
machine tipping during the lift.

Slings, ropes and other lifting gear must be positioned
where they cannot slip and where a balanced lift is
obtained.

For improved stability unbolt the driver and lift the
driver and pump separately.

For lifting the driver refer to the
dimension drawing of the driver.

Lift points for the pump or the pump
and the driver.

motor

85
86

Page 10 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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.

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 pump is a modular designed centrifugal pump
that can be built to achieve almost all chemical liquid
pumping requirements. (See 3.2 and 3.3 below.)

3.2 Name nomenclature

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

150CPXV-WW400A

Nominal casing discharge size * in mm
CPXV line shaft configuration
D-Line wet end material

WW - grey cast iron
CW - Alloy

Nominal ISO maximum impeller diameter in mm
(125, 160, 200, 250, 315, 400 or 500)

A - inducer fitted

* The soleplate discharge size is generally one or two standard
pipe diameters greater to keep pipe losses down and ensure high
efficiency.

The typical nomenclature above is the general guide
to the CPXV WW/CW 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 is designed for operation when
submerged in the sump liquid.

3.3.2 Impeller

An enclosed impeller is fitted having balance holes.
Where applicable an inducer will be fitted in front of
the impeller.

3.3.3 Shaft

The shaft has a keyed drive coupling. It is supported by
rolling bearing(s) above the soleplate and journal
bearing(s) below.

3.3.4 Bearing housing

The bearing housing has a bearing carrier which is
preset.

3.3.5 Pump bearings and lubrication

The pump is fitted with a thrust type ball bearing that
may be configured differently dependent on use.

The thrust bearing(s) may be grease or oil lubricated.
The journal bearings may be lubricated by product or

from an external source.

3.3.6 Soleplate seal

The modular design enables one of a number of
sealing options to be fitted.

3.3.7 Driver

The pump is normally driven by a flange mounted electric
motor. An air or hydraulic motor may be utilized.

The position of the terminal box can be changed by
rotating the complete motor. To do this, remove the
fasteners from the motor flange, rotate the motor and
re-fit the fasteners.

3.3.8 Accessories

Accessories may be fitted when specified by the
customer.

Page 11 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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 pump ambient temperature: +55 ºC (131 ºF)
where driver is also rated for this ambient.

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 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 and checked as
detailed in section 4.5.4, Final checks.

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.

The sump pump mounting plate should have concrete or
metal to support it around its edges.

4.3.1 Levelling

The soleplate must be level so that the pump column
hangs vertically; confirmed by inspection.

With the motor removed check the top face of the
machined motor pedestal [3160] is set level to 0.05 mm
(0.002 in.) or 0.2 mm/m (0.0025 in./ft) maximum.

Larger size motors are shipped unfitted. The motor will
need to be fitted after completion of the pump
foundation installation. Turn shaft clockwise by hand to
ensure it is free to turn.

4.3.2 Packing pieces

Where the soleplate and its counterface do not each
have a machined face, packing pieces (metallic shims)
will need to be placed evenly adjacent to the foundation
(holding down) bolts to avoid “soft-foot” distortion. Turn
shaft clockwise by hand to ensure it is free to turn.

Soft-foot distortion may significantly increase vibration
and damage equipment by causing distortion and
should normally be inspected. If high vibration occurs
when pump is run (see Section 5, Commissioning,
start-up, operation and shutdown) place a vibration
meter at the side of the motor as soft-foot is most
effectively reduced when the vibration is reduced to a
minimum. Overall vibration measurement can be used

- it is not necessary to use a vibration spectrum to pick
up soft-foot which occurs at 1x running speed and
should be the first issue to check.

To adjust for soft-foot use a dial gauge on the
soleplate top face near to the holding down bolt, zero
it, record the soft-foot spring in the soleplate and
undo one holding down bolt at a time.

Soft-foot is removed by inserting packing pieces
(metallic shims) equal to or slightly less than the soft­foot spring amount recorded at the individual holding
down point locations. Re-torque the holding down bolt.
Continue this procedure for each holding down bolt
position in turn, one at a time. The thickness of
packing pieces (metallic shims) adjacent to an
individual holding down bolt should not exceed 3 mm
(0.12 in.); ie soft-foot spring is not to exceed 3 mm
(0.12 in.) at any individual location.

4.4 Grouting

Where applicable, grout in the foundation bolts.
Grouting provides solid contact between the pump unit

and foundation, prevents lateral movement of vibrating
equipment and dampens resonant vibrations.

Page 12 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

4.5 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.

If sludge can build up in the sump it is
recommended to use a strainer with a maximum
opening size of 6 mm (0.24 in.) and a free surface
area greater than three times the pump suction area.

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:

• 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

4.5.1 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 discharge. Typically main pipework velocities
should not exceed 3 m/s (9 ft/sec) on the discharge.

Ensure piping for hazardous liquids is arranged

to allow pump flushing before removal of the pump.

4.5.2 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.

4.5.3 Maximum forces and moments allowed on
the main soleplate discharge flange

The table below uses the sign convention shown for the
pump soleplate discharge flange maximum forces and
moments. These are valid for a pump end up to 100 ºC
(212 ºF) and the soleplate on a rigid foundation.

Never use the pump as a support for

piping.

Ensure piping and fittings are flushed

before use.

Discharge

flange size

mm (in.)

40 (1.5) 0.71 (160) 0.58 (130) 0.89 (200) 1.28 (290) 0.46 (340) 0.23 (170) 0.35 (260) 0.62 (460)
50 (2.0) 0.71 (160) 0.58 (130) 0.89 (200) 1.28 (290) 0.46 (340) 0.23 (170) 0.35 (260) 0.62 (460)

80 (3.0) 1.07 (240) 0.89 (200) 1.33 (300) 1.93 (430) 0.95 (700) 0.47 (350) 0.72 (530) 1.28 (950)
100 (4.0) 1.42 (320) 1.16 (260) 1.78 (400) 2.56 (570) 1.33 (980) 0.68 (500) 1.00 (740) 1.80 (1 330)
125 (5.0) 1.95 (440) 1.58 (355) 2.45 (550) 3.50 (790) 1.93 (1 420) 0.98 (720) 1.36 (1 000) 2.56 (1 880)
150 (6.0) 2.49 (560) 2.05 (460) 3.11 (700) 4.48 (1010) 2.30 (1 700) 1.18 (870) 1.76 (1 300) 3.13 (2 310)
200 (8.0) 3.78 (850) 3.11 (700) 4.89 (1 100) 6.92 (1560) 3.53 (2 600) 1.76 (1 300) 2.58 (1 900) 4.71 (3 500)

250 (10.0) 5.34 (1 200) 4.45 (1 000) 6.67 (1 500) 9.63 (2 200) 5.02 (3 700) 2.44 (1 800) 3.80 (2 800) 6.75 (5 000)

Fx Fy Fz Fr Mx My Mz Mr

Maximum forces (F) in kN (lbf) and moments (M) in kNm (lbf•ft)

4.5.4 Auxiliary piping

4.5.4.1 Pumps fitted with a soleplate packed gland

4.5.4.2 Pumps fitted with mechanical seals

Seal housings/covers having an auxiliary quench
connection require connection to a suitable source of
liquid flow, low pressure steam or static pressure from

Ensure lubrication is supplied to the

gland packing.

a header tank. Recommended pressure is 0.35 bar
(5 psi) or less.

Page 13 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

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. 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.

Special seals may require modification to auxiliary
piping described above. Consult Flowserve if unsure
of correct method or arrangement.

4.5.4.3 Pumps fitted with heating jacket

As the pump is constructed as a heated jacketed unit,
steam must be connected to the steam inlet flange and
removed via the steam outlet flange. These flanges
are located on the upper side of the soleplate. A
flanged steam valve should be provided at the steam
inlet and outlet for control of the steam supply.

4.5.5 Final checks

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

After connecting piping to the pump, rotate the shaft
several times by hand to ensure there is no binding
and all parts are free.

Recheck the coupling is aligned within the permitted
limits. For couplings with narrow flanges use a dial
indicator as shown. The alignment values are
maximums for continuous service.

Parallel

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

If alignment needs to be adjusted, a small amount of
adjustment of the motor is available within the motor
spigot but alignment is generally achieved
automatically on assembly. Larger motors always
require re-adjustment.

If it is not possible to achieve the alignment accuracy
defined, it may be an indication that the pump has not
been installed or handled correctly.

4.6 Electrical connections

Electrical connections must be made
by a qualified Electrician in accordance with relevant
local national and international regulations.

It is important to be aware of the EUROPEAN
DIRECTIVE on potentially explosive areas where
compliance with IEC60079-14 is an additional
requirement for making electrical connections.

It is important to be aware of the EUROPEAN
DIRECTIVE on electromagnetic compatibility when
wiring up and installing equipment on site. Attention
must be paid to ensure that the techniques used during
wiring/installation do not increase electromagnetic
emissions or decrease the electromagnetic immunity of
the equipment, wiring or any connected devices. If in
any doubt contact Flowserve for advice.

The motor must be wired up in
accordance with the motor manufacturer's
instructions (normally supplied within the terminal
box) including any temperature, earth leakage,
current and other protective devices as appropriate.
The identification nameplate should be checked to
ensure the power supply is appropriate.

A device to provide emergency stopping must
be fitted. If not supplied pre-wired to the pump unit,
the controller/starter electrical details will also be

Angular

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

Page 14 of 36 flowserve.com

supplied within the controller/starter.
For electrical details on pump sets with controllers

see the separate wiring diagram.

See section 5.4, Direction of rotation

before connecting the motor to the electrical supply.

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

4.7 Protection systems

The following protection systems are
recommended particularly if the pump is installed in a
potentially explosive area or is handling a hazardous
liquid. If in any doubt consult Flowserve.

If there is any possibility of the system allowing the
pump to run against a closed valve or below
minimum continuous safe flow a protection device
should be installed to ensure the temperature of the
liquid does not rise to an unsafe level.

If there are any circumstances in which the system
can allow the pump to run dry, or start up empty, a
power monitor should, in addition to level control, be
fitted to stop the pump or prevent it from being
started. This is particularly relevant if the pump is
handling a flammable liquid.

If leakage of product from the pump or its associated
sealing system can cause a hazard it is recommended
that an appropriate leakage detection system is installed.

To prevent excessive surface temperatures at
bearings it is recommended that temperature or
vibration monitoring are carried out.

5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN

These operations must be carried

out by fully qualified personnel.

5.1 Pre-commissioning procedure

5.1.1 Lubrication

Determine the mode of lubrication of the pump set,
eg grease, oil, product lubrication, external clean
liquid etc.

For oil lubricated pumps, fill the bearing

housing with correct grade of oil to the correct level.

X

Shaft

Size Dia X (mm) Y (mm) Z (mm) C (mm)

1
2
3
4

24
32
42
48

Denco oiler

setting

14.5

16.5

17.0

13.5

21.5

23.5

24.0

20.5

Trico oiler

setting

12.5

14.5

15.0

11.5

The level setting for a Trico oiler model must

be as the Trico setting in the table.

Trico oiler option
Pumps with grease lubricated antifriction bearings are
normally supplied fitted with grease nipples and with
pre-greased bearings.

Grease lubricated electric motor bearings are generally
pre-greased. Refer to the motor UI for information on
the motor lubrication schedule.

Pumps with grease lubricated thrust bearings and
electric motors are supplied with pre-greased bearings.

In the case of product lubricated bearings
the source of product supply should be checked against
the order; there may be requirements for an external clean
supply, particular supply pressure or the commencement
of lubrication supply before pump start-up.

Approximate oil volumes are shown in section 5.2.2,
Bearing sizes and capacities.

Where the ambient is very low special lubricants are
required. If in doubt consult Flowserve for
recommendations of oil and grease types at these
lower temperatures. Where oil lubrication is utilized
and the ambient is less than -5 °C (23 °F) ensure t he
ambient is no lower than 15 °C (27 °F) over the oil
pour point or use the oil class SAE 5W-50 or API-SJ
and ensure the upper operating range of the oil is
then not exceeded. Where low ambient grease has
been specially fitted this is Shell Aeroshell 22.

Page 15 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

5.2 Pump lubricants

5.2.1 Recommended oil lubricants

Oil Splash / force feed / purge oil mist lubrication

Viscosity cSt

@ 40 ºC

Oil temperature range *

lubrication

Centrifugal pump

Oil companies and

* Note that it normally takes 2 hours for bearing temperature to stabilize and the final temperature will depend on the ambient, r/min, pumpage
temperature and pump size. Also some oils have a greater viscosity index than the minimum acceptable of 95 (eg Mobil DTE13M) which may
extend the minimum temperature capability of the oil. Always check the grade capability where the ambient is less than -5 ºC (-23 ºF).

†

Use LSC for oil mist. Oil parameters provide flash point >166 ºC (331 ºF), density >0.87 @ 15 ºC (59 ºF), pour point of -10 ºC (14 ºF) or lower.

Designation to ISO 3448

and DIN51524 part 2

BP Castrol †

ESSO †

ELF/Total †

LSC (for oil mist)

ExxonMobil †

lubricants

Wintershall (BASF Group) †

Q8 †

Shell †

Chevron Texaco †

Fuchs †

Energol HLP-HM 32 Energol HLP-HM 46 Energol HLP-HM 68

LSO 32 (Synthetic oil) LSO 46 (Synthetic oil) LSO 68 (Synthetic oil)

5.2.2 Bearing sizes and grease/oil capacities

Shaft size 1 2 3 4

Medium duty thrust bearing duplex back-to-back AC 3306C3 3309C3 3311C3 3313C3

Heavy duty thrust bearing duplex back-to-back AC 7306 pair 7309 pair 7311 pair 7313 pair

Approximate oil fill quantities - litre (fl.oz) 0.6 (20) 0.95 (32) 1.0 (34) 0.9 (31)

Note: The bearing sizes do not constitute a purchasing specification.

Grease quantities – g (oz) 14 (0.5) 25 (0.9) 35 (1.2) 46 (1.6)

5.2.3 Recommended grease lubricants

Grease NLGI 2 * NLGI 3

Temperature

range

Designation

according to DIN

BP
Elf

Fuchs

Esso

Mobil

Q8

Shell

Texaco

SKF

* NLGI 2 is an alternative grease and is not to be mixed with other

grades.

** Standard pre-packed grease for fitted antifriction bearings.

-20 to +100 ºC
(-4 to +212 ºF)

KP2K-25 KP3K-20

Energrease LS-EP2 Energrease LS-EP3

Multis EP2 Multis EP3

RENOLIT EP2 RENOLIT EP3

Beacon EP2 Beacon EP3
Mobilux EP2 Mobilux EP3 **

Rembrandt EP2 Rembrandt EP3

Alvania EP2 Alvania EP2
Multifak EP2 Multifak EP3

LGEP 2

-20 to +100 ºC
(-4 to +212 ºF)

5.2.4 Recommended fill quantities

Refer to section 5.2.2, Bearing sizes and grease/oil
capacities.

32 46 68

-5 to 65 ºC

(23 to 149 ºF)

ISO VG 32

32 HLP

NUTO HP 32 NUTO HP 46 NUTO HP 68

ELFOLNA DS 32

Azolla ZS 32

Mobil DTE 24 Mobil DTE 25 Mobil DTE 26

Q8 Haydn 32 Q8 Haydn 46 Q8 Haydn 68

Shell Tellus 32 Shell Tellus 46 Shell Tellus 68

Rando HD 32 Rando HD 46 Rando HD 68

Wiolan HS32 Wiolan HS46 Wiolan HS68

Renolin CL 32 Renolin CL 46 Renolin CL 68

-5 to 78 ºC

(23 to 172 ºF)

ISO VG 46

46 HLP

ELFOLNA DS 46

Azolla ZS 46

-5 to 80 ºC

(23 to 176 ºF)

ISO VG 68

68 HLP

ELFOLNA DS 68

Azolla ZS 68

5.2.5 Lubrication schedule

5.2.5.1 Oil lubricated bearings

Normal oil change intervals are 2 000 operating hours.
For pumps on hot service or in severely damp or
corrosive atmosphere, the oil will require changing more
frequently. Lubricant and bearing temperature analysis
can be useful in optimizing lubricant change intervals.

The lubricating oil should be a high quality mineral oil
having foam inhibitors. Synthetic oils may also be
used if checks show that the rubber oil seals will not be
adversely affected.

The bearing temperature may be allowed to rise to
50 ºC (90 ºF) above ambient, but should not exceed
82 ºC (180 ºF) (API 610 limit). A continuously rising
temperature, or an abrupt rise, indicates a fault.

Pumps that handle high temperature liquids may
require their bearings to be cooled to prevent bearing
temperatures exceeding their limits.

Page 16 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

5.2.5.2 Grease lubricated bearings

When grease nipples are fitted, one charge between
grease changes is advisable for most operating
conditions; ie 2 000 hours interval. Normal intervals
between grease changes are 4 000 hours or at least
every 6 months.

The characteristics of the installation and severity of
service will determine the frequency of lubrication.
Lubricant and bearing temperature analysis can be
useful in optimizing lubricant change intervals.

The bearing temperature may be allowed to rise to
55 ºC (99 ºF) above ambient, but should not exceed
95 ºC (204 ºF). For most operating conditions, a
quality grease having a lithium soap base and NLGI
consistency of No 2 or No 3 is recommended. The
drop point should exceed 175 ºC (350 ºF).

Never mix greases containing different

bases, thickeners or additives.

5.3 Impeller clearance

This is preset - see section 6.7, Setting impeller
clearance.

5.4 Direction of rotation

Serious damage can result if the pump

is started or run in the wrong direction of rotation.
The pump is shipped with the coupling element

removed. Ensure the direction of rotation of the motor is
correct before fitting the coupling element. Direction of
rotation must correspond to the direction arrow.

If maintenance work has been carried
out to the site's electricity supply, the direction of
rotation should be re-checked as above in case the
supply phasing has been altered.

5.5 Guarding

5.6 Priming and auxiliary supplies

5.6.1 Filling and priming

The pump end needs to be completely

submerged in the product.

5.6.2 Auxiliary supplies

Ensure all electrical, hydraulic,
pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.

5.6.3 Pumps fitted with a heating jacket

The pump should be pre-heated for at
least one hour using steam through the heating jacket
before hot liquid is brought into the pump. The
quantity, temperature and pressure can be obtained
from the dimensional drawing. This action is
important to avoid distortion and maintain the gap
between impeller and casing.

Ensure pump is electrically isolated. Then before
starting the driver rotate the shaft several times by
(gloved) hand to ensure freedom of rotation as the high
temperature will cause expansion and the increase in
lengths of the components should be identical.

5.7 Starting the pump

a) Ensure flushing and/or cooling/

heating liquid supplies are turned ON, before
starting pump.

b) CLOSE the outlet valve partially, but ensure that

air is allowed to escape out of the discharge pipe.
This is especially important for pumps with
product lubricated line bearings.

c) Ensure that the liquid level in the

sump is above the minimum pump casing
submergence level.

Guarding is supplied fitted to the pump set.
Fasteners for guards must remain captive in the guard
to comply with the Machinery Directive 2006/42/EC.
When releasing guards, the fasteners must be
unscrewed in an appropriate way to ensure that the
fasteners remain captive. Whenever guarding is
removed or disturbed ensure that all the protective
guards are securely refitted prior to start-up.

Page 17 of 36 flowserve.com

d) Ensure all vent valves are closed

before starting.
e) Start motor and check the outlet pressure.
f) If the pressure is satisfactory, SLOWLY open the

outlet valve.
g) Do not run the pump with the outlet

valve completely closed.
h) If NO pressure, or LOW pressure, STOP the pump.

Refer to section 7, Faults; causes and remedies for

fault diagnosis.

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

5.8 Running the pump

5.8.1 Pumps fitted with packed gland

If the pump has a packed gland there must be some
leakage from the gland. Gland nuts should initially be
finger-tight only. Leakage should take place soon after
the stuffing box is pressurised.

The gland must be adjusted evenly to give visible
leakage and concentric alignment of the gland ring to
avoid excess temperature. If no leakage takes place the
packing will begin to overheat. If overheating takes place
the pump should be stopped and allowed to cool before
being re-started. When the pump is re-started, check to
ensure leakage is taking place at the packed gland. If hot
liquids are being pumped it may be necessary to
slacken the gland nuts to achieve leakage.

Grease lubricated packed gland units will be fitted
with packing greased on initial assembly. If no
grease leakage takes place the packing will overheat.

The pump should be run for 30 minutes with steady
leakage and the gland nuts tightened by 10 degrees at a
time until leakage is reduced to an acceptable level.
Bedding in of the packing may take another 30 minutes.

Care must be taken when adjusting the gland
on an operating pump. Safety gloves are essential.
Loose clothing must not be worn to avoid being
caught up by the pump shaft. Shaft guards must be
replaced after the gland adjustment is complete.

Never run gland packing dry, even for

a short time.

5.8.2 Pumps fitted with mechanical seals

Mechanical seals require no adjustment. Any slight
initial leakage will stop when the seal is run in.

Before pumping dirty liquids it is advisable, if
possible, to run the pump in using clean liquid to
safeguard the seal face.

External flush or quench should be
started before the pump is run and allowed to flow for a
period after the pump has stopped.

5.8.3 Bearings

If the pumps are working in a potentially
explosive atmosphere temperature or vibration
monitoring at the bearings is recommended.

If bearing temperatures are to be monitored it is
essential that a benchmark temperature is recorded
at the commissioning stage and after the bearing
temperature has stabilized.

• Record the bearing temperature (t) and the
ambient temperature (ta)

• Estimate the likely maximum ambient
temperature (tb)

• Set the alarm at (t+tb-ta+5) ºC (t+tb-ta+10) ºF
and the trip at 100 ºC (212 ºF) for oil lubrication
and 105 ºC (220 ºF) for grease lubrication

It is important, particularly with grease lubrication, to
keep a check on bearing temperatures. After start up
the temperature rise should be gradual, reaching a
maximum after approximately 1.5 to 2 hours. This
temperature rise should then remain constant or
marginally reduce with time. (Refer to section 5.2.5
for further information.)

5.8.4 Normal vibration levels, alarm and trip

For guidance, pumps generally fall under a classification
for rigid support machines within the International
rotating machinery standards and the recommended
maximum levels below are based on those standards.

Alarm and trip values for installed pumps
should be based on the actual measurements (N) taken
on the pump in the fully commissioned as new condition.

Regular monitoring of the pump vibration is

recommended to show any deterioration in pump or
system operating conditions. The vibration is
measured adjacent to the pump thrust bearing.

For remote installations continuous monitoring and
automatic alert and shutdown is recommended.

Vibration velocity – unfiltered mm/sec (in./sec) r.m.s.

Normal N
Alarm N x 1.25
Shutdown trip N x 2.0

≤ 7.1 (0.28)
≤ 9.0 (0.35)

≤ 14.2 (0.56)

5.8.5 Stop/start frequency

Pump sets are normally suitable for the number of
equally spaced stop/starts per hour shown in the
table below. Check capability of the driver and
control/starting system before commissioning.

Motor rating kW (hp)

Up to 15 (20) 15

Between 15 (20) and 90 (120) 10

Above 90 (120) 6

Maximum stop/starts

per hour

Where duty and standby pumps are installed it is
recommended that they are run alternately every week.

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CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

5.9 Stopping and shutdown

a) Close the outlet valve, but ensure

that the pump runs in this condition for no more
than a few seconds.

b) Stop the pump.
c) After stopping a jacketed pump,

leave the steam supply on for approximately 20
minutes. Keep steam circulating in stand-by
pumps.

d) Switch off flushing and/or cooling/heating liquid

supplies at a time appropriate to the process.

e) For prolonged shut-downs and

especially when ambient temperatures are likely to
drop below freezing point, the pump and any cooling
and flushing arrangements must be drained or
otherwise protected.

5.10 Hydraulic, mechanical and electrical
duty

This product has been supplied to meet the performance
specifications of your purchase order, however it is
understood that during the life of the product these may
change. The following notes may help the user decide
how to evaluate the implications of any change. If in
doubt contact your nearest Flowserve office.

5.10.1 Specific gravity (SG)

Pump capacity and total head in metres (feet) do not
change with SG, however pressure displayed on a
pressure gauge is directly proportional to SG. Power
absorbed is also directly proportional to SG. It is
therefore important to check that any change in SG
will not overload the pump driver or over-pressurize
the pump.

5.10.2 Viscosity

For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity. Also for a given flow rate the power
absorbed increases with increased viscosity, and
reduces with reduced viscosity. It is important that
checks are made with your nearest Flowserve office if
changes in viscosity are planned.

5.10.3 Pump speed

Changing pump speed effects flow, total head, power
absorbed, NPSHR, noise and vibration. Flow varies
in direct proportion to pump speed, head varies as
speed ratio squared and power varies as speed ratio
cubed. The new duty, however, will also be
dependent on the system curve. If increasing the
speed, it is important therefore to ensure the
maximum pump working pressure and critical shaft

speed are not exceeded, the driver is not overloaded,
NPSHA > NPSHR, and that noise and vibration are
within local requirements and regulations.

5.10.4 Net positive suction head (NPSHA)

NPSH available (NPSHA) is a measure of the head
available in the pumped liquid, above its vapor
pressure, at the pump suction branch.

NPSH required (NPSHR) is a measure of the head
required in the pumped liquid, above its vapor pressure,
to prevent the pump from cavitating.

It is important that NPSHA > NPSHR. The margin
between NPSHA > NPSHR should be as large as
possible.

If any change in NPSHA is proposed, ensure these
margins are not significantly eroded. Refer to the
pump performance curve to determine exact
requirements particularly if flow has changed.

If in doubt please consult your nearest Flowserve
office for advice and details of the minimum allowable
margin for your application.

5.10.5 Pumped flow

Flow must not fall outside the minimum and maximum
continuous safe flow shown on the pump performance
curve and or data sheet.

6 MAINTENANCE

6.1 General

It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work
is carried out by authorized and qualified personnel
who have adequately familiarized themselves with
the subject matter by studying this manual in detail.
(See also section 1.6.)

Any work on the machine must be performed when it
is at a standstill. It is imperative that the procedure
for shutting down the machine is followed, as
described in section 5.9.

Guard fasteners must remain captive during
dismantling of guards, as described in section 5.5.

On completion of work all guards and safety devices
must be re-installed and made operative again.

Before restarting the machine, the relevant
instructions listed in section 5, Commissioning, start
up, operation and shut down, must be observed.

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CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

Oil and grease leaks may make the ground
slippery. Machine maintenance must always
begin and finish by cleaning the ground and the
exterior of the machine.

If platforms, stairs and guard rails are required for
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
carried out. The positioning of these accessories
must not limit access or hinder the lifting of the part to
be serviced.

When air or compressed inert gas is used in the
maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
protection.

Do not spray air or compressed inert gas on skin.
Do not direct an air or gas jet towards other people.
Never use air or compressed inert gas to clean clothes.
Before working on the pump, take measures to

prevent an uncontrolled start. Put a warning board
on the starting device with the words:
"Machine under repair: do not start".

With electric drive equipment, lock the main switch
open and withdraw any fuses. Put a warning board
on the fuse box or main switch with the words:
"Machine under repair: do not connect".

Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.

6.2 Maintenance schedule

It is recommended that a maintenance plan and
schedule is adopted, in line with these User
Instructions, to include the following:
a) Any auxiliary systems installed must be monitored,

if necessary, to ensure they function correctly.

b) Gland packings must be adjusted correctly to

give visible leakage and concentric alignment of
the gland follower to prevent excessive
temperature of the packing or follower.

c) Check for any leaks from gaskets and seals.

The correct functioning of the shaft seal must be
checked regularly.

d) Check bearing lubricant level, and if the hours

run show a lubricant change is required.

e) Check that the duty condition is in the safe

operating range for the pump.

f) Check vibration, noise level and surface

temperature at the bearings to confirm
satisfactory operation.

g) Check dirt and dust is removed from areas around

close clearances, bearing housings and motors.

h) Check coupling alignment and re-align if necessary.
Our specialist service personnel can help with

preventative maintenance records and provide
condition monitoring for temperature and vibration to
identify the onset of potential problems.

If any problems are found the following sequence of
actions should take place:
a) Refer to section 7, Faults; causes and remedies,

for fault diagnosis.

b) Ensure equipment complies with the

recommendations in this manual.

c) Contact Flowserve if the problem persists.

6.2.1 Routine inspection (daily/weekly)

The following checks should be made
and the appropriate action taken to remedy any
deviations:
a) Check operating behaviour. Ensure noise,

vibration and bearing temperatures are normal.

b) Check that there are no abnormal fluid or

lubricant leaks (static and dynamic seals) and
that any sealant systems (if fitted) are full and
operating normally.

c) Check that shaft seal leaks are within acceptable

limits.

d) Check the level and condition of oil lubricant.

On grease lubricated pumps, check running
hours since last recharge of grease or complete
grease change.

e) Check any auxiliary supplies eg heating/cooling

(if fitted) are functioning correctly.



Refer to the manuals of any associated

equipment for routine checks needed.

6.2.2 Periodic inspection (six monthly)

a) Check foundation bolts for

security of attachment and corrosion.

b) Check pump running records for hourly usage to

determine if bearing lubricant requires changing.

c) The coupling should be checked for correct

alignment and worn driving elements.



Refer to the manuals of any associated

equipment for periodic checks needed.

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CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

6.2.3 Re-lubrication

For general guidelines refer to section 5.2.5,

Lubrication schedule.

Lubricant and bearing temperature analysis can be
useful in optimizing lubricant change intervals.

6.2.4 Mechanical seals

When leakage becomes unacceptable the seal will
need replacement.

6.2.5 Gland packing

The stuffing box is normally supplied with a lantern ring
to enable it to be lubricated to the centre of the packing
with the required Molykote 44 Medium or equivalent
grease from a Staufer or equivalent.

6.3 Spare parts

6.3.1 Ordering of spares

Flowserve keeps records of all pumps that have been
supplied. When ordering spares the following
information should be quoted.

1) Pump serial number.

2) Pump size.

3) Part name – taken from section 8.

4) Part number – taken from section 8.

5) Number of parts required.

The pump size and serial number are shown on the
pump nameplate.

To ensure continued satisfactory operation,
replacement parts to the original design specification
should be obtained from Flowserve. Any change to
the original design specification (modification or use
of a non-standard part) will invalidate the pump’s
safety certification.

6.3.2 Storage of spares

Spares should be stored in a clean dry area away
from vibration. Inspection and re-treatment of
metallic surfaces (if necessary) with preservative is
recommended at 6 monthly intervals.

6.4 Recommended spares

(For two years operation - as per VDMA 24296)

Item Designation

2100.1/

2100.2
2200 Impeller 1 2 3 30%
2215 Inducer 1 2 3 30%

2400.1

2400.2

2912.1 Impeller nut 1 2 3 30%
3013 Bearing - thrust 1 2 3 4 50%

3300.1 Bearing - pump end 1 2 3 4 50%

3300.2 Bearing - lineshaft # 1 2 3 4 50%

3400.1

3712.1 Bearing nut 1 2 3 4 50%
4120 Lantern halves # 1 2 3 30%

4130
4200 Mechanical seals # 1 2 3 30%

4305 Lip seal # 4 6 8 9 10 100%

4590.1

4590.2

4610.1 O-ring impeller 4 6 8 9 12 150%

4610.2 O-ring carrier 2 3 4 50%

4610.3

6570.8

6700.2 Impeller key 1 2 3 30%

# When required due to fitting as part of the original build specification.

Shaft 1 2 3 30%

Shaft sleeve ­pump end

Sleeve ­mechanical seal #

Shaft sleeve ­intermediate #

Gland packing ­complete set #

Pump casing
gasket

Discharge flange
gasket

O-ring mechanical
seal sleeve #

Shaft sleeve screw
for 3400.1

- Power end - - - - - 1 2

Number of pumps

(including stand-by)

2 3 4 5 6/7 8/9 10(+)

2 3 4 50%

2 3 4 50%

2 3 4 50%

2 3 4 40%

4 6 8 9 12 150%

4 6 8 9 12 150%

2 3 4 50%

2 3 4 50%

6.5 Tools required

A typical range of tools that will be required to
maintain these pumps is listed below.

Readily available in standard tool kits, and dependent
on pump size:

• Open ended spanners (wrenches) to suit up to
M 48 screws/nuts

• Socket spanners (wrenches), up to M 48 screws

• Allen keys, up to 10 mm (A/F)

• Range of screwdrivers

Soft mallet

More specialized equipment:

• Bearing pullers

• Bearing induction heater

• Dial test indicator

• C-spanner (wrench) - for removing shaft nut.

(If difficulties in sourcing are encountered, consult
Flowserve.)

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CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

6.6 Casing, seal housing and fastener
torques

Fastener Screw size Torque Nm (lbf ft)

All except where
otherwise stated

Impeller nut

M8
M10
M12
M16
M20
M12
M16
M22
M24

16 (12)
25 (18)
35 (26)
80 (59)

130 (96)

16 (12)
41 (31)

106 (79)

135 (100)

6.7 Setting impeller clearance

The impeller is pre-set at the factory. This procedure
is required after the pump has been dismantled.
a) Before carrying out this procedure ensure that any

mechanical seal(s) fitted can tolerate a change in
their axial setting, otherwise it will be necessary to
dismantle the unit and reset the seal axial position
after adjusting the impeller clearance.

b) Disconnect the coupling if it has limited axial

flexibility.

c) Record the gap between the bearing carrier

[3240.1] and stool [3160] using feeler gauges.

d) Loosen the bearing carrier setscrews [6570.3] and

back off the bearing carrier adjusting screws
[6570.4] by 2 mm (0.08 in.).

Some mechanical seal types may be

impaired if moved more than 0.5 mm (0.02 in.)
from their nominal setting.

e) Tighten the bearing carrier screws evenly, drawing

the bearing carrier towards the soleplate, until the
impeller contacts the pump casing. Turn the shaft,
during this procedure, until a detectable rub is
obtained. This is the zero clearance position.

The shaft must be turned in the direction

indicated on the casing and soleplate.

f) Set a dial indicator to zero on the shaft end or

measure the bearing carrier [3240.1] to stool

[3160] gap and record the measurement.
g) Slacken the bearing carrier setscrews [6570.3].
h) Tighten adjusting screws [6570.4] evenly (about

one flat at a time) drawing the bearing carrier away

from the soleplate until the impeller contacts the

impeller rear cover. Turn the shaft during this

procedure until a detectable rub is obtained. The

dial indicator or feeler gauge shows the

maximum float position from the zero clearance

position.
i) Evenly tighten the bearing carrier setscrews [6570.3]

keeping the dial indicator or feeler gauges reading

the correct setting. Then tighten the hexagon nuts

[6580.1] to lock the jacking screws in position.

j) Compare the nominal and final gaps between the

bearing carrier and soleplate to check if the
movement of the shaft permits sufficient clearance
in the axial direction. The impeller design
clearance is midway. Re-position the seal to

correct this.
k) Check that the shaft can turn freely without binding.
l) If a cartridge seal is fitted, reset it at this point.
m) Ensure the coupling distance between shaft ends

(DBSE) is correct. Reset/re-align if necessary.

6.8 Renewal clearances

As wear takes place between the impeller and casing
ring the overall efficiency of the pump set will
decrease. To maintain optimum efficiency it is
recommended that the wearing clearances tabulated
below are maintained.

Wearing clearances

Pump

size

65-100
50-125
50-160
40-200
40-250
32-125
32-160
32-200
65-125
65-160
50-200
50-250
50-315
80-125 111.47/111.38 93.54/93.45 0.71/0.53 0.64/0.46
25-161 55.54/55.47 55.54/55.47 0.60/0.46 0.60/0.46
80-160
65-200
65-250

65-315
100-160
100-200
100-250
125-250
100-315
125-315
100-400
125-225 168.10/168.00 168.10/168.00 0.80/0.60 0.80/0.63
125-400 184.00/183.90 184.00/183.90 0.71/0.53 0.71/0.53
150-250
150-315
150-400
200-401 269.24/269.14 269.24/269.14 0.85/0.65 0.85/0.65
150-500 219.47/219.37 219.47/219.37 0.73/0.53 0.73/0.53

Impeller hub diameter

(mm)

Front Back Front Back

82.54/82.45 82.54/82.45 0.64/0.46 0.64/0.46

70.54/70.47 70.54/70.47 0.60/0.46 0.60/0.46

93.54/93.45 93.54/93.45 0.64/0.46 0.64/0.46

111.47/111.38 111.47/111.38 0.71/0.53 0.71/0.53

152.47/152.37 152.47/152.37 0.67/0.53 0.67/0.53

209.40/209.30 209.40/209.30 0.80/0.60 0.80/0.63

Diametral ring or
casing clearance

mm)

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CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

On product lubricated bearings it is recommended
that these are renewed at the diametrical clearance in
the as fitted condition stated in the following table:

Bearing bush material

All 0.5 mm (0.02 in.)

Diametrical clearance in the

as fitted condition

It is recommended to renew when wearing clearances
have doubled.

6.9 Disassembly

Refer to Safety section before dismantling the

pump.

For pumps with heating jackets, ensure that the
pump is cooled down correctly and sufficiently before
handling. After evacuating the tank and shutting off
the pump, the pumped liquid flows down through the
pump into the sump. After approximately 30 minutes
the heating steam line should be closed.

b) Pull impeller off shaft.
c) Remove impeller key.
d) Remove impeller sealing gasket and discard. (A

new sealing gasket will be required for assembly.)

6.9.3 Support columns, shafts and bearings

a) Remove the two screws which fix the lower

bearing carrier to the lower support column.

b) Remove the lower bearing carrier.

Before dismantling the pump for
overhaul, ensure genuine Flowserve replacement
parts are available.

Refer to sectional drawings for part numbers and
identification. See section 8, Parts lists and drawings.

6.9.1 Pump disassembly

a) Disconnect all auxiliary pipes and tubes where

applicable.
b) Disconnect all discharge and auxiliary pipework.
c) Remove coupling guard, disconnect coupling and

remove motor.
d) If oil lubricated unit, drain oil.
e) Remove nuts securing soleplate to foundations

and lift the complete unit clear.
f) Record the gap between bearing carrier and

soleplate so that this setting can be used during

workshop assembly.
g) Remove suction pipe and/or strainer if fitted.
h) Remove all flushing lines as appropriate, casing

screws and discharge flange bolts.
i) Remove pump casing.
j) Remove pump casing and discharge flange

gaskets and discard. (A replacement gasket will

be required for assembly.)
k) Clean the gasket mating surfaces.

6.9.2 Impeller removal

a) Relieve impeller nut lockwasher from flat of impeller

nut. Remove impeller nut and lockwasher.

Where an inducer is fitted, this replaces
the impeller nut and lockwasher and is fitted with
Loctite 222.

If silicon carbide, carbon or high graphite
iron bearings are fitted extreme care should be taken
to avoid chipping or cracking these relatively brittle
components.

c) Unbolt and remove support column(s).
d) Unscrew the overhanging shaft section prior to

removing the next section of support column.

e) Any long length of shaft should be temporarily

supported to avoid bending or damage whilst
removing the muff coupling(s).

6.9.4 Bearings, seals and upper shaft

a) If a seal is fitted in the soleplate, determine its

type and remove the seal cover screws and any
accessible seal to shaft clamp screws as
appropriate.

b) Remove the bearing housing screws.
c) Drive out the labyrinth disk from the soleplate

(if fitted).

d) Pull the bearing housing and upper shaft assembly

out of the soleplate. Take care to support the long
shaft to avoid bending or damage to it and any
attached components.

e) Pull off the coupling and remove the coupling key.
f) Unscrew the bearing outer nut (left hand thread).
g) Remove the drive side flinger and or labyrinth seal

(if fitted) from the shaft.

h) Slide the bearing carrier off of the bearing(s).
i) Remove the bearing nut.
j) Pull off the bearing(s).
k) Loosen any remaining seal to shaft clamp screws

and slide the seal(s) and seal covers off the shaft.
Any bearings or sleeves can then be pressed out/off
as required after first removing any retaining screws.

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CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

6.10 Examination of parts

Used parts must be inspected before
assembly to ensure the pump will subsequently run
properly. In particular, fault diagnosis is essential to
enhance pump and plant reliability.

6.10.1 Casing, seal housing and impeller

Inspect for excessive wear, pitting, corrosion, erosion
or damage and any sealing surface irregularities.
Replace as necessary.

6.10.2 Shaft and sleeve (if fitted)

Obtain and fit a new shaft or sleeve if grooved, pitted
or worn.

6.10.4 Gaskets and O-rings

After dismantling, discard and replace.

6.10.5 Bearings

It is recommended that bearings are not re-used after
any removal from the shaft.

The plain bearings may be re-used if both the bearing
bush and bearing sleeve show no sign of wear, grooving
or corrosion attack. It is recommended that both the
bush and sleeve are replaced at the same time.

6.11 Assembly

To assemble the pump consult the sectional
drawings. See section 8, Parts lists and drawings.

Ensure threads, gasket and O-ring mating faces are
clean. Apply thread sealant to non-face sealing pipe
thread fittings.

6.11.1 Mechanical seal or gland packing seal

(If there is no mechanical seal or gland packing at the
soleplate, go to section 6.11.2, Thrust bearing carrier
and shaft sub-assembly.)

Where a mechanical seal is used, extreme cleanliness
is required during assembly. In many instances a pre­assembled cartridge seal will be used. Where this is not
the case the sealing faces must be checked to be free
from scratches or other damage.
a) Use olive oil for fitting elastomers.
b) Where an anti-rotation pin is fitted ensure that

correct engagement with the slot is achieved.

c) Carefully press stationary mechanical seal seat(s)

into their housing such that these are not deformed
or damaged.

d) Work to the specific manufacturer’s

instructions for the mechanical seal.

Where a packed stuffing box is fitted, pack the stuffing
box cover before fitting on to the shaft as follows:
a) Position each ring into the box individually, evenly

and firmly.

b) Check that the shaft sleeve freely rotates after

fitting the first ring.

c) Stagger the 45 degree scarf joints by 90 degrees

from each other in the box.
d) Insert the inner two packing rings.
e) Insert lantern ring halves (if required).
f) Insert the remaining packing rings.
g) Position the gland squarely against the last ring,

tighten the gland nuts finger-tight only and install

onto bearing housing assembly.

Jacketed sump pumps are fitted with a

gland packing seal at the soleplate.

6.11.2 Thrust bearing carrier and shaft sub­assembly

a) Clean the inside of the bearing carrier and bores

for the bearings.
b) On grease lubricated bearings fill the bearing

carrier retaining ring internal slot with the

appropriate grease. The three thin grease rings

may now be inserted into this internal slot.
c) The bearing carrier retaining ring sub-assembly

and bearing sleeve, applicable on shaft sizes 3

and 4, should now be placed over the shaft

before fitting the thrust bearing. The retaining

ring must have the C spanner slots facing the

impeller end.

(Note 1: On units fitted with a proprietary

soleplate mechanical seal, this and any additional

housing should be passed over the shaft before

the thrust bearing outer nut.)

(Note 2: In the case of a proprietary PTFE vapor

seal, this is fitted into the locking ring as a

subassembly. Place the thrust bearing on to the

shaft. If an optional pair of thrust bearings is to

be fitted, these must be mounted back-to-back,

as described below.)
d) Press the thrust bearing onto the shaft using

equipment that can provide a steady, even load

to the inner race.
e) Oil bath lubricated thrust bearing is an option.
f) If grease lubrication as standard, use a spatula to fill

sides of the bearing with grease of NLGI 3 grade.

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CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

On aggressive solvent/acid vapor
service a special fluoro-silicone grease (Molykote
FS3451) may be required. Pack the bearing fully
by hand as no grease nipple is used in the design.

g) Fit the self locking thrust bearing nut onto the

shaft and tighten with a C spanner.

h) Fit O-ring on the bearing carrier and lubricate the

bearing carrier bore and O-ring with oil.

i) Ensure the shaft coupling keyway edges are free

of burrs. If optional proprietary labyrinth type
bearing housing seals are used the O-rings
should be oiled to assist assembly.

j) Install the bearing carrier onto the shaft/bearing

assembly and screw the bearing carrier locking
ring into the bearing carrier. Tighten up the
bearing carrier locking ring using a C spanner.

LH thread.

k) Check shaft for free rotation.
l) Units with an oil lubricated bearing housing may

be fitted with shim-packs between the motor
pedestal and motor pedestal spacer. The shim­packs are factory set to ensure alignment
between pump and motor shafts and should be
re-fitted in their original positions.

m) To fit an inter bearing shaft sleeve, slide it over

the shaft from the impeller end and tighten up the
sleeve drive screw.

n) To fit the pump end sleeve, slide it over the shaft;

this is driven by the impeller.

6.11.3 Bearing bushes

a) If the pit depth and pump speed are such that an

intermediate bearing is fitted, this is pressed into
the upper support column. The pump end bush
is fitted into the pump end bush carrier [3240.2].

b) When fitting the intermediate bearing bush or

pump end bearing bush these must be pressed in
such that the chamfered end goes in first.

The orientation must be checked such
that locking pegs [6570.9] correctly line up.

6.11.4 Installing the shaft sub-assembly

a) Prior to assembling the shaft sub-assembly into the

soleplate, first fasten on the upper suspension
pipe/bearing bush sub-assembly to the soleplate.

b) If the sump is short there may only be a lower

suspension pipe. In this case, the lower
suspension pipe and the pump end bearing
carrier/bush will need to be fitted to the soleplate
to support the shaft subassembly.

If there is an upper suspension pipe,
the lower suspension pipe and pump end bearing
bush carrier should only be fitted after the shaft
sub-assembly. Install the shaft assembly into the
motor stool and soleplate until the bearing carrier
gap is nominally 4 mm (0.16 in.).

c) Install the bearing carrier hexagon screws and

the hexagon adjustment screws and hexagon
nuts but do not tighten.

d) Press the flinger onto the shaft, where applicable.

This should be set between 0.5 and 2 mm (0.02
and 0.08 in.) from the bearing carrier.

e) Turn the shaft to check for freedom from rubbing.
f) Refit the coupling.

6.11.5 Impeller and casing assembly

a) Install the impeller, impeller key, impeller

lockwasher and nut.

b) Torque up impeller nut.
c) Tighten the impeller nut and peen the lockwasher

onto the nut.

Where an inducer is fitted, this replaces
the impeller nut and lockwasher and is fitted with
Loctite 222.

d) Clean the casing spigot and gasket position

mating surfaces.

e) Fit a new casing gasket.
f) Install the pump casing with a new casing to

discharge gasket.

g) Install casing hexagon screws to the specified

torques.

h) Check freedom to rotate and impeller clearance

within pump casing.

6.11.6 Cartridge seal assembly (if fitted)

a) To set, or reset, a cartridge seal having a PTFE

setting ring-throttle and no separate setting clips,
finger tighten the seal cover stud nuts, then fully
torque up the sleeve screws.

b) Torque up the seal cover stud nuts.

Page 25 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

6.11.7 Coupling, motor and ancillaries

a) Reconnect pump ancillary fittings and piping.
b) Install pump into sump and connect up remaining

fittings and piping.
c) Re-check freedom of shaft to rotate by hand.
d) If pump has an oil lubricated thrust bearing, ensure

the oil breather and oiler are assembled in their

correct tappings as shown below and fill with the

correct grade and quantity of oil through the oiler.

e) Re-install motor (check for correct rotation) and

then fit coupling drive element and guards.
f) If all is correct continue with the procedure described

under Section 4, Installation and section 5,

Commissioning, start-up, operation and shutdown.

Page 26 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

7 FAULTS; CAUSES AND REMEDIES

FAULT SYMPTOM
Pump overhea ts and seizes

Bearings have sh ort life

⇓⇓⇓⇓

⇓⇓⇓⇓

Pump vibrate s or is noisy

⇓⇓⇓⇓

⇓⇓⇓⇓

Mechanical se al has short life

⇓⇓⇓⇓

⇓⇓⇓⇓

Mechanical se al leaks excessivel y

⇓⇓⇓⇓

⇓⇓⇓⇓

Pump requires excessive power

⇓⇓⇓⇓

⇓⇓⇓⇓

Pump loses prime after starting

⇓⇓⇓⇓

⇓⇓⇓⇓

Insufficient pressur e developed

⇓⇓⇓⇓

⇓⇓⇓⇓

Insufficient capacit y del ivered

⇓⇓⇓⇓

⇓⇓⇓⇓

Pump does not deliver liquid

⇓⇓⇓⇓

⇓⇓⇓⇓

⇓⇓⇓⇓

⇓⇓⇓⇓

PROBABLE CAUSES POSSIBLE REMEDIES

A. System troubles












B. Mechanical troubles

     

  

    
















 



    









 



  

  









  







  









 











 





 

Insufficient margin between suction pressure and

 

vapor pressure.
Excessive amount of air or gas in liquid. Check and purge pipes and system.

 

Inlet of suction pipe insufficiently submerged. Check out system design.



Speed too low. CONSULT FLOWSERVE.
Speed too high. CONSULT FLOWSERVE.
Total head of system higher than differential head

of pump.
Total head of system lower than pump design

head.
Specific gravity of liquid different from design.
Viscosity of liquid differs from that for which

designed.
Operation at very low capacity.

Operation at high capacity.

Misalignment due to pipe strain.

Improperly designed foundation.

Shaft bent.
Rotating part rubbing on stationary part internally. Check and CONSULT FLOWSERVE, if necessary.

Bearings worn Replace bearings.
Wearing ring surfaces worn. Replace worn wear ring/surfaces.

Impeller damaged or eroded.
Leakage under sleeve due to joint failure. Replace joint and check for damage.

Shaft sleeve worn or scored or running off centre. Check and renew defective parts.
Mechanical seal improperly installed.

Check NPSHA > NPSHR, proper submergence,
losses at strainers and fittings.

Check system losses.
Remedy or CONSULT FLOWSERVE.

Check and CONSULT FLOWSERVE.

Measure value and check minimum permitted.
Remedy or CONSULT FLOWSERVE.

Measure value and check maximum permitted.
Remedy or CONSULT FLOWSERVE.

Check the flange connections and eliminate strains
using elastic couplings or a method permitted.

Check setting of soleplate: tighten, adjust, grout
base as required.

Check shaft runouts are within acceptable values.
CONSULT FLOWSERVE.

Replace or CONSULT FLOWSERVE for improved
material selection.

Check alignment of faces or damaged parts and
assembly method used.

Page 27 of 36 flowserve.com

FAULT SYMPTOM
Pump overhea ts and seizes

Bearings have sh ort life

⇓⇓⇓⇓

⇓⇓⇓⇓

Pump vibrate s or is noisy

⇓⇓⇓⇓

⇓⇓⇓⇓

Mechanical se al has short life

⇓⇓⇓⇓

⇓⇓⇓⇓

Mechanical se al leaks excessivel y

⇓⇓⇓⇓





 



 

 

 

⇓⇓⇓⇓

Pump requires excessive power

⇓⇓⇓⇓

⇓⇓⇓⇓

Pump loses prime after starting

⇓⇓⇓⇓

⇓⇓⇓⇓

Insufficient pressur e developed

⇓⇓⇓⇓

⇓⇓⇓⇓

Insufficient capacit y del ivered

⇓⇓⇓⇓

⇓⇓⇓⇓

Pump does not deliver liquid

⇓⇓⇓⇓

⇓⇓⇓⇓

⇓⇓⇓⇓

⇓⇓⇓⇓

PROBABLE CAUSES POSSIBLE REMEDIES

  

  



 

 

 

Incorrect type of mechanical seal for operating
conditions.

Shaft running off centre because of worn bearings
or misalignment.

Impeller out of balance resulting in vibration.
Abrasive solids in liquid pumped.
Internal misalignment of parts preventing seal ring

and seat from mating properly.
Mechanical seal was run dry.

Internal misalignment due to improper repairs
causing impeller to rub.

Excessive thrust caused by a mechanical failure
inside the pump.

Excessive grease in ball bearings. Check method of regreasing.
Lack of lubrication for bearings.

Improper installation of bearings (damage during
assembly, incorrect assembly, wrong type of
bearing etc).

Damaged bearings due to contamination.

    

    

  

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

CONSULT FLOWSERVE.
Check misalignment and correct if necessary. If

alignment satisfactory check bearings for excessive
wear.

Check and CONSULT FLOWSERVE.

Check mechanical seal condition and source of dry
running and repair.

Check method of assembly, possible damage or
state of cleanliness during assembly.
Remedy or CONSULT FLOWSERVE, if necessary.

Check wear condition of impeller, its clearances and
liquid passages.

Check hours run since last change of lubricant, the
schedule and its basis.

Check method of assembly, possible damage or
state of cleanliness during assembly and type of
bearing used. Remedy or CONSULT
FLOWSERVE, if necessary.

Check contamination source and replace damaged
bearings.

C. MOTOR ELECTRICAL PROBLEMS










 






 















Wrong direction of rotation. Reverse 2 phases at motor terminal box.



Motor running on 2 phases only. Check supply and fuses.





Motor running too slow. Check motor terminal box connections and voltage.



Page 28 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

8 PARTS LISTS AND DRAWINGS

8.1 CPXV – WW/CW

Drawing taken from B736/507, sheet 1, rev A

Page 29 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

CPXV – WW/CW parts list

Item Description

1100 Casing

1350.1 Column pipe (lower)

1350.1 Column pipe (upper)
1360 Discharge pipe

1500.1 Wear ring (pump casing)

1500.2 Wear ring (P.E. bearing carrier)

2100.1 Shaft (lower)

2100.2 Shaft (upper)
2200 Impeller
2215 Inducer

2400.1 Sleeve (pump end)
2530 Retaining ring
3013 Thrust ball bearing
3160 Motor stool

3240.1 Bearing carrier, thrust

3240.2 Bearing carrier, pump end

3240.3 Bearing carrier, intermediate

3300.1 Bearing bush, pump end

3300.2 Bearing bush, intermediate

3400.1 Sleeve, intermediate

3712.1 Bearing nut

3712.2 Bearing outer nut

3840.1 Lubricating pipe

3840.2 Lubricating pipe
3853 Grease nipple
3864 Grease retainer rings
4300 Inpro bearing seal

4590.1 Gasket (pump casing)

4590.2 Gasket (discharge flange)

4610.1 O-ring (shaft sleeve)

4610.2 O-ring (bearing carrier)
6140 Sole plate
6531 Suction strainer
6541 Bearing nut lockwasher

6570.1 Screw (P.E. bearing bush)

6570.2 Screw (column/casing)

6570.3 Screw (bearing carrier)

6570.4 Screw (adjusting)

6570.5 Screw (stool/soleplate)

6570.6 Screw (motor/stool)

6570.7 Screw (discharge pipe/casing)

6570.8 Screw

6570.9 Screw (intermediate bearing bush)

6570.10 Screw (column)

6572.1 Stud (column/soleplate)

6580.1 Nut (locking)

6580.2 Nut (column/soleplate)

6580.3 Nut (suction strainer)

6580.4 Nut (discharge pipe/casing)

6580.5 Nut (column)

6700.1 Key (coupling)

6700.2 Key (impeller)
6810 Driving pin
7000 Coupling
7020 Muff coupling
7450 Coupling guard
8010 Motor

Page 30 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

sizes 1 and 2.)

Shaft rigid coupling

8.2 CPXV – WW/CW bearing options

7120

SHAFT RIGID COUPLING

6569.1

PAIR OF 40° ANGULAR CONTACT BEARINGS,

Pair of 40 degree angular contact bearings,

GREASE LUBRICATED.

grease lubricated. (No sleeve [2400.3] fitted

(NO SLEEVE (2400.3) FITTED ON SHAFT

on shaft sizes 1 and 2.)

SIZES 1 & 2)

3400.2

3300.2

241.1

2530.2

3400.1

3300.1

241.3

2530.3

Rigid coupling option

Item Description

7120 Rigid coupling (split)

Silicon carbide line bearings option

241.1 Tolerance ring

241.2 Tolerance ring

2530.2 Retaining ring

3300.2 Bearing bush

3400.2 Bearing sleeve

6569.1 Plug

6570.10 Screw

6570.10

241.2

6570.11

6570.12

241.4

3855

Pair of 40 degree angular contact bearings with

PAIR OF 40° ANGULAR CONTACT BEARINGS

oil lubrication option. (No sleeve fitted on shaft

WITH OIL LUBRICATION OPTION.

(NO SLEEVE FITTED ON SHAFT SIZES 1 & 2)

2540.2

6570.13
PROPRIATORY LABYRINTH RING

Proprietary labyrinth ring fitted into retaining ring.

FITTED INTO RETAINING RING,

Shown with optional flinger

Oil lubrication option

3855 Constant level oiler
4223 Pumping ring

6569.2 Plug (breather)

6569.3 Plug (oil drain)

Labyrinth ring option

4330 Labyrinth ring

Flinger option (short depths)

2540.2 Flinger (liquid)

6570.13 Screw

6569.2

4223

6569.3

4330

Page 31 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

Drawings taken from B736/048, sheet 4, rev F

Carbon segmental seal

Proprietary labyrinth seal

Magnetic seal

PTFE lip seal

8.3 CPXV – WW/CW sealing options

4590.3

Item Description

4590.3 Gasket *

* Liquid sealant used in specific builds.

Carbon segmental seal option

4305 Shaft seal ring

Proprietary labyrinth seal

4330 Labyrinth ring

Magnetic seal option

4305 Shaft seal ring

PTFE lip seal option

4305 Shaft seal ring

6572.3

6580.6

4110

4590.3

4610.3

Packed gland

Packed gland option

2400.2 Sleeve
4110 Stuffing box housing

4120 Gland
4130 Gland packing
4134 Lantern ring

4590.3 Gasket

4610.3 O-ring

6570.13 Screw

6572.2 Stud

6572.3 Stud

6580.5 Nut

6580.6 Nut

6570.13

4120

6580.5
4134

4130

6572.2

2400.2

Page 32 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

8.4 Parts interchangeability

Refer to the factory to ensure interchangeability
between units having different sizes of pump casing.

8.5 General arrangement drawing

The typical general arrangement drawing and any
specific drawings required by the contract will be sent
to the Purchaser separately unless the contract
specifically calls for these to be included into the User
Instructions. If required, copies of other drawings
sent separately to the Purchaser should be obtained
from the Purchaser and retained with these User
Instructions.

9 CERTIFICATION

Certificates determined from the Contract
requirements are provided with these Instructions
where applicable. Examples are certificates for CE
marking, ATEX marking etc. If required, copies of
other certificates sent separately to the Purchaser
should be obtained from the Purchaser for retention
with these User Instructions.

10 OTHER RELEVANT
DOCUMENTATION AND MANUALS

10.1 Supplementary User Instruction
manuals

Supplementary instruction determined from the contract
requirements for inclusion into User Instructions such as
for a driver, instrumentation, controller, sub-driver, seals,
sealant system, mounting component etc are included
under this section. If further copies of these are
required they should be obtained from the purchaser for
retention with these User Instructions.

Where any pre-printed set of User Instructions are
used, and satisfactory quality can be maintained only
by avoiding copying these, they are included at the
end of these User Instructions such as within a
standard clear polymer software protection envelope.

10.2 Change notes

If any changes, agreed with Flowserve Pump
Division, are made to the product after its supply, a
record of the details should be maintained with these
User Instructions.

10.3 Additional sources of information

Reference 1:

NPSH for Rotordynamic Pumps: a reference guide,
Europump Guide No. 1, Europump & World Pumps,
Elsevier Science, United Kingdom, 1999.

Reference 2:

Pumping Manual, 9th edition, T.C. Dickenson,
Elsevier Advanced Technology, United Kingdom, 1995.

Reference 3:
Pump Handbook, 2nd edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.

Reference 4:

ANSI/HI 1.1-1.5. Centrifugal Pumps - Nomenclature,
Definitions, Application and Operation.

Reference 5:

ANSI B31.3 - Process Piping.

Page 33 of 36 flowserve.com

Notes:

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

Page 34 of 36 flowserve.com

Notes:

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

Page 35 of 36 flowserve.com

CPXV - WW/CW USER INSTRUCTIONS ENGLISH 85392698 10-09

Your Flowserve factory contacts:

Flowserve Pumps
Flowserve GB Limited
Lowfield Works, Balderton
Newark, Notts NG24 3BU
United Kingdom

Telephone (24 hours) [phone]
Sales & Admin Fax [phone]
Repair & Service Fax [phone]
Email [e-mail]

Your local Flowserve representative:

North America:
Flowserve Pump Division
3900 Cook Boulevard
Chesapeake, VA 23323-1626, USA

Telephone [phone]
Customer Service Fax [phone]

Flowserve Pompes
Route d'Angers - 72234 ARNAGE
BP 305, 72001 LE MANS Cedex, France

Telephone (24 hours) [phone]
Sales & Admin [phone]
Repair & Service Fax [phone]

To find your local Flowserve representative please
use the Sales Support Locator System found at
www.flowserve.com

FLOWSERVE REGIONAL
SALES OFFICES:

USA and Canada

Flowserve Corporation
5215 North O’Connor Blvd.,
Suite 2300
Irving, Texas 75039-5421, USA
Telephone [phone]
Fax [phone]

Europe, Middle East, Africa

Worthing S.P.A.
Flowserve Corporation
Via Rossini 90/92
20033 Desio (Milan), Italy
Telephone [phone]
Fax [phone]

Latin America and Caribbean

Flowserve Corporation
6840 Wynnwood Lane
Houston, Texas 77008, USA
Telephone [phone]
Fax [phone]

Asia Pacific

Flowserve Pte. Ltd
200 Pandan Loop #06-03/04
Pantech 21
Singapore 128388
Telephone [phone]
Fax [phone]