Flowserve DMX User Manual
DMX/DMXD/DMXH/DMXDH centrifugal
pumps
USER INSTRUCTIONS
Installation
Operation
Multistage, single/double suction, horizontally split volute
type centrifugal pumps
PCN = 85392728 – 10/09 (E)
O
riginal instructions
Maintenance
SLEEVE/KTB CONFIGURATION
These instructions must be read prior to installing,
operating, using and maintaining the equipment.
DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
CONTENTS
1 INTRODUCTION AND SAFETY ...................... 3
1.1 General ....................................................... 3
1.2 CE marking and approvals ......................... 3
1.3 Disclaimer ................................................... 3
1.4 Copyright .................................................... 3
1.5 Duty conditions ........................................... 3
1.6 Safety.......................................................... 4
1.7 Warning labels ............................................ 7
1.8 Specific machine performance ................... 8
1.9 Noise level .................................................. 8
2 TRANSPORT AND STORAGE ...................... 10
2.1 Consignment receipt and unpacking ........ 10
2.2 Handling ................................................... 10
2.3 Lifting ........................................................ 10
2.4 Extended storage ..................................... 11
2.5 Recycling and end of product life ............. 14
3 PUMP DESCRIPTION .................................... 15
3.1 Configurations .......................................... 15
3.2 Name nomenclature ................................. 15
3.3 Design of major parts ............................... 15
3.4 Performance and operating limits ............. 16
4 INSTALLATION .............................................. 17
4.1 Location .................................................... 17
4.2 Foundation ................................................ 17
4.3 Grouting .................................................... 18
PAGE PAGE
5.5 Guarding................................................... 31
5.6 Priming and auxiliary supplies.................. 31
5.7 Starting the pump ..................................... 31
5.8 Running or operation ................................ 31
5.9 Stopping and shutdown ............................ 32
5.10 Hydraulic, mechanical and electrical duty 32
6 MAINTENANCE ............................................. 34
6.1 Maintenance schedule ............................. 34
6.2 Spare parts ............................................... 35
6.3 Recommended spares and consumable
items ......................................................... 35
6.4 Tools required ........................................... 35
6.5 Fastener torques ...................................... 35
6.6 Disassembly ............................................. 36
6.7 Examination of parts................................. 39
6.8 Assembly of pump and seal ..................... 40
7 FAULTS; CAUSES AND REMEDIES ........... 47
8 PARTS LIST AND DRAWINGS ..................... 49
9 CERTIFICATION ............................................ 55
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ...................................................... 55
10.1 Supplementary user instruction manuals . 55
10.2 Change notes ........................................... 55
10.3 Additional sources of information ............. 55
10.4 Customer Data Sheet ............................... 56
4.4 Initial alignment ......................................... 20
4.5 Piping ........................................................ 24
4.6 Electrical connections ............................... 26
4.7 Final shaft alignment check ...................... 27
4.8 Protection systems ................................... 27
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN .......................................... 28
5.1 Precommissioning procedure ................... 28
5.2 Pump lubricants ........................................ 29
5.3 Impeller wearring clearance ..................... 31
5.4 Direction of rotation .................................. 31
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
1 INTRODUCTION AND SAFETY
1.1 General
These Instructions must always be kept
close to product's operating location or directly
with the product.
Flowserve's 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 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
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 Flowserve's 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 Corporation.
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
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user seeks
Flowserve’s written agreement 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 substances
and toxic fluid” safety instructions where noncompliance would affect personal safety and could
result in loss of life.
This symbol indicates safety
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
This symbol indicates explosive atmosphere
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 indicates is used in safety
instructions to remind not to rub non-metallic surfaces
with a dry cloth; ensure cloth is damp. It is used 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 co-ordinate repair activity with operations and
health and safety personnel, and follow all plant safety
requirements and applicable safety and health laws
and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
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.)
Do not use pump as a support for piping. Do not
mount expansion joints, unless authorized by
Flowserve in writing, so that their force, due to
internal pressure, acts on the pump flange.
(See section 5, Commissioning, startup, operation
and shutdown.)
opened (Unless otherwise instructed at a specific
point in the user instructions). This is recommended
to minimize the risk of overloading at full flow and
damaging the pump at 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.)
pump is running. Running the pump at zero flow or
below the recommended minimum flow continuously
will cause damage to the pump and seals. Low flow
rates may cause a reduction in pump/bearing life,
Prevent excessive external pipe load
Ensure correct lubrication
Start the pump with outlet valve partly
Never run the pump dry.
Inlet valves to be fully open when
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
overheating of the pump, instability and cavitation/
vibration.
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 backpressure on
the pump may overload the motor and cause pump
cavitation.
Never do maintenance work when
the unit is connected to power.
When the pump is handling hazardous
liquids care must be taken to avoid exposure to
the liquid by appropriate sitting of the pump,
limiting personnel access and by operator
training. If the liquid is flammable and/or
explosive, strict safety procedures must be
applied.
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 an appropriate crane for the mass and in
accordance with current local regulations.
Coupling guards must not be removed while
the pump is operational.
THERMAL SHOCK
Rapid changes in the temperature of the liquid
within the pump will cause thermal shock, which
can result in damage or breakage of components
and should be avoided.
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must
be taken to avoid accidental contact. If complete
protection is not possible, the machine access
must be limited to maintenance staff only, with
clear visual warnings and indicators to those
entering the immediate area. Note: bearing
housings must not be insulated and drive motors
and bearings may be hot.
If the temperature is greater than 68 °C (154°F) or
below -5 °C (20 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
• Avoid excessive temperature
• Prevent the 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.
Both electrical and non-electrical equipment must
meet the requirements of European Directive
94/9/EC.
1.6.4.1 Scope of compliance
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of
the specific atmosphere in which they are to be
installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the ATEX pump set
shall select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating effects in the motor and so,
for 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.
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
II 2 GD c IIB 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D= Dust
c = Constructional safety
(in accordance with prEN13463-5)
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.)
1.6.4.3 Avoiding excessive surface
temperatures
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
contact between rotating and stationary components.
Where there is any risk of the pump being run against
a closed valve generating high liquid and casing
external surface temperatures, the users shall 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 shall
be made and dirt removed from areas around close
clearances, bearing housings and motors.
1.6.4.4 Preventing the build up of explosive
mixtures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient temperature of 40 °C
(104 °F); refer to Flowserve for higher ambient
temperatures.
The temperature of the liquid handled influences the
surface temperature on the pump. The maximum
permissible liquid temperature depends on the ATEX
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
prEN 13463-1
T6
T5
T4
T3
T2
T1
*The table only takes the ATEX temperature class into
consideration. Pump design or material as well as component
design or material may further limit the maximum working
temperature of the liquid.
Maximum surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
liquid
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, users shall fit an appropriate dry
run protection device (e.g. liquid detection or a power
monitor).
To avoid potential hazards from fugitive emissions of
vapor or gas to atmosphere the surrounding area
shall 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 baseplate shall be
properly grounded.
Avoid electrostatic charge: do not rub non-metallic
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
surfaces with a dry cloth; ensure cloth is damp.
The coupling must be selected to comply with 94/9/EC
and correct alignment must be maintained.
1.6.4.6 Preventing leakage
The pump shall 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 shall be
monitored.
1.7 Warning labels
If leakage of liquid to atmosphere can result in a
hazard, then a liquid detection device shall be
installed.
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 owner
or operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
A maintenance plan and schedule shall be adopted.
(See section 6, Maintenance).
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
Oil lubricated units only:
1.8 Specific machine performance
For performance parameters see 10.4 Customer
Data Sheet. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. 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.
1.9.1 Pump noise levels
The following tables may be used to determine the
estimated sound pressure levels (SPL), expressed in
dBA (dB), for DMX/DMXD/DMXH/DMXDH pumps.
The values shown have been derived from actual
noise test data and are based on the following
conditions:
a) Equipment is located in a free field above a
reflecting plane in which the reduction in noise
level in all directions is 6 dB in each octave band
for each doubling of distance.
b) Background noise is 10 dB (minimum) below all
noise levels in each octave band.
c) The values shown are at a distance of 1 m
(3.281 ft), horizontally from major pump surfaces
and 1.5 m (4.78 ft) above the floor using the
standard pressure reference of 20 µPa
(0.00002 N/m2).
d) Overall noise level, dBA ("A" scale) is determined
at points of maximum noise level, and the values
of all mid-band frequencies are basis "C" scale
readings.
1.9.2 Overall noise level
Tables below show dBA levels for two stage and
three or more stage pumps, based on the best
efficiency point BEP at design RPM and required
impeller diameter.
For specific gravities less than 1.0, use 1.0 specific
gravity. For specific gravities above 1.0, use the
actual specific gravity.
When the required condition flow falls outside the
range of 75% to 125% of BEP, a Part Load
Correction (PLC) must be added to the noise levels
as follows:
Percent of BEP at required Impeller
Diameter
74 to 62 % or 126 to 136 % +1
61 to 50 % or 137 to 150 % +2
49 to 38 % +3
37 to 25 % +4
PLC DB
Brake Horse Power at Best Efficiency
Point.
2 Stage pump
250 to 350 87
350 to 500 88
500 to 700 89
700 to 940 90
940 to 1100 91
1100 to 1300 92
1300 to 1500 93
Above 1500, contact Flowserve 94
dBA
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
Brake Horse Power at Best Efficiency
Point.
3 to 14 Stages
90 to 110 79
110 to 140 80
140 to 180 81
180 to 220 82
220 to 280 83
280 to 360 84
360 to 450 85
450 to 560 86
560 to 720 87
720 to 900 88
900 to 1125 89
1125 to 1400 90
1400 to 1800 91
1800 to 2250 92
2250 to 2800 93
2800 to 3600 94
3600 to 4500 95
4500 to 5700 96
5700 to 7200 97
7200 to 9000 98
9000 to 11,000 99
11,000 to 14,000 100
dBA
1.9.3 Combined noise levels for pump and
driver components
When two or more sources produce noises that are
sufficiently unrelated (so that interference effects do
not occur) the total combined noise level may be
obtained by a simple addition of dB values according
to the below table.
Difference between two
levels to be Combined, dB
0 3
1 2.5
2 2
4 1.5
6 1
9 0.5
10 0
Add to higher level to
obtain Combined level, dB
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation.
Any shortage and or damage must be reported
immediately to Flowserve and received in writing
within one month of receipt of the equipment. Later
claims cannot be accepted.
Check any crates, boxes and wrappings for any
accessories or spare parts which may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check that
this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.1.1 Receipt inspection
In general, care is to be taken when removing
crating, coverings, and strapping in order not to
damage any auxiliary equipment and/or the paint
finish.
2.1.3 Paint/rust preventive
Internal parts of the pump and bearing housings are
protected prior to shipment with a rust preventive
such as Dasco guard 2408M. This can be removed
with petroleum solvents.
External non-machined surfaces are painted with one
of applicable Flowserve coating.
Parts ordered separately are protected with a rust
preventive such as Dasco guard 2408M. This can be
removed with petroleum solvents.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using forklift vehicles or slings dependent on their
size and construction.
2.3 Lifting
The following information regarding
receiving is only offered as a general guideline to the
customer. Flowserve requires that all receiving
be conducted in accordance with specifications set
forth in Chapter 3, Jobsite Receiving and Protection
from API Recommended Practices 686/PIP REIE
686, First Edition.
The pump and its associated equipment were
carefully inspected at the factory prior to
shipment to ensure quality compliance. It is
suggested that the pump be inspected upon
arrival and that any irregularities or damage be
reported to the carrier immediately.
The condition of the skid and covering is indicative of
the way the shipment was handled. Broken skids,
torn coverings, bent hold-down bolts, broken straps,
etc. indicate rough handling.
The protective covers on the pump nozzles should be
in place and undamaged.
2.1.2 Unpacking
The pump should arrive already mounted on the
baseplate and it is therefore suggested that the
unpacking of the equipment should proceed per
instruction as outlined in this manual.
To avoid distortion, the pump unit
should be lifted as shown.
TRAINED PERSONNEL
A crane must be used for all pump sets in excess
of 25 kg (55 lb). Fully trained personnel must
carry out lifting, in accordance with local
regulations. The driver and pump weights are
recorded on their respective nameplates or mass
plates.
2.3.1 Lifting equipment
The following information regarding lifting is
only offered as a general guideline. Flowserve
requires that all lifting and rigging be performed in
accordance with specifications set forth in Chapter 2,
Lifting and Rigging from API Recommended
Practices 686/PIP REIE 686, First Edition.
EQUIPMENT CAPACITY
Make sure that any equipment used to lift the
pump or any other of its components is capable
of supporting the total weight encountered. Make
sure that all parts are properly rigged before
attempting to lift.
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
2.3.2 To lift unit
The complete unit with pump, driver
and auxiliary equipment all mounted on the baseplate
can NOT be lifted as a unit. Driver must be removed
from baseplate before lifting. To lift unit sling
baseplate from all lifting eyes. Failure to do this may
result in permanent deformation of baseplate.
Damage to baseplate caused by mishandling or
improper setting prior to grouting is not covered by
Flowserve’s warranty.
2.3.3 To lift driver
Refer to driver manufacturers instructions.
2.3.4 To lift pump
Install sling from overhead hoist and under bearing
housing mounting brackets (cast portion of casing
where bearing housings attach).
To lift the pump bottom half casing, slings can be
attached to the pump feet, casing boltholes or
padded slings can be used around the outer casing.
2.3.6 To lift pump rotor
Using slings that will not damage shaft, rig around
shaft close to the impellers and to overhead hoist.
Carefully lift rotor from lower half casing.
Proper lifting practice for pump
2.4 Extended storage
Proper lifting practice for pump
LIFTING PRACTICE
Do not lift entire pump from cast lifting lugs on
upper half casings. These lugs are for lifting
upper half casing only.
2.3.5 To lift half casing
To lift upper half casing, rig to overhead hoist from
cast lifting lugs provided.
Proper lifting practice for upper case
The following information regarding
receiving is only offered as a general guideline.
Flowserve requires that all receiving be conducted in
accordance with specifications set forth in Chapter 3,
Jobsite Receiving and Protection from API
recommended Practices 686/PIP REIE 686, First
Edition.
During extended periods of storage prior to
installation and from the time of installation until
commercial operation, precautions must be taken to
protect the pump from deterioration. The various
parts of the pump are protected prior to shipment by
applying varying grades of preservative and paint.
However, during shipment and handling, the
preservatives are subjected to conditions that can
cause their removal. Also, during extended periods of
time, the preservatives may deteriorate. The following
procedures should be followed to prevent
deterioration of the pump during the extended
storage period. These procedures may also be
supplemented by the experience of the person(s)
performing the tasks.
It should be noted, that unless otherwise agreed to,
full responsibility and costs associated with the
storage and inspection of this equipment rests with
the customer.
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
If pump is equipped with a mechanical
seal and is stored or has not been run for 1 year or
more, the mechanical seal must be removed before
start-up and faces re-lapped to guard against the
possibility of seal leakage. When reinstalling the seal,
new “O” rings and gaskets must be used.
2.4.1 Pump inspection upon arrival
When the pump is received, it should be inspected
for damage or other signs of rough handling. Any
damage if found should be reported to the carrier
immediately.
Inspect the preservative coating on the various parts.
If necessary, renew the preservative in areas where it
has rubbed off or scraped.
Inspect all painted surfaces. If necessary, touch up
the areas where paint has been chipped or scraped.
Inspect all covers over pump openings and piping
connections. If covers or seals for the covers are
damaged or loose, they are to be removed, and a
visual inspection made of the accessible interior
areas for accumulation of foreign materials or water.
If necessary, clean and re-coat the interior parts with
preservative to restore the parts to the “as shipped”
condition. Install or replace covers and fasten secure.
2.4.2 Storage area
When selecting a storage area, the following should
be taken into consideration:
a) The deterioration of the equipment will be
proportionate to the class/type of storage
provided.
b) The expenses involved in restoring the
equipment at time of operation will be
proportionate to the class/type of storage
provided.
2.4.3 Storage preferred (dry)
If at all possible, the pump and its components
should be stored indoors where they will be protected
from the elements. If it is not possible to store the
pump and its components indoors, precautions must
be taken to protect them from the elements.
Regardless of whether storage is inside or outside,
the storage area should be vibration-free. All boxes
that are marked for inside storage must be stored
indoors. Coverings of heavy gauge plastic sheets,
canvas, waterproof burlap or other suitable coverings
should protect the pump and its components from
dirt, dust, rain, snow or other unfavorable conditions
when stored outdoors.
All equipment must be placed upon skids or blocks to
prevent contact with the ground and surface
contaminants. Equipment must be adequately
supported to prevent distortion and bending.
2.4.3.1 Rotor storage
It is recommended that pump rotor be removed from
pump and stored vertically. Rotors may also be
stored horizontally in the pump. Rotors that have to
be stored horizontally outside the pump must be
supported close to impeller to eliminate sag that may
cause rotor to take a permanent set.
2.4.3.2 Customer inspection
The stored equipment is to be placed on a periodic
inspection schedule by the customer.
The responsibility for setting up an
inspection and maintenance schedule rests with the
customer and will be dependent upon the class/type
of storage provided. It will be expected that initially
inspection would occur weekly, then depending upon
the inspection reports being favorable or unfavorable,
inspection would continue weekly, monthly, or
quarterly, as may be determined. Inspection reports
must be kept on file.
Every inspection should consist of a general surface
inspection.
a) Pump supports are firmly in place.
b) Pump covers over openings are firmly in place.
c) Pump coverings, plastics or tarps, are firmly in
place. Any holes or tears must be repaired to
prevent entrance of dirt or water.
d) Pump covers are periodically removed from
openings and interior accessible areas inspected.
If surface rusting has occurred, clean and repaint
or re-coat with preservative.
e) If rusting occurs on exterior surfaces, clean and
repaint or re-coat with preservative.
f) Loosen casing drain plugs to allow seepage of
any accumulated moisture.
g) If the rotor is stored horizontally, rotate pump
rotor 1-1/4 revolutions at least once a month to
prevent rotor from taking a permanent set.
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
Make sure bearings have adequate
lubrication before turning rotor.
The oil inlet blanking plates should be
removed and a small amount of oil injected into the
bearings before turning. Refit blanking plates.
h) Periodically remove bearing covers and inspect
for accumulation of moisture, rust and foreign
material. As required, clean bearings and bearing
housing and re-preserve. Install bearing cover
and secure to assure maximum protection.
Bearings removed for storage should be coated
with preservative, wrapped in oil/wax paper, and
stored in a warm dry area.
i) Check individually wrapped parts for signs of
deterioration. If necessary, renew preservative
and wrapping.
If storage is over one month,
Instrumentation (Controls, Electrical devices,
Temperature switches) should be removed and
placed in a climate control environment if
Instrumentation is not powered up.
2.4.3.3 Prior to installation maintenance
Six months prior to the scheduled installation date, a
Flowserve representative is to be employed to
conduct an inspection. All costs involved during
inspection, dismantling, restoration, replacement of
parts, and reassembly will be the responsibility of the
customer. The customer will supply all necessary
labor, tools, and cranes. This inspection will include
(not necessarily in its entirety) but not be limited to
the following:
a) An inspection of all periodic inspection records as
kept on file by the customer, and all inspection
reports that have been compiled during the
storage period.
b) An inspection of the storage area to determine
the “as stored” condition of the equipment prior to
any protection being removed.
c) An inspection of the equipment with protection
covers and flange covers removed.
d) Depending upon the length of time the equipment
was stored, the class/type of storage provided,
(i.e.: indoor, heated, unheated, ground floor,
concrete floor, out-of-doors, under roof, no roof,
waterproof coverings, on concrete, on ground)
and as a result of the inspection of a, b and c
above, Flowserve representative may require a
partial or complete dismantling of the equipment.
e) Dismantling may necessitate restoration of
painted or preserved surfaces, and/or
replacement of gaskets, “O” rings and
mechanical seal and bearings. Use only
Flowserve recommended replacement materials.
Upon completion of the inspection, the Flowserve
representative shall submit a report to the Customer,
and to the Manager of Customer Service, stating in
detail the result of the inspection.
If there are any discrepancies identified, it is the
customer's responsibility for correction before initial
startup.
2.4.4 Storage non-preferred (wet)
It is not recommended that the rotor be subjected to
extended periods of submergence or wetting prior to
start-up. However, it is recognized that in some
cases, a long period of time may lapse from
installation until commercial operation.
If the pump must be stored after being installed and
wetted, the following inspection and maintenance
should be performed.
• Isolate the pump with valving - tag (seal) all
valves.
• Preserve the pump internals.
If storage is over one month,
Instrumentation (Controls, Electrical devices,
Temperature switches) should be removed and
placed in a climate controlled environment if
Instrumentation is not powered up.
Electric motors (pump driver) should
not be stored in damp places without special
protection (refer to motor manufacturer’s
instructions).
2.4.4.1 Corrosive pumpage.
Fill entirely the pump with an approved preservative
such as #2004-Chempagard 9 from Chempak. The
pump should be filled to highest level possible,
affording the greatest protection possible to all
internal parts of the pump.
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
This solution, when drained, will result in a thin
residual oil film (less than 0.0127 mm (0.0005 in.)) on
all internals after the water has evaporated. This
residue provides added corrosion protection until
pump is again filled with liquid or put into service.
Pump cannot be fully drained. Volutes in
the lower half cannot be drained below the bottom of
the main casing bore.
2.4.4.2 Non-corrosive pumpage.
Fill pump with pumpage to the highest level possible.
Open periodically drain connection to drain off any
moisture that may have accumulated. Refill to highest
level possible. Drain and inspect pump prior to startup.
a) Rotate pump rotor 1-1/4 revolutions at least once
a month.
Make sure bearings have adequate
lubrication before turning rotor.
b) Periodically remove bearing covers and inspect
for accumulation of moisture, rust and foreign
material. As required, clean bearings and bearing
housing and re-preserve. Install bearing cover
and secure to assure maximum protection.
2.4.4.3 Painting and preservation
Paints and preservatives used are either Flowserve
standard or special as required by the contract
specification. Refer to 2.1.3, Paint/Rust Preventive for
the description of paints and preservatives used in
this order or contact the branch office through which
the order was placed.
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 regulations. If the
product contains substances which 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 in the "seal system"
or other utilities.
specifications must be in accordance with the current
regulations at all times.
Make sure that hazardous substances or
toxic fluids are disposed of safely and that the correct
personal protective equipment is used. The safety
Page 14 of 60
DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
3 PUMP DESCRIPTION
The “DMX” is a multistage single or double suction,
opposed impeller, horizontally split volute pump.
The suction and discharge nozzles are cast integral
with the lower half casing. Rotating parts are
accessible by removing the upper half casing, which
can be removed without breaking suction and
discharge piping.
3.1 Configurations
The DMX can have the following configurations:
3.1.1 Single suction
Single suction configuration
Single suction impeller at first stage (DMX)
3.1.2 Double suction
Double suction configuration
Double suction impeller at the first stage (DMXD)
3.2 Name nomenclature
The pump nomenclature is: 3X10DMX10
The 3 is the pump discharge size
The X is the separator
The 10 is the nominal impeller size
The DMX is pump type
The 10 is the number of stages and depending
on pump size, they go from 2 to 14 stages
DMX= Single suction standard pressure
DMXD = Double suction standard pressure
DMXH = Single suction high pressure
DMXDH = Double suction high pressure
3.3 Design of major parts
3.3.1 Casing
The casing provides for immediate containment of
the liquid being pumped, while directing the flow of
liquid from the suction nozzle to the impellers and
subsequently through the volute to the discharge
nozzle.
The casing halves are sealed by the use of a gasket
and are joined together by studs, which are installed
in the lower half casing and fastened with washers
and cap-nuts.
3.3.2 Impellers
The series’ impellers are single suction, enclosed
type, and one-piece construction and are dynamically
balanced. They are fitted with renewable impeller
rings (front and back), which are held in place by
headless set-screws.
The impellers are keyed and have a shrink fit to the
pump shaft. They are held in axial position by a split
ring.
3.3.3 Casing rings
Casing rings are positioned over the impeller front
rings. These rings are tubular and renewable.
3.3.4 Channel rings
Renewable cast channel rings are positioned over
the impeller back rings. They divide the casing into
stages. These rings are horizontally split and are held
together by shoulder screws or dowel pins.
3.3.5 Center sleeve
A renewable type center sleeve is used under the
center bushing. The center sleeve is tubular and
keyed to the shaft (via the impeller key).
3.3.6 Center bushing
The renewable center bushing is horizontally split,
and the two halves are held together by socket head
cap screws and taper dowel pins. It is held in position
by the raised annular ring of the bushing engaging
the annular groove in the casing. The center bushing,
in conjunction with center sleeve, divides the casing
at the center (back to back) impellers.
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DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
3.3.7 Throttling sleeve
Renewable type throttling sleeve is used under the
throttling bushing. The throttling sleeve is tubular,
keyed, has a shrink fit to the shaft, and is held in
position by a split ring.
3.3.8 Throttling bushing
Renewable type throttling bushing is used. It is held
in position by the raised annular ring of the bushing
engaging the annular groove in the casing. The
throttling bushing, in conjunction with the throttling
sleeve, allows pressure to be bled off through the
balance line, so that pressure on the Seal Chambers
is balanced. The throttling bushing also balances the
axial thrust of the pump rotor.
3.3.9 Crossover sleeve
A renewable type crossover sleeve under crossover
bushing is only used on double suction pumps
(DMXD/DMXDH). The crossover sleeve is tubular,
keyed, has a shrink fit to the shaft, and is held in
position by a split ring.
3.3.10 Crossover bushing
A renewable type crossover bushing is only used on
double suction pumps (DMXD/DMXDH). The
crossover bushing is horizontally split, and the two
halves are held together by taper dowel pins. It is
held in position by the raised annular ring of the
bushing engaging the annular groove in the casing.
The crossover bushing, in conjunction with crossover
sleeve, controls the leakage between the first and
second stage impellers.
3.3.11 Shaft
The high strength shaft is ground over its entire
length to close tolerances. The shaft is designed to
transmit the required power without vibration and is
stepped at each impeller fit for ease of assembly and
disassembly.
3.3.12 Bearings
The sleeve bearings are carbon steel backed, babbitt
lined, sleeve type insert bearings. The renewable
bearing inserts are mounted in bearing housings kept
from rotating by means of stop pins.
Each bearing is lubricated by an external pressure
supply system.
The thrust bearing is of the titling type with pads on
each side of the shaft mounted thrust
collar. It is capable of transmitting the thrust load in
either direction. It is lubricated from the
pressure lubrication system.
3.3.13 Seal Chambers
The Seal Chambers are cast integral with the casing.
Your pump is typically shipped with the mechanical
seal already installed.
The mechanical seal is designed to suit each
application. This creates the correct seal loading
face when seal gland is bolted in place.
Cartridge type mechanical seals are preset at the
seal manufacturer’s facility and require no field
settings. The seal installation should be checked
before startup.
Refer to the mechanical seal manufacturers drawing
and instructions found in section 8 of this manual for
detailed information.
3.4 Performance and operating limits
Refer to section 10.4 Customer Data Sheet.
Page 16 of 60
DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
4 INSTALLATION
The installation/commissioning of this
equipment must be conducted in accordance with
API Recommended Practices 686/PIP REIE 686 First Edition.
Copies of API Recommended ‘Practices’ 686/PIP
REIE 686 - First Edition may be obtained from
America Petroleum Institute
1220 L Street, N.W.
Washington, D.C. 20005.
Telephone: (202) 682-8000.
4.1 Location
Install the unit close to the source of the liquid to be
pumped.
Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
When selecting the location, be sure to allow
adequate space for operation as well as for
maintenance operations involving dismantling and
inspections of parts.
Headroom is an important consideration as an
overhead lift of some type is required.
4.2 Foundation
The following information regarding
foundation is only offered as a general guideline.
Flowserve requires that all foundations be designed
and installed in accordance with specifications set
forth in Chapter 4, Foundations from API
Recommended Practices 686/PIP REIE 686, First
Edition.
The design of foundation is not the responsibility of
Flowserve. It is therefore recommended that the
customer consult a competent specialist skilled in the
field of foundations, to insure proper
design/installation of the foundation.
The foundation should be properly prepared
according to the planned grouting method. See 4.3
Grouting for details.
The foundation should be rigid and substantial to
support the baseplate at all points to prevent any
pump vibration and to permanently.
The most satisfactory foundations are made of
reinforced concrete. These should be poured well in
advance of the installation to allow proper time for
drying and curing.
The General Arrangement Drawing will show
required anchor bolt locations and size of bolts.
Allow a little more than the specified threaded bolt
length above the rail of the baseplate. The excess
can always be cut off if it is not needed.
A clean rough-finish top surface is required when
applying grout.
4.2.1 Installation check list
a) Level Baseplate.
b) Preliminary Alignment.
c) Grout Baseplate - Check Foundation Bolts
d) Alignment Shaft/Coupling.
e) Piping installed – correct vent, gauge, valve,
suction strainer and pipe support locations?
f) Check Coupling Alignment.
g) Coupling guard correctly installed?
4.2.2 Level the baseplate
The following information regarding leveling
of equipment is only offered as a general guideline.
Flowserve requires that all leveling of equipment be
performed in accordance with specifications set forth
in Chapter 5, Mounting Plate Grouting from API
Recommended Practices 686/PIP REIE 686, First
Edition.
Before putting the unit on the foundation, thoroughly
clean the top of the foundation. Break off any loose
pieces of cement and roughen the top with a chisel to
afford a good hold for grout.
When lifting baseplate with pump, sling
baseplate from all lifting eyes provided. Failure to do
Page 17 of 60
DMX/DMXD/DMXH/DMXDH USER INSTRUCTIONS ENGLISH 85392728 - 10/09
this may result in permanent deformation of
baseplate.
Pump, driver auxiliary equipment and
piping shall be removed from the baseplate before
leveling the baseplate.
Locate the baseplate in its proper position on the
concrete block together with the leveling screws as
shown in the General Arrangement Drawing.
Using a precision level across the machined surfaces
of the pump and driver mounting pads, adjust leveling
screws as necessary to ensure that baseplate is
leveled in all directions.
When the baseplate is leveled, snug the foundation
bolts, but do not completely tighten.
4.2.3 Preliminary alignment
Using the previous procedure, adjust baseplate until
pump and driver are within 0.076 mm (0.003 in.).
4.3 Grouting
The following information regarding
grouting is only offered as a general guideline.
Flowserve requires that all grouting be installed in
accordance with specifications set forth in Chapter 5,
Mounting Plate Grouting from API Recommended
Practices 686/PIP REIE 686, First Edition. Refer to
API 610 - Eighth Edition - Appendix `L` for baseplate
grouting requirements. It is recommended that the
customer consult a competent specialist skilled in the
field of grouting, to insure the proper installation of all
grouting.
The following ASTM Specifications are furnished as
references for test methods used in conjunction with
installation of grouting materials and should be used
to obtain proper results:
ASTM C 78-84, Test Method for Flexural Strength for
Concrete
ASTM C 109-90, Test Method for Compressive
Strength of Hydraulic Cement Mortars – Modified
ASTM C 469-87a, Test Method for Static Modulus of
Elasticity and Poisson’s Ratio of Concrete in
Compression
ASTM C 496-90, Test Method for Splitting Tensile
Strength of Cylindrical Concrete Specimens
ASTM C 531-85, Test Method for Linear Shrinkage
and Coefficient of Thermal Expansion of Chemical
Resistant Grouts and Monolithic Surfacing - Modified
ASTM C 666-90, Test Method for Resistance of
Concrete to Rapid Freezing and Thawing
ASTM C 939-87, Test Method for Flow of Grout for
Preplaced Aggregate Concrete (Flow Cone Method)
ASTM C 942-86, Test Method for Compressive
Strength of Grouts for Preplaced Aggregate Concrete
in the Laboratory
ASTM C 1090-88, Test Method for Measuring
Changes in Height of Cylindrical Specimens from
Hydraulic Cement Grout
ASTM C 1107-91, Standard Specification for
Packaged Hydraulic-Cement Grout (Non-Shrink)
(CRD-C 621-92), ACI 351, Grouting for Support of
Equipment and Machinery
24-Hour Test, MBT Test Method for Grout
Performance
Minimum requirements for epoxy grout
(typical properties at 23 oC (73 oF))
ASTM D-635, Fire Resistant
ASTM C-579B, Minimum Compressive Strength –
12000 psi
ASTM C-827, Height Change @ 38 oC (100 oF) –
Positive – Effective Bearing Area – 95%
ASTM C-1181, Maximum Creep in 1 Year –
1.6X10
-3
in./in. at 140 oF, 400 psi
ASTM C-307, Minimum Tensile Strength – 12.4 Mpa
(1800 psi)
ASTM C-580, Minimum Flexural Strength – 26.2 Mpa
(3800 psi)
ASTM C-580, Minimum Flexural Secant Modulus –
1.2X104 Mpa (1.8X106 psi)
ASTM C-531, Maximum Coefficient of Expansion –
-6
17X10
in./in./oF. Maximum Peak Exotherm 1000 g
(35.27 oz.) insulated – 35 oC (95 oF). Full Aggregate
Must Be Used.
Page 18 of 60
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