Flowserve DS User Manual

USER INSTRUCTIONS

DS centrifugal pump

Single-stage, horizontal end suction, double volute type
centrifugal pump

PCN=71576283 – 02/13 (E) Original instructions.

Installation

Operation

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

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 .......................... 8

1.8 Specific machine performance ....................... 8

1.9 Noise level ...................................................... 9

2 TRANSPORT AND STORAGE ........................... 11

2.1 Consignment receipt and unpacking ............ 11

2.2 Handling ....................................................... 11

2.3 Lifting ............................................................ 12

2.4 Storage ......................................................... 12

2.5 Recycling and end of product life ................. 12

3 PUMP DESCRIPTION ......................................... 13

3.1 Configurations .............................................. 13

3.2 Nomenclature ............................................... 14

3.3 Design of major parts ................................... 15

3.4 Guide to store “vulcanized rubber” ............... 15

Page

6 MAINTENANCE .................................................. 24

6.1 General ......................................................... 24

6.2 Maintenance schedule ................................. 25

6.3 Spare parts ................................................... 30

6.4 Recommended spares and consumable ..........

items ................................................................... 30

6.5 Disassembly ................................................. 30

7 FAULTS; CAUSES AND REMEDIES ................. 32

8 PARTS LIST AND DRAWINGS .......................... 33

8.1 Sectional drawings ....................................... 33

8.2 Sectional drawing parts list ........................... 34

8.3 General arrangement drawing ...................... 34

9 CERTIFICATION ................................................ 34

10 OTHER RELEVANT DOCUMENTATION AND

MANUALS .............................................................. 34

10.1 Supplementary User Instructions ............... 34

10.2 Change notes ............................................. 34

10.3 Additional sources of information ............... 34

4 INSTALLATION .................................................... 16

4.1 Location ........................................................ 16

4.2 Foundation ................................................... 16

4.3 Grouting ........................................................ 17

4.4 Initial alignment ............................................ 17

4.5 Piping ........................................................... 18

4.6 Electrical connections................................... 20

4.7 Final shaft alignment check .......................... 20

4.8 Protection systems ....................................... 20

5 COMMISSIONING, START-UP, OPERATION AND

SHUTDOWN ........................................................... 20

5.1 Direction of rotation ...................................... 20

5.3 Priming and auxiliary supplies ...................... 21

5.4 Starting the pump ......................................... 21

5.5 Running the pump ........................................ 22

5.6 Stopping and shutdown ................................ 23

5.7 Hydraulic, mechanical and electrical duty .... 24

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INDEX

Page

Additional sources (10.3) ....................................... 34

Alignment of shafting (see 4.2, 44 and 4.7)

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

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

Certification (9) ...................................................... 34

Change notes (10.2) .............................................. 34

Commissioning, start-up, operation (5) ................. 20

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

Configurations (3.1) ............................................... 13

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

Design of major parts (3.3) .................................... 15

Direction of rotation (5.1) ....................................... 20

Disassembly (6.5) .................................................. 30

Discharge piping (4.5.3) ....................................... 19

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

Dismantling (see 6.5, Disassembly) ...................... 30

Drawings (8.1) ....................................................... 33

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

Ecodesign (1.8.1) ..................................................... 9

Electrical connections (4.6) ................................... 20

End of product life (2.5) ......................................... 12

Faults; causes and remedies (7) ........................... 32

Final checks (4.5.4) .............................................. 19

First pump start up (5.4.2) .................................... 22

Foundation (4.2) .................................................... 16

General arrangement drawing (8.3) ...................... 34

Gland packing (6.2.5) ............................................ 29

Grouting (4.3) ......................................................... 17

Guarding (5.2) ........................................................ 21

Handling (2.2) ........................................................ 11

Hydraulic, mechanical and electrical duty (5.7) ..... 24

Inspection (6.2.1 and 6.2.2) ................................... 26

Installation (4) ........................................................ 16

Internal coating (6.2.6) ........................................... 30

Lifting (2.3) ............................................................. 12

Location (4.1) ......................................................... 16

Maintenance (6) ..................................................... 24

Maintenance schedule (6.2) .................................. 25

Nomenclature (3.2) ................................................ 14

Nameplate (1.7.1) .................................................... 8

Operating limits (see 3.1) ...................................... 13

Ordering spare parts (6.3.1) .................................. 30

Parts lists (8.2) ....................................................... 34

Piping (4.5) ............................................................ 18

Protection systems (4.8) ........................................ 20

Pump masses (2.2.2) ............................................ 12

Receipt and unpacking (2.1) .................................. 11

Recommended fill quantities (see 6.2.3 and 6.2.4)

............................................................................... 27

Recommended grease lubricants (see 6.2.3) ....... 26

Recommended oil lubricants (see 6.2.4) ............... 27

Recommended spares (6.4) .................................. 30

Recycling (2.5) ....................................................... 12

Replacement parts (see 6.3 and 6.4) .................... 30

Routine inspection (6.2.1) ..................................... 26

Running the pump (5.5) ......................................... 22

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

Safety labels (1.7.2) ................................................. 8

Page

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

Safety, protection systems (see 1.6 and 4.8) 5

Sectional drawings (8.1) ........................................ 33

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

Sources, additional information (10.3) ................... 34

Spare parts (6.3) .................................................... 30

Specific machine performance (1.8) ........................ 8

Starting the pump (5.4) .......................................... 21

Stop/start frequency (5.5.6) ................................... 23

Stopping and shutdown (5.6) ................................. 23

Storage, pump (2.4) ............................................... 12

Storage, spare parts (6.3.2) ................................... 30

Suction piping (4.5.2) ............................................ 19

Supplementary manuals or information sources ... 34

Thermal expansion (4.4.1) .................................... 17

Transport and storage (2) ..................................... 11

Trouble-shooting (see 7) ........................................ 32

Vibration (5.5.5) ..................................................... 23

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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’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,
utilizing sophisticated quality techniques, and safety
requirements.

Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.

These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all
plant safety requirements and applicable safety and
health laws and regulations.

These instructions 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) “minimum efficiency for some water pumps
(Ecodesign)” 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
organizations. 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 authorized 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.

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.

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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:

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.

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
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.

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.

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.

This symbol 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 non­compliance in the hazardous area would cause the
risk of an explosion.

This sign is not a safety symbol but indicates

an important instruction in the assembly process.

1.6.2 Personnel qualification and training

All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.

Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.

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.

If the temperature is greater than 68 °C (155 °F)
or below -5 °C (23 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.

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HAZARDOUS LIQUIDS
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.

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.

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

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 motor at full or
zero flow. Pumps may be started with the valve
further open only on installations where this situation
cannot occur. Pump outlet valve shall may need to
be adjusted to comply with the duty following the
run-up process. (See section 5, Commissioning
start-up, operation and shutdown.)

NEVER RUN THE PUMP DRY

INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the seal.

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 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

The following instructions for pumps and pump
units when installed in potentially explosive
atmospheres must be followed to help ensure
explosion protection.

The terminology and procedures ensure that the
installed pump is in compliance with the European
Directive 94/9/EC, known as the ATEX Directive, which
is mandatory in Europe and may also be specified in
other countries. Where applicable, both electrical and
non-electrical equipment must meet the requirements
94/9/EC.

Even if the installation is in a region where ATEX is not
the applicable regulation, the general measures
described shall be followed to ensure safe operation.

The measures are explained under the headings of:

• Avoiding excessive surface temperature

• Preventing build up of explosive mixtures

• Preventing the generation of sparks

• Preventing leakages

• Maintaining the pump to avoid hazard

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 pump set shall
select the coupling, driver and any additional
equipment, with the necessary CE 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 affects 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.

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1.6.4.2 Marking

An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.

II 2 GD c IIC 135 ºC (T4)

Equipment Group
I = Mining
II = Non-mining

Category
2 or M2 = High level protection
3 = normal level of protection

Gas and/or Dust
G = Gas; D= Dust

c = Constructional safety
(in accordance with EN 13463-5)

Gas Group (Equipment Category 2 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

ENSURE THE EQUIPMENT TEMPERATURE

CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the

ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 °C (104 °F); refer to
Flowserve for higher ambient temperatures.

The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends
on the temperature class and must not exceed the
values in the table that follows.

The temperature rise at the seals, bearings and due
to the minimum permitted flow rate is taken into
account in the temperatures stated.

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) *

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)

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 the pump could be
installed in different hazardous atmospheres. In this
case the user is responsible for ensuring that the
pump surface temperature does not exceed that
permitted in the particular hazardous atmosphere.

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. Furthermore, confinement of liquid in
the pump and pipes must be avoided (valve closed).
If the liquid heats up this may cause excessive
pressure and lead to bursting of pump components.

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.

1.6.4.4 Preventing the build up of explosive
mixtures

ENSURE PUMP IS PROPERLY FILLED AND

VENTED AND DOES NOT RUN DRY.
Ensure 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 (eg liquid
detection or power monitor).

To avoid potential hazards from fugitive emissions of
vapor or gas to atmosphere the surrounding area
must be well ventilated.

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1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking.
To avoid the potential hazard from random induced
current generating a spark the ground contact on the
baseplate must be used.

Avoid electrostatic charge: do not rub non­metallic surfaces with a dry cloth, ensure cloth is
damp.
Where applicable the coupling must be selected to
comply with 94/9/EC and correct alignment must be
maintained.

Additional requirements for metallic pumps on
non-metallic baseplates.

When metallic components are fitted on a non­metallic baseplate they must be individually earthed
(grounded).

1.6.4.6 Preventing leakage

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, or separate documentation included with

these User Instructions.

1.7.2 Safety labels

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.

Oil lubricated units only:

1.8 Specific machine performance

For performance parameters see section 1.5, Duty
conditions. 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.

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1.8.1 Ecodesign

EU Regulation 547/2012 of the Directive
2009/125/EC, for the minimum efficiency of defined
classes of water pumps, requires that products must
show their Minimum Efficiency Index (MEI) value.
The EU Benchmark MEI ≥ 0.70.

Also product information must be available to users.
Performance curves will have been provided with
the quotation or order or are available at
flowserve.com.

The efficiency of a pump with trimmed impeller is
usually lower than that of a pump with the full
impeller diameter. The trimming of the impeller will
adapt the pump to a fixed duty point, leading to
reduced energy consumption. The minimum
efficiency index (MEI) is based on the full impeller
diameter.

The operation of this water pump with variable duty
points may be more efficient and economic when
controlled, for example, by the use of a variable
speed drive that matches the pump duty to the
system.

Information on benchmark efficiency is available at
www.europump.org/efficiencycharts.

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 17 dBA to the sound pressure value.

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02

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 90 85 86

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 1 1

Pump and

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

motor

Pump

only

Pump and

motor

Pump

only

85 87 83 85

Pump and

motor

Pump

only

Pump and

motor

Page 10 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

In areas where the staff has to intervene, remember
that when the level of the sound pressure is:

• below 70 dBA: it is not necessary to take special
precautions.

• above 70 dBA: people working continuously in
the machine room must be supplied with
protective devices against noise.

• below 85 dBA: no particular measures need to
be taken for casual visitors staying in the room
during a limited period.

• above 85 dBA: the room must be considered as
a dangerous area because of the noise and a
warning sign must be fixed at each entry
warning the people coming into the room, even
for a short period, that they must wear hearing
protection.

• above 105 dBA: special hearing protection
adapted to this noise level and to the spectral
noise components must be installed and a
warning sign to this effect erected at each entry.
The staff in the room must wear ear protection.

Make sure that the noise, which travels through the
walls and windows, does not generate too high
noise levels in the machine room's surroundings.

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be
checked against the delivery and 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 crate, boxes and wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to
sidewalls of the box or equipment.

Each product has a unique serial number. Check
that this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.

2.2 Handling

2.2.1 General instructions concerning handling

Boxes, crates, pallets or cartons may be unloaded
using forklift vehicles or slings dependent on their
size and construction. See 2.3.1 for positioning of
slings.

To lift heavy pieces above 25 kg (55 lb), use a winch
adapted to the mass and in accordance with the
current local regulations.

To lift machines or pieces with one or several
suspension rings, only use hooks and chains in
compliance with the local regulations concerning
safety.

Never put cables, chains or ropes directly on or in
the suspension rings. Cables, chains or lifting ropes
must never present excessive bending.

Never bend the lifting hooks, suspension rings,
chains, etc., which should only be made to endure
stresses within, calculated limits.

Remember that the capacity of a lifting device
decreases when the direction of the lifting force
direction makes an angle with the device axis.

To increase the safety and the efficiency of the lifting
device, all the lifting elements must be as
perpendicular as possible. If necessary a lifting
beam can be placed between the winch and the
load.

When heavy pieces are lifted up, never stay or work
under the load or in the area, which could be in the
path of the load if it were to swing or fall away.

Never leave a load hanging from a winch. The
acceleration or the slowing-down of lifting equipment
must stay in the safety limits for the staff.

A winch must be positioned in such a way that the
load will be raised perpendicularly. Where possible
necessary precautions must be taken to avoid the
swing of the load, using for example two winches
making approximately the same angle, below 30°,
with the vertical.

Page 11 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

2.2.2 Pump masses

PUMP TYPE

200 DS 401 320 706
200 DS 451 340 750
200 DS 552 470 1036
250 DS 401 340 750
250 DS 452 360 794
250 DS 552 500 1102
300 DS 401 500 1102
300 DS 452 575 1268
300 DS 553 670 1477
350 DS 703 990 2183
350 DS 854 1150 2535
400 DS 553 1010 2227
400 DS 603 1160 2558
400 DS 704 1250 2756
400 DS 855 1550 3417
500 DS 704 1280 2822
600 DS 604 1590 3505

PUMP MASS

kg lb

Bareshaft pump

When handling always wear gloves, safety

boots and an industrial safety helmet.

For masses above 25 kg (55 lb), manual

handling is forbidden.

2.4 Storage

All motors (for masses see the motor

description plate) must be handled with a winch.

2.3 Lifting

2.3.1 Slinging of motor pumps units

Use handling means in accordance with motor
pump unit mass mentioned on the CE plate. For the
masses of the pumps bare end of shaft see table §

2.2.2 and nameplate.

To avoid distortion, the pump unit

should be lifted as shown.

A crane must be used for all pump sets in
excess of 25kg (55 Ib). Fully trained personnel must
carry out lifting, in accordance with local regulations.

Motor pump unit

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.

Do not store pumps starting on the fan guard.
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 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.

Make sure that hazardous substances or toxic
fluid 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.

Page 12 of 36 flowserve.com

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02

3 PUMP DESCRIPTION

3.1 Configurations

The pump is mounted on a common base plate and consists of a WORTHINGTON centrifugal pump type DS
and an E-motor connected by an adequate coupling.

MAXIMUM PRESSURE

Maximum working pressure Maximum test pressure

PUMP

bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi

200 DS 401 4 58 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
200 DS 451 5 72 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
200 DS 552 6 87 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
250 DS 401 3 43 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
250 DS 452 4 58 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
250 DS 552 5 72 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
300 DS 401 8 116 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
300 DS 452 3 43 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
300 DS 553 3 43 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
350 DS 703 6 87 10 145 13 188 15 218 16 232 18 261 15 218 19 276 18 261 19 276 22 319
350 DS 854 6 87 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
400 DS 553 3 43 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
400 DS 603 7 101 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
400 DS 704 3 43 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
400 DS 855 4 58 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
500 DS 704 2.6 38 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
600 DS 604 3 43 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319

Maxi.

pressure

suction

CAST

IRON

EN-GJL-

250

NI

RESIST

(D2)

NODU-

LAR

IRON

EN-GJS-

400-15

STEEL
X2CrNiM
o17-12-2

NODU-

LAR

IRON

EN-GJS-

400-15

STEEL
X2CrNiM
o17-12-2

CAST

STEEL

CAST

STEEL

CAST

IRON

EN-GJL-

250

NI

RESIST

(D2)

• Minimum pumped fluid temperature

................................................ - 10 °C (14 °F)

• Maximum ambient temperature

................................................ 40 °C (104 °F)

Maximum solid suspension

•

....................................... 50 g/m3 (0.003 lbm/ft

• Density................................. 1

• Viscosity .............................. 1 mm²/s (31 SSU)

3

)

The maximum speed is shown on

the pump nameplate.

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DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

3.2 Nomenclature

Characteristics shown on the nameplate fixed on the pump are as shown below:
Each pump is supplied with the following nameplate:

Speed of rotation

Radial/thrust bearing

Year of construction +
Manufacture number

Each pump unit is supplied with the following nameplate:
Mass of the set:

Pump type

Flow rate

Head

Mass
Maximum admissible

Pressure at 20 °C (68 °F)
Maximum / minimum

temperature

EU Regulation 547/2012 requires the statement on a product nameplate:

• MEI ≥ 0.10 [--.-] (Between 1st January 2013 and 1st January 2015)

• MEI ≥ 0.40 [--.-] (From 1st January 2015)

Page 14 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

3.3 Design of major parts

3.3.1 Pump casing

The double volute type casing is centerline
supported and provided with drain and seal
connections.

Suction and discharge nozzles are cast integrally,
permitting inspection and repair of the pump without
disturbing the suction and discharge piping.

The suction and discharge nozzles are horizontally
or vertically arranged refer to elevation drawing.

All casings are provided with stop pieces in the
suction nozzle to prevent pre-rotation of the liquid as
it enters the impeller.

3.3.2 Stuffing box head

The stuffing box head is supplied with the shaft
sealing equipment consisting of a packing seal or a
mechanical seal. Furthermore it is supplied with a
bore for gland seal.

3.3.3 Shaft sealing

The sealing against leakage along the shaft sleeve
at this point where it passes through the casing is
accomplished by a packing seal or a mechanical
seal.

Packing seal

The seal is equipped with packing rings and a
lantern ring. The packing ring quality has been
chosen in accordance with the service conditions.
To prevent corrosion the pumps will be shipped
without packing rings.

Sealing liquid

Normally the liquid seal connection is piped from the
discharge side to the lantern ring. If the pumped
liquid cannot be used for sealing inpended clean
sealing liquid should be supplied with a pressure
slightly higher than the pump suction pressure.

3.3.4 Wearing rings

Pump casing and stuffing box head are furnished
with shrunk in wearing rings.

3.3.5 Shaft and shaft sleeve

The pump shaft is provided with a shaft sleeve
axially, secured by the impeller and a shaft shoulder.

3.3.6 The impeller

The single suction impeller is keyed to the shaft.
Axial movement is prevented by a cap with lock
screw and the shaft sleeve.

3.3.7 The bearing bracket

The bearings are mounted in the bearing bracket.
For grease: lubrication grease nipples are provided.

3.3.7.1 The bearing

The thrust bearing

The thrust bearing consists of two angular contact
ball bearings mounted "face to face".

The inner races are secured axially by the shaft
shoulder and the lock nut. The outer races are
contained between the circlips and the outer cover.

The line bearing

The line bearing is a cylinder roller bearing with its
inner race mounted against a shaft shoulder. The
outer race is contained between the circlips and the
inner cover.

3.3.8 The couplings

For details about the fitted coupling refer to
manufacturer's instructions.

3.3.9 The driver

For details about the installed driver refer to
manufacturer's instructions.

3.4 Guide to store “vulcanized rubber”

(Max. time of storage 2 years)

3.4.1 Introduction

Most vulcanized rubbers change in physical
properties during storage and may become
unserviceable because of excessive hardening,
softening, cracking, crazing or other surface
degradation caused by the action of oxygen, ozone,
light, heat and humidity or improper storage.

The deleterious effects of these factors may,
however, be minimized by careful choice of storage
condition.

3.4.1.1 Storage room

The storage room should be cool, dry, dust free and
moderately aired.

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DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

3.4.2 Temperature

The storage temperature should not exceed 25 °C
(77 °F) and should not. Drop below -10 °C (14 °F)
[Neoprene +12 °C (53.6 °F)]. Adhesives and
solutions should not be stored below 0 °C (32 °F).
Not keeping these limits will result in detoriation and
affect the service life.

The effects of low temperature are not permanently
deleterious, but care should be taken to avoid
destroying them during handling. When articles are
taken from low temperature storage for immediate
use, their temperature should be raised to about 20
°C (68 °F) throughout.

3.4.3 Humidity

Moist condition should be avoided; storage
conditions should be such that condensation does
not occur. Favorable humidity should be about 65
per cent.

3.4.4 Light

The articles should be protected from light, in
particular direct sunlight and strong artificial light with
a high ultra-violet content. Unless the articles are
packing in opaque containers, it is advisable to
cover the windows of storage rooms with a red or
orange coating or screen.

3.4.5 Oxygen and Ozone

As ozone is particularly deleterious, storage rooms
should not contain equipment that is capable of
generating ozone, such as electrical equipment,
electric motors or other equipment which may give
rise to electric sparks or silent electrical discharges.

Combustion gases and organic vapors should be
excluded, as they may give rise to ozone via
petrochemical processes. Solvents, fuels, lubricants,
chemicals, acid, etc. should not be stored in this
room.

3.4.6 Deformation

The articles should be stored in a relaxed condition
free from tension, compression or other deformation.
(O-rings should not be stored hanging up on a
hook).

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.

All equipment must be grounded.

4.1 Location

Fulfill the following requirements:

• Accessibility for operation and inspection and
space for maintenance

•

Simple piping layout, no pipe bends immediately
preceding suction nozzle

• Suction line as short as possible for minimum
suction losses

• Ample headroom to lift components for
maintenance

4.2 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 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 base plate should be mounted onto a firm
foundation, either an appropriate thickness of quality
concrete or sturdy steel framework. It should NOT
be distorted or pulled down onto the surface of the
foundation, but should be supported to maintain the
original alignment.

Anchor bolts must be in accordance with the foot
bolt holes. Use anchor bolts of accepted standards
and sufficient to ensure a secure fitting in the
foundation. Particularly, this applies to individual
plates where the anchor bolts have to withstand the
driving torque.

Page 16 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

NF E 27 811

Provide sufficient space in the foundation to
accommodate the anchor bolts. If necessary,
provide concrete risers.

Usually the pump and its drive are mounted on a
common base plate. If not, individual base plates
underneath each machine foot shall be installed.
Base plates are to be fully grouted.

4.2.1 Setting the base plate for anchoring

a) Clean the foundation surface thoroughly.
b) Put shims on the foundation surface [approx 20-

25 mm (0.79-0.98 in.) thick], one on each side of
the bolt hole (as an alternative, leveling screws
can be used).

c) Lay the base plate and level in both directions

with extra shims. The base plate should be level
to within 0.5 mm per 1 m (0.02 in. per 3.3 ft).

.

d) If anchor bolts have been pre-cast in the

foundation slightly tighten the anchor bolts.
Otherwise let them hang in the foundation holes.

4.3 Grouting

4.3.1 Base plate grouting

a) Prepare the site for grouting. Before grouting

clean the foundation surface thoroughly and
provide external barriers as shown. The base
plate is provided with holes to be filled with the
concrete.

barriers

b) Prepare grouting product (concrete, resin) in

accordance with manufacturers' instructions.

c) Use grouting products with anti-shrinking

components.

d) To grout up to the required level. Polish

surfaces. Take necessary precautions to avoid
air bubbles.

e) Lay-down the barrier, break external angles, and

polish the different surfaces.

f) After grout starts to cure, definitively tighten

anchor bolts.

g) Control the alignment such as described as

follows.

4.4 Initial alignment

Before connecting the couplings
verify the motor rotation direction.

4.4.1 Thermal expansion

The pump and motor will normally
have to be aligned at ambient temperature and
should be corrected to allow for thermal expansion
at operating temperature. In pump installations
involving high liquid temperatures, the unit should be
run at the actual operating temperature, shut down
and the alignment checked immediately.

4.4.2 Alignment methods

Ensure pump and driver are isolated
electrically and the half couplings are disconnected.
Ensure that the pump pipework, suction and
discharge, is disconnected.

Page 17 of 36 flowserve.com

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02

The alignment MUST be checked.

Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the
pump to the motor.

Alignment
Parallelism and concentricity check:

Check the alignment at three or four

points, before piping assembly.

with a rule with a comparator

Admissible margin for a motor with roller bearings
with European couplings:
= 0.15 mm parallel checking
= 0.1 mm angular checking

For US supplied couplings values to be used are:
= 0.02 in. parallel checking
= 0.05 in. angular checking

Check the couplings manual for further details.

Angular checking:

→

Pump and motor mounted on individual base

plates:

Machines are (or must be) first mounted on their
own base plate in the workshop. Once the pump is
set, it will be regarded as the fixed piece. Any
alignment necessary shall be carried out on the
motor.

Never connect the electric motor
before the setting has been completely finished.

4.5 Piping

The user must verify that the equipment is

isolated from any external sources of vibration.

Protective covers are fitted to the
pipe connections to prevent foreign bodies entering
during transportation and installation. Ensure that
these covers are removed from the pump before
connecting any pipes.

4.5.1 Suction and discharge piping

The dimensions of the pipes do not directly depend
on suction and discharge diameters of the pump:
a) First, choose a flow speed < 2 m/s (7 ft/s) at

suction, and about 3 m/s (10 ft/s) at discharge.

b) Take into account the available NPSH, which

must be superior to the required NPSH of the
pump.

Never use pump as a support for
piping.

with a sliding rule

with a caliper gauge

The alignment will be definitive only

after pipe connection (see § 4.5.1).
In case of DSV with cardan shaft drive refer to

respective instruction.
If necessary, improve the machine alignment:

→

Complete unit mounted on common base plate:

The machines are first aligned accurately in our
workshops. Usually, any misalignment observed on
site is due to a wrong adjustment under the base
plate (disturbed during transport or because of
forces exerted by the piping). It is only necessary to
rectify the adjustment under base plate. If it proves
to be insufficient, modify the motor and the piping.

Do not mount expansion joints in
such a way that their force, due to internal pressure,
may act on the pump flange.

Maximum forces and moments allowed on the pump
flanges vary with the pump size and type.

These external strains may cause misalignment, hot
bearings, worn couplings, vibrations and the
possible failure of the pump casing.

When designing the pipes (§ 4.5.2.1, § 4.5.2.2, §

4.5.3.1) take necessary precautions in order not to
exceed maximum allowed strains.

Forces and moments applied to the pump flanges
must never exceed the values shown in the overall
dimension.

Ensure piping and fittings are flushed
before use.

Ensure piping for hazardous liquids is
arranged to allow pump flushing before removal of
the pump.

Page 18 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

flow valve

D

I ≥ 3 x D

02

4.5.2 Suction piping

4.5.2.1 Design of a flooded suction line

The suction line must be as short and direct as
possible, never mount an elbow directly on the inlet
flange of the pump.

Valve

Non return valve

Motor

Continous

Baseplate Coupling guard

Coupling

Flooded suction configuration

a) Avoid sharp elbows or sudden narrowing. Use

convergent ≤ 20° (total angle).

b) Arrange the piping so that there are no air

pockets (no bulges).

c) If high points cannot be avoided in suction line,

provide them with air relief cocks.

d) If a strainer is necessary, its net area should be

three or four times the area of the suction pipe.

e) If an inlet valve is necessary, choose a model

with direct crossing.

a) Avoid sharp elbows or sudden narrowing. Use

convergent ≤ 20° (total angle) with upright
generating.

b) Arrange that the suction piping is inclined

upwards towards the pump ensuring that there
are no peaks.

c) If a foot valve is necessary, do not oversize it

because it would generate pulsations (valve
beating).

Do not tighten flanges before the final

check (see § 4.5.4).

4.5.3 Discharge piping

4.5.3.1 Design of a discharge line

a) If discharge line is provided with a divergent, its

total angle will be between 7° and 12°.

b) Install the discharge valve after the non-return

valve downstream.

The non-return valve will be set in the discharge
pipe to protect the pump from any excessive
pressure surge and from reverse rotation.

If necessary, a control manometer (pressure gauge)
can be connected on the piping.

Manometer

Do not tighten flanges before the final

check (see § 4.5.4).

4.5.2.2 Design of a suction lift line

The inlet pipe must be as short and as direct as
possible, never place an elbow directly on the pump
inlet nozzle.

I Sufficient
Immersion

Installation of the control manometer

Do not tighten flanges before the final

check (see § 4.5.4).

4.5.4 Final checks

a) Check the tightening of anchor bolts. Tighten

them if necessary.

b) Check that protective covers on suction and

discharge flanges are removed.

c) Check that holes of piping flanges are parallel

and correspond to those of the pump.

d) Tighten suction and discharge flanges.

Page 19 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

4.6 Electrical connections

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

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.

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

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
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 shall be
fitted.

Carry out the ground connections according to the
current local regulations.

To avoid any risk of jamming, the
direction of rotation will be checked after priming of
the pump (§ 5.3.1, 5.3.2) and before the first start (§

5.4.2).

4.7 Final shaft alignment check

a) Check the alignment pump-motor according to

the procedure § 4.4.2. Rectify if necessary by
adjusting the motor only.

b) Check by hand that the pump turns freely.

A binding indicates a distortion of the pump,
which is due to excessive pipe strain. If
necessary the pipe design must be re-examined.

c) If it provided, connect auxiliary pipe systems

(hydraulic, pneumatic, sealing system).

d) Control tightness and functionality of auxiliary

piping.

4.8 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 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 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. See sections

5.5.4 and 5.5.5.
If a defect of cooling can lead to temperature higher

than those acceptable a system of cooling
surveillance must be installed.

Except when explicitly required by the customer in
the specifications, when a possibility of reverse
rotation exists the customer must install a reverse
rotation protection device.

The customer must install all equipment required to
avoid water hammer.

5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN

These operations must be carried out by

fully qualified personnel.

5.1 Direction of rotation

Starting or operating pumps with the
wrong direction of rotation can be harmful to the
pumps. Ensure that the pump rotation is the same
as the arrow on the pump casing.

It is preferable to check the direction of rotation
before installing the coupling. If not, the pump must
be filled in with the liquid before start-up.

Page 20 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

External source

02

5.3.2 Priming of a sump suction pump

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.

5.2 Guarding

* With foot valve:
a) Fill suction pipe and casing with liquid from an

independent source (pressure 1 to 2 bars or 15
to 30 psi).

b) Let air escape by removing the plugs located on

the piping.

c) When the pump is totally free of air bubbles,

Guarding is supplied fitted to the pump set.

replace the plugs.

If this has been removed or disturbed ensure
that all the protective guards around the pump
coupling and exposed parts of the shaft are securely
fixed.

Air escape

5.3 Priming and auxiliary supplies

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.

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

Ensure the inlet pipe and pump
casing are completely full of liquid before starting
continuous duty operation.
These operations must be carried out by personnel
with approved qualifications.

5.3.1 Priming of a flooded pump

a) Close the discharge valve, fill the pump by

opening the suction valve. Let air escape by
removing the plug located on the piping.

b) The discharge pipe is headed and there is a by-

pass valve on the check valve, open slightly the
discharge valve and the by-pass of the check
valve.

c) When the pump is totally free of air bubbles,

replace the plugs.

Priming of a sump suction configuration with

foot valve

* Without foot valve:
Priming may be accomplished by means of venting
system.

Foot valves are not recommended when
the pumped liquid has suspended solid particles.
They may lodge between foot valve seat and
shutter.

5.4 Starting the pump

5.4.1 Bring controls and preparation before the
first starting and after each service call

Necessarily:

a) Check the tightening of the different plugs.
b) Check that the gland lightly tightens the packing

rings.

Page 21 of 36 flowserve.com

Air escape

Priming of a flooded suction pump

c) Risk of seal ring overheating.
d) Check the direction of rotation of the motor.

Refer to the rotation arrow of the pump.

e) Install all protection systems and more

particularly the coupling guard and the shield
grid of the bearing.

f) Open all suction valves (if existing).
g) Close the outlet valve and the bypass valve.

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

h) Ensure inlet pipe and pump casing are

completely full of liquid.

i) If stuffing box sealing/quenching from a remote

source is required make sure there is liquid
supply.

j) Check for sufficient lube oil.

5.4.2 First pump start-up

Suction valves must be fully open
when pump is running. Never run the pump dry, it
will cause damage.

a) Start motor and check outlet pressure.
b) If pressure is satisfactory, slowly OPEN outlet

valve.

c) Do not run the pump with the outlet valve closed

for a period longer than 30 seconds.

d) If NO pressure, or LOW pressure, STOP the

pump. Refer to faultfinding chart for fault
diagnosis.

The pump should run smoothly and without
vibration.

The pump must never run at a capacity of less than
40 % of that at the best efficiency.

The pump should be run for ten minutes with steady
leakage and the gland nuts tightened by 10 degrees
at a time until leakage is reduced to an acceptable
level.

The temperature of the gland should be checked
after each round of tightening. If the temperature
starts to climb rapidly then back off the gland nuts
until the temperature drops down. Wait for the
temperature to stabilize before tightening again.

The leakage must not be reduced below a rate of 20
drops per minute. Bedding in of the packing may
take several hours.

Shield grids being removed during installation
of the gland packing, it must be ensured that they
are replaced as soon as this operation is completed.

Never remove a plug when the pump is

running.

5.5 Running the pump

5.5.1 Venting the pump

Vent the pump to enable all trapped air to
escape taking due care with hot or hazardous
liquids.

Under normal operating conditions, after the pump
has been fully primed and vented, it should be
unnecessary to re-vent the pump.

5.5.2 Pump fitted with a stuffing box

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 pressurized. 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 restarted.
When the pump is restarted it should be checked to
ensure leakage is taking place at the packed gland.

When adjusting an operating stuffing box
(shield grids removed for this operation) the operator
must be very careful. Safety gloves are compulsory
and loose clothes are not allowed (above all to the
arms) to avoid being caught by the pump shaft.

5.5.3 Pump fitted with mechanical seal

A mechanical seal ensures a seal without leakage
and does not need any adjustment. Nevertheless if a
light leakage occurs during start-up, it should
disappear after the initial running in of the friction
faces.

NEVER RUN A MECHANICAL SEAL

DRY, EVEN FOR A SHORT WHILE.

SAFETY INSTRUCTIONS WHEN THE PUMP IS
RUNNING:

If hot or freezing components of the machine
can present a danger to operators, they must be
shielded to avoid accidental contact. If a 100 %
protection is not possible, the machine access must
be confined to the maintenance staff only.

If the temperature is greater than 80 °C (176
°F), a warning plate must be clearly placed on the
pump.

It is strictly forbidden to open switch
cupboards, switch boxes, or all other live electric
equipment.

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Horizontal Configuration

02

If it is necessary to open them in order to take
readings, to carry out tests or adjustments for
example, only a skilled technician may do them with
adapted tools. Make sure that physical protection
against electrical risks is used.

5.5.4 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) °C [(t+tb-ta+10) °F]

and the trip at 100 °C (212 °F) for oil lubrication
and 105 °C (220 °F) 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.

5.5.5 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 site on the bearing
housings of the pump in the fully commissioned as
new condition.

The example (N) value is given for the preferred
operating flow region (typically this may extend to 70
to 120 % of the pump best efficiency point); outside
the preferred flow region the actual vibration
experienced may be multiplied by up to 2.

These standard values can vary with the rotational
speed and the power absorbed by the pump. For
any special case, do not hesitate to consult us.

Measuring vibration at regular intervals will then
show any deterioration in pump or system operating
conditions.

Vibration Velocity - unfiltered

Normal N
Alarm N x 1.25
Shutdown Trip N x 2.0

mm/s (in./s) r.m.s.

≤ 5.6 (0.22)
≤ 7.1 (0.28)

≤ 11.2 (0.44)

5.5.6 Stop/start frequency

Pump sets are normally suitable for the number of
equally spaced stop/starts per hour shown in the
table below. Check actual 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

90 (120) to 150 (200) 6

Above 150 (200) Refer

Maximum stop/starts

per hour

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

5.6 Stopping and shutdown

According to hydraulic conditions of
the installation and its automation degree, stop and
restart procedures can have different forms.
Nevertheless all of them must respect imperatively
the following rules:

5.6.1 Stopping < 1 hour

a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does

not reach the foot valve.

5.6.2 Stopping < 1 month

a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does

not reach the foot valve.

d) Close the outlet valve. Eventually close the inlet

valve.

e) Switch off external power supply,

flushing/quench, cooling liquid.

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DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

5.6.3 Shutdown > 1 month

a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does

not reach the foot valve.

d) Close the outlet valve. Eventually close the inlet

valve.

e) Switch off external power supply,

flushing/quench, cooling liquid.

f) Keep the pump fully filled with water. In case of

pumped liquid other than water, drain the pump
entirely.

g) Turn once per week the pump shaft of one or

two turns.

h) Never restart the pump without carrying out the

verifications recommended before starting (see

§ 5.4.1).

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

5.6.4 Restarting in continuous running

a) Ensure that the pump is completely full of liquid.
b) Ensure a continuous supply with a sufficient

available NPSH.

c) Ensure a backpressure so that the motor power

is not in excess.

d) Respect the starting frequency

imposed by the motor manufacturer.

e) Protect the pump against water hammer

when stopping or starting.

5.7 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.

5.7.1 Specific gravity (SG)

Pump capacity and total head in meters (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.

5.7.2 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.

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

5.7.4 Net positive suction head (NPSHA)

NPSH available (NPSHA) is the head available at the
impeller inlet, above the vapor pressure of the
pumped liquid.

NPSH required (NPSHR) is the minimum head required
at the impeller inlet, above the vapor pressure of the
pumped liquid, to avoid excessive cavitation and
extreme performance degradation.

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.

5.7.5 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

If a belt drive is used, the assembly and
tension of the belts must be verified during regular
maintenance procedure.

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

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02

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

1.6.2).
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 5.6.
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.

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 guardrails 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. It should include the following:
a) The pump must be completely vented and

drained and rendered inert before any
disassembly operation.

b) Any auxiliary systems installed must be

monitored, if necessary, to ensure they function
correctly.

c) During cleaning of the pump ensure the

compatibility between the cleaning products and

the gaskets.
d) Verify the condition of the gaskets.
e) Gland packing must be adjusted correctly to give

visible leakage and concentric alignment of the

gland follower to prevent excessive temperature

of the packing or follower. Mechanical seals

should present no leakage.
f) Check for any leaks from gaskets and seals.

The correct functioning of the shaft seal must be

checked regularly.
g) Check bearing lubricant level, and if the hours

run show a lubricant change is required.
h) Check that the duty condition is in the safe

operating range for the pump.
i) Check vibration, noise level and surface

temperature at the bearings to confirm

satisfactory operation.
j) Check the tightness of the connections.
k) Check dirt and dust is removed from areas

around close clearances, bearing housings and

motors.
l) Check coupling alignment and re-align if

necessary.
m) Verify the correct operation of the system.

The equipment used for maintenance and
disassembly in an ATEX zone must be in conformity
with the requirements zone.

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.

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02

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 behavior. 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) Pump fitted with a stuffing box: leakage of 20

drops per minute.
d) Pump fitted with a mechanical seal: no leakage.
e) Check the level and condition of oil lubricant. On

grease lubricated pumps, check running hours

since last recharge of grease or complete

grease change.

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.

If a check shows a bad running of the

motor pump unit, the user must:

a) Move the axial seal ring back so the gap

between pump shaft and bearing cover can be
seen.

b) Connect grease gun to the nipple.

c) Press grease into bearing housing until the first

signs of it appear in the gap between housing
and shaft. Then stop greasing.

a)



Refer to the "fault finding chart" chapter 7

of this leaflet to apply the recommended

solutions.
b) Ensure that your equipment corresponds to the

arrangements of this leaflet.
c) Contact Flowserve after-sales Department if the

problem persists.

6.2.3 Grease lubricated anti-friction bearings

Grease lubricated anti friction
bearings are factory lubricated to prevent rusting for
a short period of time only.
a) Before starting the pump, the bearings must be

properly greased.

b) Check the bearings for the first hour or so after

the pump was started to insure proper function.

c) Proper grease lubrication is very important. Anti

friction bearings can be over greased as well as
under greased. The characteristics of the
installation and severity of the service will
determine the frequency of lubrication.

Type of grease:

• At ordinary room temperatures: Grease N° 2

• At low ambient temperatures: Grease N° 1

• For specific recommendations consult a

reputable grease manufacturer.

• Do not use graphite

The maximum allowable operating temperatures for
anti friction bearings will differ from unit to unit.
Depending on ambient and fluid temperature, the
difference to the bearing housing temperature
should not exceed 50 °C (122 °F).
Continuously rising temperatures and an abrupt
temperature rise are indicative for trouble.
These symptoms require immediate stopping of the
pump and a thorough investigation to determine the
cause of trouble. V-rings should be seated at the
proper distance from the sealing surface to avoid
overheating.

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02

TEMP

TIME

REGULAR GREASE CHANGE:
Change the grease every 4000 operating hours.

COMPLETE CLEANING DURING A MAJOR
OVERHAUL:

a) Remove bearing housing from the rotor

assembly.

b) Brush bearing housing with hot kerosene (100-

115 °C) [(212-239 °F)] or other non-toxic
solvent.

c) Flush out the housing with a light mineral oil.
d) Do not use waste oil to clean the

housing.
To clean the bearings:
a) Wipe off as much grease as possible with clean

nonlinting cloth.
b) Brush bearings with hot kerosene (80-90 °C)

[(176-194 °F)] while gently spinning the outer

bearing ring.
c) Spin each ball to insure that it is clean.

6.2.4 Oil lubricated anti friction bearings

The bearing housing is filled with oil to a defined
level, which is maintained during operation by a
constant level oiler. A breather filter connects the
housing space with the atmosphere. The correct oil
level is very important.

At too low oil level the bearing will run dry and wear
out fast. At too high oil level the bearing may run hot
and oil will leak past the V-rings.

The bearing housing is provided with a constant
level oiler. It feeds enough oil to maintain the
required level. The control operates on the liquid
seal principle, feeding only when the level is lowered
and breaks the liquid seal at the shank end, thus
permitting air to enter the bottle. It will not feed as
long as the oil covers the hole in the shank end.

The constant level oiler has a fixed level, which is 7
mm (0.28 in.) above connection centerline. If it is
replaced by another model make sure that this
distance is maintained. As long as oil is visible in the
glass dome there is no need to refill.

To remove badly oxidized grease, which refuses to
come off:
a) Support rotor in vertical position and immerse

bearing in hot kerosene or a mixture of alcohol

and light mineral solvent.
b) Gently spin bearing outer ring.
c) Reflush bearing with clean light oil and force

fresh grease into it.

IF OIL NEEDS TO BE REFILLED:

a) Turn the dome out at its hinge.
b) Screw the glass dome off.
c) Fill the glass dome with oil.
d) Screw it back and swing the dome in upward

operating position.

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Oil volume

300 DS 401

400 DS 603

500 DS 704

02

OIL CHANGE

Operating conditions and severity of service will
determine the intervals between oil changes.

Normal intervals are 4000 operating hours. If
bearings maintain their normal temperature and no
contamination is observed in the oil the intervals
may be prolonged.

If bearing temperature increases, check immediately
for improper lubrication, a faulty bearing or improper
V-ring seat.

OIL QUANTITY:

Pump type

200 DS 401
200 DS 451
250 DS 401

1.0 (33.8)

200 DS 552
250 DS 552
300 DS 452

300 DS 553
350 DS 703
400 DS 553

350 DS 854
400 DS 704
600 DS 604

400 DS 855 5.0 (169.1)

1.5 (50.7)

4.0 (135.3)

3.5 (118.3)

OIL GRADE:

• Use high quality turbine or circulating oil with

rust and oxidation inhibitors

• Recommended viscosity grade: VSO VG32, 46

or 68

• For abnormal conditions, refer to a reputable

lubricant supplier for recommendations

• Oil must be clean and free of any abrasive

matter and foreign liquid (i.e. water)

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02

Viscosity grade ISO 46
Ambient temperature
Bearings temperature 80 °C (176 °F) maximum

BP

MANUFACTURER TYPE

CHARACTERISTICS

Density at 15 °C (59 °F) 0.885 0.881 0.868 0.878 0.87 0.872 0.877
Viscosity at 40 °C (104 °F).cSt 45 48.6 43 43 46 46 46
Viscosity at 50 °C (122 °F).cSt 30 31.5 29.4 28 30 29.5 30
Viscosity at 100 °C (212 °F).cSt 6.9 7.1 6.7 7 6.9 6.9 6.8
Pour-point °C / °F - 30 - 22 - 27 - 17 - 12 10.4 - 15 5 - 30 - 22 - 12 10 - 21 - 6
Flash-point °C / °F 210 410 220 428 220 428 220 428 214 417 230 446 230 446
Fire-point °C / °F 240 464 252 486 280 536 240 464 245 473
Aniline point °C / °F 99 210 102 216 110 230 102 216 109 228 101 214 101 214
Viscosity index 105 106 109 105 113 100 100
Acid value 0.2 0.6 0.2 0.13 0.7 0.1 0.7 to 1.2
Color 1 ½ 2 1 2 2 1 ½ 1

Antierosion additives yes yes yes yes yes
Foam inhibitors yes yes yes yes yes yes yes
Anticorrosion additives yes yes yes yes yes yes yes
Antioxidant yes yes yes yes yes yes yes
Conradson carbon residue 0.01 0.2

Limits on temperature °C / °F
Saponification < 0.5 1.2

ENERGOL

HLP

46

ELF

TURBELF

SA

46

TERESSO

TABLE OF EQUIVALENCE AND CHARACTERISTICS

ESSO

46

OF RECOMMENDED OILS

MOBIL

DTE

MEDIUM

SHELL

TELLUS

T

37

TOTAL

PRESLIA

46

- 12 to

120 °C (10

to 248 °F)

TOTAL

AZOLLA

ZS

46

- 21 to

110 °C (- 6

to 230 °F)

6.2.5 Gland packing

6.2.5.1 Pump fitted with a packed gland

A well run in and correctly adjusted packing gland

For that purpose, wind the packing helically around
the shaft sleeve or a chuck of the same diameter.
(Take precautions to avoid damaging sleeve).

requires little maintenance. If, after some time, the
leakage becomes too great, the gland should be
tightened again in order to return these to a normal
level.

If re-tightening is not possible, new packing must be
installed

6.2.5.2 Gland packing inspection and removal

Example of straight cut Example of bevel cut

a) Remove the shield guards.
b) Slide back the gland.
c) Remove the packing rings with an extractor

designed for this purpose (including the lantern

ring if it exists; note its position and its direction

box housing and not on the sleeve.

SETTING OF PACKING

Ensure a tightening on the stuffing

of rotation).
d) Inspect the state of the sleeve surface; the

presence of many marked grooves will indicate

that it must be replaced.
e) Carefully clean the different pieces of the

packing gland.

6.2.5.3 Gland packing fitting

If the packing is supplied as cord the packing must
be cut so that the external diameter is lightly
tightened and there is an initial gap between the
sleeve and the packing ring.

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02

Follow the instructions:
a) Assemble of the packing in S.

b) Stagger by about 90° between two rings.
c) Assemble packing after packing.

After setting the last packing ring, secure the
packing with the gland and tighten the nut by hand.

After tightening, the shaft should turn by hand as
easily as before the setting of the packing.

6.2.6 Internal coating

If the pump has an internal coating, this coating
must be inspected periodically. Any wear or cracks
of the coating found must be immediately repaired.

Failure to do this may lead to accelerated wear of
the coating during operation and corrosion of the
exposed base metal, depending on the material and
pumped liquid.

Special attention must be paid to the coating edges.
Any loss of coating material is considered to be
normal wear and tear on the pump and is not
considered as warranty.

Flowserve has applied the coatings according to the
supplier's instructions but will not be held
responsible for coating wear or cracks that may
develop over time.

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

4) Part number

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 are
recommended at 6 monthly intervals.

6.4 Recommended spares and
consumable items

[4610-01], [1500-01], [1500-02], [3011], [3012],
[2250], [4130], [4200]

a) Destroy all the gaskets after dismantling, replace

them when reassembling.

b) It is recommended that bearings

are not reused after any removal from the shaft.

c) After serving during two years, replace the gland

packing.

6.5 Disassembly

Refer to section 1.6, Safety, and section 6

Maintenance, before dismantling the pump.

Before dismantling the pump for
overhaul, ensure genuine Flowserve replacement
parts are available. Refer to sectional drawings for
part numbers and identification.

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02

REPAIR OF THE PUMP

If the pump presents abnormalities or a

persistent malfunction, contact immediately:

FLOWSERVE

After-sales Service
Tel.: [phone]

(33) 2 43 40 57 57

Fax.: [phone]

(33) 2 43 40 58 17

According to the After-sales Service instructions,
disassembly will be limited to the dismantling of the
pump:

a) DISCONNECT THE UNIT FROM

POWER.
b) Close the inlet valve (if fitted) and outlet valve.
c) Wait for the moment when the pump casing is

cooled and at ambient temperature.
d) DRAIN PUMP.

e) Dismantle inlet and outlet pipeworks as well as

all pipeworks.
f) REMOVE PUMP TAKING INTO

ACCOUNT SAFETY (§ 1) AND HANDLING (§

2.2) PROCEDURES.
ANY DISASSEMBLY, REPAIR OR

REASSEMBLY WILL BE CARRIED OUT UNDER
FLOWSERVE' RESPONSABILITY, EITHER
DIRECTLY BY THE AFTER-SALES SERVICE OR
BY OTHER FLOWSERVE-AGENTS WHO WILL
GET THE REQUIRED INSTRUCTIONS AND
APPROVALS. THIS IS THE CASE OF
AUTHORIZED REPAIRERS WHOSE ADDRESSES
AND TELEPHONE NUMBERS WILL BE GIVEN
ON REQUEST.

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Insufficient flow rate

Irregular pump running

Driver overloaded

Mechanical seal leak

Equipment vibration

Excessive pump casing temperature

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Insufficient pressure

Pump looses prime after starting

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02

7 FAULTS; CAUSES AND REMEDIES

POSSIBLE CAUSES SOLUTIONS

POSSIBLE CAUSES SOLUTIONS

Rotation speed too low (check the driver)

Presence of air - Check and de-aerate
Suction pressure insufficient - Check: the available NPSH > the required NPSH
Mechanical defects - CONSULT FLOWSERVE
Air leak in the suction pipe - Check suction pipe is airtight
Restriction in suction pipe - Check diameter of suction pipe
Suction level too low - Check the NPSH >NPSH

Obstruction of suction pipe - Check condition of pipe
Defective gland packing on the shaft - Check and replace all the gland packing.

Defective gasket - CONSULT FLOWSERVE

Pump or suction pipe not completely filled - Check and complete filling
Air bubbles in pipes - Check and desecrate the pipes
Suction level too low - Check: the available NPSH > the required NPSH

- Reduce geometrical suction lift

- Reduce head losses in pipes and in fittings (diameter increase
and appropriate fitting positions)

- Check valves and strainers

- Check the immersion head of the suction valve
Wrong rotation - Reverse 2 phases on motor terminal boxes
The motor is running on 2 phases only - Check and control the motor electrical power supply
Motor running too low

Total manometric head system higher than
pump differential head

Total manometric head system lower than
pump differential head

Pipes (valves, filter...) - Control, dismantle and clean
Insufficient flow rate - Check the suction and discharge pipes (valves, back pressure)
Worn wear-ring surfaces - Foresee pump mending: CONSULT FLOWSERVE
Seizure, jamming - CONSULT FLOWSERVE
Excessive strains on flanges

Defective gland packing on the shaft - Check and replace all the gland-packing parts.

Defective motor bearings - CONSULT FLOWSERVE
Specific gravity or viscosity of liquid too high - Consult our local agent to analyze the problem
Misalignment - Check the alignment of the pump and of its driver
Foundations not sufficiently rigid

- Check the connection in the terminal box according to the

voltage

- Check the discharge head

- Check the head losses in discharge pipes (partly closed valve,

foreign particles, back pressure too high)

- Modify the installation or change the pump set

- Throttle at discharge valve or trim the impeller (contact our

local agent): CONSULT FLOWSERVE

- Check the flange connections and eliminate strains (pipe

positioning or elastic sleeves mounting)

- Mechanical seal: CONSULT FLOWSERVE

- Check the setting of base plates: tightening, bad adjustment,

seal

- Check the connection in the terminal box according to the

voltage

- Reduce geometrical suction lift

- Reduce head losses in pipes and in fittings (diameter increase

and appropriate fitting positions)

- Check valves and strainers

- Check the immersion head of the suction valve

- Mechanical seal: CONSULT FLOWSERVE

Page 32 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

Joint filler

Joint filler

Cartridge seal

02

8 PARTS LIST AND DRAWINGS

8.1 Sectional drawings

Grease bearing

Oil bearing

Page 33 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

Item Designation

Item Designation

02

8.2 Sectional drawing parts list

1110 Pump casing

1221 Casing cover
1500-01 Wear ring
1500-02 Wear ring

2110 Shaft

2250 Impeller
2450-01 Shaft sleeve
2450-02 Shaft sleeve
2540-01 Deflector
2540-02 Deflector

2900 Washer

2905 Washer

3011 Radial ball bearing

3012 Radial roller bearing

3126 Shim

3134 Support foot

3200 Bearing housing
3260-01 Bearing cover
3260-02 Bearing cover

3712 Bearing nut

3852 Constant level oiler

3853 Grease nipple

3863 Grease regulator

4120 Gland

4130 Gland packing

4134 Lantern ring

4200 Mechanical seal

4213 Carrier for mechanical seal
4590-01 Gasket
4590-02 Gasket
4590-03 Gasket
4590-04 Gasket
4590-05 Gasket

4590-06 Gasket
4590-07 Gasket
4590-08 Gasket
4590-09 Gasket
4610-01 O-ring
4610-02 O-ring

6515 Drain plug
6521 Vent plug
6541 Lock washer

6544 Circlips
6569-01 Screwed plug
6569-02 Screwed plug
6569-03 Screwed plug
6569-04 Screwed plug
6569-05 Screwed plug
6569-06 Screwed plug
6570-01 Hexagon socket grub screw
6570-02 Hexagon socket grub screw
6572-01 Stud
6572-02 Stud
6572-03 Stud
6577-01 Hexagon bolt
6577-02 Hexagon bolt
6577-03 Hexagon bolt
6577-04 Hexagon bolt
6581-01 Hexagon nut
6581-02 Hexagon nut
6581-03 Hexagon nut

6810 Grooved pin
6700-01 Key
6700-02 Key

9331 Cover plate

8.3 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 Instructions

Supplementary instructions such as for a driver,
instrumentation, controller, seals, sealant system
etc are provided as separate documents in their
original format. If further copies of these are
required they should be obtained from the supplier
for retention with these User Instructions.

10.2 Change notes

If any changes, agreed with Flowserve, 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 Rotor dynamic Pumps: a reference
guide, Euro pump Guide No. 1, Euro pump &
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 34 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

02

Note :

Page 35 of 36 flowserve.com

DS USER INSTRUCTIONS ENGLISH 71576283 - 02/13

www.flowserve.com

Repair & Service Fax:

+33 2 43

40 58 17

Your Flowserve factory contacts:

Flowserve Pompes SAS
13, rue Maurice Trintignant
CS 10001
72234 Arnage Cedex, France

Telephone (24 hours): [phone]
Sales & Admin: [phone]

Local Flowserve factory representatives:

North America:
Flowserve Pump Division
5310 Taneytown Pike, PO Box 91
Taneytown, MD 21787-0091, USA

Telephone: [phone]
Customer Service FAX: [phone]
Parts inquiry/Order PH: [phone]

South America:
Flowserve do Brasil Ltda
Av. Don Helder Camara, 5451
20771-001 Rio de Janerio, Brasil

Telephone: [phone]
Fax: [phone]

To find your local Flowserve representative please
use the Sales Support Locator System found at

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

Flowserve FSG - Italy
Worthing S.P.A.
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
10 Tuas Loop
Singapore 637345
Telephone [phone]
Fax [phone]