USER INSTRUCTIONS
Durco® Mark 3™ ISO frame mounted
Installation
Operation
Standard two piece bearing frame foot mounted, centreline
mounted and unitized self-priming chemical process pumps
PCN= 85392719 06-12 (E). Original instructions.
Maintenance
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
CONTENTS
Page
1 INTRODUCTION AND SAFETY ........................... 4
1.1 General ........................................................... 4
1.2 CE marking and approvals .............................. 4
1.3 Disclaimer ....................................................... 4
1.4 Copyright ......................................................... 4
1.5 Duty conditions ............................................... 4
1.6 Safety .............................................................. 5
1.7 Nameplate and safety labels........................... 9
1.8 Specific machine performance........................ 9
1.9 Noise level....................................................... 9
2 TRANSPORT AND STORAGE ............................ 11
2.1 Consignment receipt and unpacking ............ 11
2.2 Handling ........................................................ 11
2.3 Lifting ............................................................. 11
2.4 Storage .......................................................... 12
2.5 Recycling and end of product life .................. 12
3 DESCRIPTION .................................................... 12
3.1 Configurations ............................................... 12
3.2 Name nomenclature ...................................... 12
3.3 Design of major parts .................................... 12
3.4 Performance and operating limits ................. 13
4 INSTALLATION .................................................... 13
4.1 Location ......................................................... 13
4.2 Part assemblies ............................................ 13
4.3 Foundation .................................................... 13
4.4 Grouting ........................................................ 14
4.5 Initial alignment ............................................. 14
4.6 Piping ............................................................ 15
4.7 Electrical connections ................................... 20
4.8 Final shaft alignment check .......................... 20
4.9 Protection systems ........................................ 20
6 MAINTENANCE .................................................. 26
6.1 General ......................................................... 26
6.2 Maintenance schedule .................................. 26
6.3 Spare parts ................................................... 28
6.4 Recommended spares ................................. 28
6.5 Tools required ............................................... 28
6.6 Fastener torques ........................................... 28
6.7 Setting impeller clearance ............................ 29
6.8 Disassembly ................................................. 30
6.9 Examination of parts ..................................... 31
6.10 Assembly .................................................... 32
6.11 Sealing arrangements ................................. 34
7 FAULTS; CAUSES AND REMEDIES .................. 37
8 PARTS LISTS AND DRAWINGS ........................ 39
8.1 Mark 3 ISO .................................................... 39
8.2 Center line mounted, recessed impeller
9 CERTIFICATION ................................................. 48
10 OTHER RELEVANT DOCUMENTATION
and self primer configurations .................... 41
8.3 Additional details ........................................... 44
8.4 Parts interchangeability ................................ 45
8.5 General arrangement drawing ...................... 48
AND MANUALS ............................................... 48
10.1 Supplementary User Instruction manuals... 48
10.2 Change notes ............................................. 48
10.3 Additional sources of information ................ 48
Page
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN ........................................... 20
5.1 Pre-commissioning procedure ...................... 21
5.2 Pump lubricants ............................................ 22
5.3 Impeller clearance ......................................... 23
5.4 Direction of rotation ....................................... 23
5.5 Guarding ....................................................... 23
5.6 Priming and auxiliary supplies ...................... 23
5.7 Starting the pump .......................................... 23
5.8 Running the pump ......................................... 24
5.9 Stopping and shutdown ................................ 25
5.10 Hydraulic, mechanical and electrical duty ... 25
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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
INDEX
Page
Additional sources (10.3) ......................................... 48
Alignment of shafting (see 4.3, 4.5 and 4.8)
Assembly (6.10) ....................................................... 32
ATEX marking (1.6.4.2) ............................................. 7
Bearing sizes and capacities (5.2.2) ....................... 22
CE marking and approvals (1.2) ................................ 4
Certification (9) ........................................................ 48
Change notes (10.2) ................................................ 48
Clearances, impeller (6.7) ....................................... 29
Commissioning and operation (5) ........................... 21
Compliance, ATEX (1.6.4.1) ...................................... 6
Configurations (3.1) ................................................. 12
Copyright (1.4) ........................................................... 4
Design of major parts (3.3) ...................................... 12
Direction of rotation (5.4) ......................................... 23
Disassembly (6.8) .................................................... 30
Disclaimer (1.3).......................................................... 4
Dismantling (6.8, Disassembly) ............................... 30
Drawings (8) ........................................................... 39
Duty conditions (1.5) .................................................. 4
Electrical connections (4.7) ..................................... 20
End of product life (2.5) ........................................... 12
Examination of parts (6.9) ....................................... 31
Fastener torques (6.6) ............................................. 29
Faults; causes and remedies (7) ............................. 37
Foundation (4.3) ...................................................... 12
General arrangement drawing (8.5) ........................ 48
General assembly drawings (8) ............................... 39
Grouting (4.4)........................................................... 14
Guarding (5.5).......................................................... 23
Handling (2.2) .......................................................... 11
Hydraulic, mechanical and electrical duty (5.10) ..... 25
Impeller clearance (see 5.3 and 6.7)
Inspection (6.2.1 and 6.2.2) ..................................... 27
Installation (4) .......................................................... 13
Lifting (2.3) ............................................................... 11
Location (4.1) ........................................................... 13
Lubrication (see 5.1.1, 5.2 and 6.2.3)
Lubrication schedule (5.2.5) .................................... 23
Maintenance (6) ....................................................... 26
Maintenance schedule (6.2) .................................... 27
Name nomenclature (3.2) ........................................ 12
Nameplate (1.7.1) ...................................................... 9
Nozzle loads (4.6.4) ................................................. 17
Operating limits (3.4.1) ............................................ 13
Ordering spare parts (6.3.1) .................................... 28
Part assemblies (4.2) ............................................... 13
Parts interchangeability (8.4) ................................... 45
Parts lists (8) ............................................................ 39
Performance (3.4) .................................................... 13
Piping (4.6) .............................................................. 15
Pre-commissioning (5.1) .......................................... 21
Priming and auxiliary supplies (5.6) ........................ 23
Page
Protection systems (4.9) ..........................................20
Reassembly (6.10, Assembly) .................................32
Receipt and unpacking (2.1) ....................................11
Recommended fill quantities (see 5.2.2) ..................22
Recommended grease lubricants (5.2.3) .................22
Recommended oil lubricants (5.2.1) ........................22
Recommended spares (6.4) .....................................28
Recycling (2.5) .........................................................12
Replacement parts (6.3 and 6.4) ..............................28
Running the pump (5.8) ...........................................24
Safety action (1.6.3) ................................................... 5
Safety labels (1.7.2) ................................................... 9
Safety markings (1.6.1) .............................................. 5
Safety, protection systems (see 1.6 and 4.9)
Sealing arrangements (6.11) ....................................34
Sectional drawings (8) ..............................................39
Setting impeller clearance (6.7) ...............................29
Sound pressure level (1.9, Noise level) ..................... 9
Sources, additional information (10.3) .....................48
Spare parts (6.3) ......................................................28
Specific machine performance (1.8) .......................... 9
Starting the pump (5.7).............................................24
Stop/start frequency (5.8.5) ......................................25
Stopping and shutdown (5.9) ...................................25
Storage, pump (2.4) .................................................12
Storage, spare parts (6.3.2) .....................................28
Supplementary manuals or information sources ......48
Supplementary User Instructions (10.1)...................48
Thermal expansion (4.5.1) .......................................14
Tools required (6.5) ..................................................28
Torques for fasteners (6.6) .......................................29
Trouble-shooting (see 7) ..........................................37
Vibration (5.8.4) ........................................................25
Page 3 of 52 flowserve.com
DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilising sophisticated quality techniques and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws 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) and Equipment for
Potentially Explosive Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory provision
of technical documents and safety instructions. Where
applicable this document incorporates information
relevant to these Directives and Approvals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certification.)
1.3 Disclaimer
Information in these User Instructions is believed to
be complete and reliable. However, in spite of all of
the efforts of Flowserve Corporation to provide
comprehensive instructions, good engineering and
safety practice should always be used.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality
Assurance organisations. Genuine parts and
accessories have been designed, tested and
incorporated into the products to help ensure their
continued product quality and performance in use.
As Flowserve cannot test parts and accessories
sourced from other vendors the incorrect
incorporation of such parts and accessories may
adversely affect the performance and safety features
of the products. The failure to properly select, install
or use authorised Flowserve parts and accessories is
considered to be misuse. Damage or failure caused
by misuse is not covered by the Flowserve warranty.
In addition, any modification of Flowserve products or
removal of original components may impair the safety
of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchase order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application.
If there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
Page 4 of 52 flowserve.com
DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user seeks
the written agreement of Flowserve before start up.
1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction would
cause hazards. The specific safety markings are:
This symbol indicates electrical safety
instructions where non-compliance will involve a high
risk to personal safety or the loss of life.
This symbol indicates safety instructions where
non-compliance would affect personal safety and could
result in loss of life.
This symbol indicates “hazardous and toxic fluid”
safety instructions where non-compliance would affect
personal safety and could result in loss of life.
This symbol indicates safety instructions
where non-compliance will involve some risk to safe
operation and personal safety and would damage the
equipment or property.
This symbol indicates explosive atmosphere zone
marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but indicates
an important instruction in the assembly process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the personnel
in question do not already possess the necessary
knowledge and skill, appropriate training and instruction
must be provided. If required the operator may
commission the manufacturer/supplier to provide
applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to help
prevent injury to personnel and damage to the
environment and to equipment. For products used
in potentially explosive atmospheres section 1.6.4
also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
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.
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 vapour could cause an explosion.
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
If the temperature is greater than 80 ºC (175 ºF) or
below -5 ºC (23 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and or explosive, strict safety procedures
must be applied.
Gland packing must not be used when pumping
hazardous liquids.
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not mount
expansion joints, unless allowed by Flowserve in
writing, so that their force, due to internal pressure, acts
on the pump flange.
NEVER RUN THE PUMP DRY
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation and
shutdown.)
ONLY CHECK DIRECTION OF
MOTOR ROTATION WITH COUPLING ELEMENT/
PINS REMOVED
Starting in reverse direction of rotation will damage the
pump.
START THE PUMP WITH OUTLET
VALVE PART OPENED
(Unless otherwise instructed at a specific point in the
User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump or motor at full or
zero flow. Pumps may be started with the valve further
open only on installations where this situation cannot
occur. The pump outlet control valve may need to be
adjusted to comply with the duty following the run-up
process. (See section 5, Commissioning start-up,
operation and shutdown.)
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the pump and mechanical 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 back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/vibration.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
• Avoid excess temperature
• Prevent build up of explosive mixtures
• Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
For ATEX, both electrical and non-electrical equipment
must meet the requirements of European Directive
94/9/EC. Always observe the regional legal Ex
requirements eg Ex electrical items outside the EU may
be required certified to other than ATEX eg IECEx, UL.
1.6.4.1
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of the
specific atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the ATEX pump set
shall select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable
for the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating effects in the motor and so,
for pumps sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
where electrical supply is from the VFD. This
particular requirement still applies even if the VFD is
in a safe area.
Scope of compliance
Use equipment only in the zone for which it is
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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
Temperature class
1.6.4.2
Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = high level protection
3 = normal level of protection
Gas and/or dust
G = Gas
D = Dust
c = Constructional safety
(in accordance with EN13463-5)
Gas Group
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3.)
1.6.4.3
Avoiding excessive surface
temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 ºC (104 ºF); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends on
the ATEX temperature class and must not exceed the
values in the table that follows.
Maximum permitted liquid temperature for pumps
to EN13463-1
T6
T5
T4
T3
T2
T1
Maximum surface
temperature permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of
liquid handled
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
Maximum permitted liquid temperature for pumps
with self-priming casing
Temperature
class to
EN 13463-1
T6
T5
T4
T3
T2
T1
* The table only takes the ATEX temperature class into consideration. Pump
design or material, as well as component design or material, may further
limit the maximum working temperature of the liquid.
Maximum surface
temperature permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of
liquid handled
Consult Flowserve
Consult Flowserve
110 °C (230 °F) *
175 °C (347 °F) *
270 °C (518 °F) *
350 °C (662 °F) *
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
The operator is responsible to ensure that the
specified maximum liquid temperature is not
exceeded.
Temperature classification “Tx” is used when the liquid
temperature varies and when the pump is required to be
used in differently classified potentially explosive
atmospheres. In this case the user is responsible for
ensuring that the pump surface temperature does not
exceed that permitted in its actual installed location.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitors or a
power monitor and make routine vibration monitoring
checks.
In dirty or dusty environments, make regular checks
and remove dirt from areas around close clearances,
bearing housings and motors.
Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures fit an external surface
temperature protection device.
1.6.4.4
Pumps with threaded on impellers only
Do not attempt to check the direction of rotation with the
coupling element/pins fitted due to the risk of severe
contact between rotating and stationary components.
1.6.4.5
Pumps with key drive impellers only
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.
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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
1.6.4.6
Where the system operation does not ensure control of
priming, as defined in these User Instructions, and the
maximum permitted surface temperature of the T Class
could be exceeded, fit an external surface temperature
protection device.
1.6.4.7
AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
atmosphere is prevented.
In addition it is essential to make sure that seal
chambers, auxiliary shaft seal systems and any
heating and cooling systems are properly filled.
If the operation of the system cannot avoid this
condition, fit an appropriate dry run protection device
(for example liquid detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
1.6.4.8
contact, the coupling guard must be non-sparking.
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.
surfaces with a dry cloth; ensure cloth is damp.
For ATEX the coupling must be selected to comply
with 94/9/EC. Correct coupling alignment must be
maintained.
1.6.4.9
When metallic components are fitted on a non-
metallic baseplate they must be individually earthed.
Additional requirements for self-priming
pumps only
Preventing the build-up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY FILLED
Preventing sparks
To prevent a potential hazard from mechanical
Avoid electrostatic charge: do not rub non-metallic
Additional requirement for metallic
pumps on non-metallic baseplates
1.6.4.10
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, install a liquid detection device.
1.6.4.11
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with maintenance
instructions is with the plant operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
Preventing leakage
The pump must only be used to handle liquids
Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO
Page 8 of 52 flowserve.com
DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
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
Oil lubricated units only:
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. Where performance data has been supplied
separately to the purchaser these should be obtained
and retained with these User Instructions.
1.9 Noise level
Attention must be given to the exposure of personnel
to the noise, and local legislation will define when
guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA.
The usual approach is to control the exposure time to
the noise or to enclose the machine to reduce
emitted sound. You may have already specified a
limiting noise level when the equipment was ordered,
however if no noise requirements were defined, then
attention is drawn to the following table to give an
indication of equipment noise level so that you can
take the appropriate action in your plant.
Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.
Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected from standard
and high efficiency motors when on load directly driving
the pump. Note that a motor driven by an inverter may
show an increased noise at some speeds.
If a pump unit only has been purchased for fitting with
your own driver then the “pump only” noise levels in the
table should be combined with the level for the driver
obtained from the supplier. Consult Flowserve or a
noise specialist if assistance is required in combining
the values.
It is recommended that where exposure approaches
the prescribed limit, then site noise measurements
should be made.
The values are in sound pressure level LpA at 1 m
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.
For estimating sound power level LWA (re 1 pW) then
add 14 dBA to the sound pressure value.
Page 9 of 52 flowserve.com
DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
1 1 85
Typical sound pressure level LpA at 1 m reference 20 µPa, dBA
Motor size
and speed
kW (hp)
<0.55 (<0.75) 72 72 64 65 62 64 62 64
0.75 (1) 72 72 64 66 62 64 62 64
1.1 (1.5) 74 74 66 67 64 64 62 63
1.5 (2) 74 74 66 71 64 64 62 63
2.2 (3) 75 76 68 72 65 66 63 64
3 (4) 75 76 70 73 65 66 63 64
4 (5) 75 76 71 73 65 66 63 64
5.5 (7.5) 76 77 72 75 66 67 64 65
7.5 (10) 76 77 72 75 66 67 64 65
11(15) 80 81 76 78 70 71 68 69
15 (20) 80 81 76 78 70 71 68 69
18.5 (25) 81 81 77 78 71 71 69 71
22 (30) 81 81 77 79 71 71 69 71
30 (40) 83 83 79 81 73 73 71 73
37 (50) 83 83 79 81 73 73 71 73
45 (60) 86 86 82 84 76 76 74 76
55 (75) 86 86 82 84 76 76 74 76
75 (100) 87 87 83 85 77 77 75 77
90 (120) 87 88 83 85 77 78 75 78
110 (150) 89 90 85 87 79 80 77 80
150 (200) 89 90 85 87 79 80 77 80
200 (270)
300 (400) – 87
1 The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are inappropriate.
Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.
3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min
Pump
only
1 1
Pump
and
motor
Pump
only
Pump
and
motor
Pump
only
Pump
and
motor
87 83
90 85
Pump
only
Pump
and
motor
85
86
Page 10 of 52 flowserve.com
DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve and must be
received in writing within one month of receipt of the
equipment. Later claims cannot be accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check
that this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
A crane must be used for all pump sets or
components in excess of 25 kg (55 lb.). Fully trained
personnel must carry out lifting, in accordance with
local regulations.
Slings, ropes and other lifting gear should be
positioned where they cannot slip and where a
balanced lift is obtained. The angle between sling or
ropes used for lifting must not exceed 60°.
2.3.1 Bare pump
The bare pump should be lifted as shown:
2.3.2 Pump and folded steel or polycrete
baseplate set
Where the baseplate is folded steel or polycrete there
are no specific lifting points provided for the complete
machine set. Any lifting points that can be seen are
provided only for dismantling parts for servicing.
The pump and folded steel, or polycrete, baseplate set
should be lifted as shown. With a sling around the
pump discharge nozzle, and around the outboard end
of the motor frame using choker hitches pulled tight.
The sling should be positioned so the weight is not
carried through the motor fan housing. Make sure the
completion of the choker hitch on the discharge nozzle
is toward the coupling end of the pump.
2.3.3 Pump and cast iron or fabricated,
baseplate set
The pump and cast iron, or fabricated, baseplate set
which has specific lifting points, should be lifted as
shown:
Before lifting the driver alone, refer to the
manufacturer’s instructions.
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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
2.4 Storage
Store the pump in a clean, dry location
away from vibration. Leave piping connection covers
in place to keep dirt and other foreign material out of
pump casing. Turn pump at intervals to prevent
brinelling of the bearings and the seal faces, if fitted,
from sticking.
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and local requirements. If the
product contains substances that are harmful to the
environment, these should be removed and disposed
of in accordance with current regulations. This also
includes the liquids and/or gases that may be used in
the "seal system" or other utilities.
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the current
regulations at all times.
3 DESCRIPTION
3.1 Configurations
The pump is a modular designed centrifugal pump
that can be built to achieve almost all chemical liquid
pumping requirements. (See 3.2 and 3.3 below.)
3.2 Name nomenclature
The pump size will be engraved on the nameplate
typically as below:
1K80-50-H200A-RV
• 1 = ISO Frame size (1, 2, 3, 4)
• K = Durco Mark 3 family
• 80 = Nominal suction size in mm
• 50 = Nominal discharge size in mm
• Configuration modifier:
Blank or no letter = standard frame mounted
P = Self priming casing
R = Recessed impeller, low shear design
N = Center-line mounted high pressure casing
H = High pressure casing
• 200 = Nominal impeller diameter
• A = Extended flow hydraulic (B = standard
hydraulic)
• RV = Impeller design (RV = Reverse vane, OP =
Open)
The typical nomenclature above is the general guide
to the Durco Mark3 ISO configuration description.
Identify the actual pump size and serial number from
the pump nameplate. Check that this agrees with the
applicable certification provided.
3.3 Design of major parts
3.3.1 Pump casing
The pump casing is designed with a horizontal
centerline end inlet and a vertical centerline top outlet
that makes it self-venting.
In addition, the P self-priming pump casing is
designed with a self-priming action which works on
the reflux principle for suction lifts up to 7 m (23 ft.).
For ease of maintenance, the pump is constructed so
that pipe connectors do not have to be disturbed
when internal maintenance is required.
Casing feet pads are provided underneath the casing
except on the N casing where they are on the shaft
centerline.
3.3.2 Impeller
Depending on the product, the impeller is either reverse
vane or open. (On the R impeller it is recessed into
the back of the casing.)
3.3.3 Shaft
The large diameter stiff shaft, mounted on bearings,
has a keyed drive end.
3.3.4 Bearing housing
The bearing housing enables adjustment of impeller
face clearance via the bearing carrier micrometer
mechanism.
3.3.5 Pump bearings and lubrication
The pump is fitted with ball and or roller type bearings
which may be configured differently dependent on
use. The bearings may be oil or grease lubricated.
3.3.6 Adaptor
The pump is fitted with an adaptor between bearing
housing and cover for optimum interchangeability.
3.3.7 Cover (Seal chamber)
The cover has spigots between the pump casing and
bearing housing for optimum concentricity.
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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
A fully confined gasket forms the seal between the
pump casing and the cover.
The cover designs provide improved performance of
mechanical seals.
The design enables one of a number of sealing
options to be fitted.
3.3.8 Shaft seal
The mechanical seal(s) attached to the drive shaft
seals the pumped liquid from the environment. Gland
packing may be fitted as an option, except on the P
self-primer casing.
3.3.9 Driver
The driver is normally an electric motor. Different drive
configurations may be fitted such as internal combustion
engines, turbines, hydraulic motors, and driving via
couplings, belts, gearboxes, drive shafts etc.
3.3.10 IPS Beacon
The pump is fitted with a temperature and vibration
monitor as standard. For additional information see
the User Instructions which are supplied separately.
3.3.11 Accessories
Accessories may be fitted when specified by the
customer.
Fan cooling is available for high temperature operation.
(This is a fan fitted within the coupling guard to blow
cooling air over the bearing housing and shaft.)
3.4 Performance and operating limits
This product has been selected to meet the
specifications of the purchase order. See section 1.5.
The following data is included as additional
information to help with your installation. It is typical,
and factors such as temperature, materials, and seal
type may influence this data. If required, a definitive
statement for your particular application can be
obtained from Flowserve.
3.4.1 Operating limits
Normal maximum ambient temperature:
+40 ºC (104 ºF).
Normal minimum ambient temperature:
-20 ºC (-4 ºF).
Maximum pump speed: refer to the nameplate.
4 INSTALLATION
Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
4.1 Location
The pump should be located to allow room for access,
ventilation, maintenance and inspection with ample
headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped. Refer
to the general arrangement drawing for the pump set.
4.2 Part assemblies
On baseplated pump sets the coupling elements are
supplied loose. It is the responsibility of the installer
to ensure that the pump set is finally lined up as
detailed in section 4.5.2, Alignment methods.
4.3 Foundation
There are many methods of installing
pump units to their foundations. The correct method
depends on the size of the pump unit, its location and
noise and vibration limitations. Non-compliance with
the provision of correct foundation and installation
may lead to failure of the pump and, as such, would
be outside the terms of the warranty.
Ensure the following are met:
a) The baseplate should be mounted onto a firm
foundation, either an appropriate thickness of
quality concrete or sturdy steel framework. (It
should NOT be distorted or pulled down onto the
surface of the foundation, but should be
supported to maintain the original alignment.)
b) Install the baseplate onto packing pieces evenly
spaced and adjacent to foundation bolts.
c) Level with shims between baseplate and packing
pieces.
d) The pump and driver have been aligned before
dispatch however the alignment of pump and motor
half coupling must be checked. If this is incorrect, it
Page 13 of 52 flowserve.com
DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
indicates that the baseplate has become twisted
and should be corrected by re-shimming.
e) If not supplied, guarding shall be fitted as necessary
to meet the requirements of ISO 12100 and EN953.
4.4 Grouting
Where applicable, grout in the foundation bolts.
After adding pipework connections and rechecking the
coupling alignment, the baseplate should then be
grouted in accordance with good engineering practice.
Fabricated steel, folded steel and cast iron baseplates
can be filled with grout. Polycrete baseplates cannot be
grouted in the same way, see their User Instructions
71569284 (E) for installation and use. If in any doubt,
please contact your nearest service center for advice.
Grouting provides solid contact between the pump unit
and foundation, prevents lateral movement of vibrating
equipment and dampens resonant vibrations.
Foundation bolts should only be fully tightened when
the grout has cured.
4.5 Initial alignment
4.5.1 Thermal expansion
The pump and motor will normally
have to be aligned at ambient temperature with an
allowance for thermal expansion at operating
temperature. In pump installations involving high
liquid temperatures, the unit should be run at the
actual operating temperature, shut down and the
alignment checked immediately.
4.5.2 Alignment methods
For couplings with narrow flanges use a dial indicator
as shown. The alignment values are maximums for
continuous service.
Parallel
Angular
Permissible misalignment limits at working temperature:
• Parallel alignment
- 0.25 mm (0.010 in.) TIR maximum
• Angular alignment
- 0.3 mm (0.012 in.) TIR maximum for couplings
not exceeding 100 mm (4 in.) flange diameter
- 0.5 mm (0.020 in.) TIR maximum for couplings
over 100 mm (4 in.) diameter
When checking parallel alignment, the total indicator
read-out (TIR) shown is twice the value of the actual
shaft displacement.
Align in the vertical plane first, then horizontally by
moving motor. Maximum pump reliability is obtained
by near perfect alignment of 0.05 - 0.075 mm (0.002 -
0.003 in.) parallel and 0.05 mm (0.002 in.) per 100 mm
(4 in.) of coupling flange diameter as angular
misalignment.
4.5.3 Check for soft foot
Pump and driver must be isolated
electrically and the half couplings disconnected.
The alignment MUST be checked.
Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.
Alignment is achieved by adding or removing shims
under the motor feet and also moving the motor
horizontally as required. In some cases where the
alignment cannot be achieved it will be necessary to
move the pump before recommencing the above
procedure.
This is a check to ensure that there is no undue
stress on the driver holding down bolts; due to nonlevel baseplate or twisting. To check, remove all
shims and clean surfaces and tighten down driver to
the baseplate. Set a dial indicator as shown in sketch
and loosen off the holding down bolt while noting any
deflection reading on the dial test Indicator - a
maximum of 0.05 mm (0.002 in.) is considered
acceptable but any more will have to be corrected by
adding shims. For example, if the dial test indicator
shows the foot lifting 0.15 mm (0.006 in.) then this is
the thickness of shim to be placed under that foot.
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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
Tighten down and repeat the same procedure on all
other feet until all are within tolerance.
Complete piping as below and see sections 4.8,
Final shaft alignment check, up to and including section
5, Commissioning, startup, operation and shutdown,
before connecting driver and checking actual rotation.
4.6 Piping
Protective covers are fitted to the pipe
connections to prevent foreign bodies entering during
transportation and installation. Ensure that these
covers are removed from the pump before connecting
any pipes.
4.6.1 Suction and discharge pipework
Never use pump as a support for piping.
Maximum forces and moments allowed on the pump
flanges vary with the pump size and type. To minimize
these forces and moments that may, if excessive, cause
misalignment, hot bearings, worn couplings, vibration
and the possible failure of the pump casing, the
following points should be strictly followed:
• Prevent excessive external pipe load
• Never draw piping into place by applying force to
pump flange connections
• Do not mount expansion joints so that their force,
due to internal pressure, acts on the pump flange
Ensure piping and fittings are flushed
before use.
Ensure piping for hazardous liquids is arranged
to allow pump flushing before removal of the pump.
Take into account the available NPSH which must be
higher than the required NPSH of the pump.
4.6.1.1
In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose
pipework that is one or two sizes larger than the
pump suction and discharge. Typically main
pipework velocities should not exceed 2 m/s (6
ft./sec) suction and 3 m/s (9 ft./sec) on the discharge.
4.6.1.2
The delivery pipework must permit priming air to
escape unhindered from the pump during the priming
cycle, without back pressure and prevent excessive
run-back of liquid on shutdown to minimize syphoning.
Non self-primer casings
Self-priming casing
Priming air may be vented in one of the following ways:
1) The discharge pipework regulating valve, if fitted,
may be partly opened during the priming cycle to
freely vent the air.
2) An automatic air release valve may be fitted to the
discharge pipework, between the pump and any
valves, providing that gases and vapors given off
are environmentally safe and acceptable for
release into the atmosphere.
3) An air bleed pipe may be run from the discharge
pipework, between the pump and any valves, back
to the suction tank or sump. This arrangement has a
disadvantage in that manual/automatic control will be
necessary during operation to prevent continuous recirculation of the pumped liquid.
4.6.2 Suction piping
4.6.2.1
a) The inlet pipe should be one or two sizes larger
b) On suction lift the piping should be inclined up
c) On positive suction, the inlet piping must have a
d) The pipe next to the pump should be the same
e) Fitting isolation and non-return valves will allow
f) Never throttle pump on suction side and never
4.6.2.2
a) The inlet pipe should be as short as possible,
b) It is recommended that the pump inlet pipe is no
c) Take into account the available NPSH, which must
d) Allow a minimum of two pipe diameters of straight
Non self-primer casing suction piping
than the pump inlet bore and pipe bends should
be as large a radius as possible.
towards the pump inlet with eccentric reducers
incorporated to prevent air locks.
constant fall towards the pump.
diameter as the pump suction and have a minimum
of two pipe diameters of straight section between
the elbow and the pump inlet flange. Where the
NPSH margin is not large, it is recommended that
the pipe straight is 5 to 10 pipe diameter. (See
section 10.3, Reference 1.) Inlet strainers, when
used, should have a net 'free area' of at least three
times the inlet pipe area.
easier maintenance.
place a valve directly on the pump inlet nozzle.
Self-priming casing suction piping
airtight and the smallest volume as practical for the
pump flow rate so as to be able to prime quickly.
Where inlet pipe volume is large an inlet ball-foot
valve or flap valve will be required.
larger than the pump inlet bore or such that the
suction velocity is in the range of 3 to 5 m/s
(10 to 16 ft./sec). The piping should slope down
towards the pump casing suction flange.
be higher than the required NPSH of the pump.
section between the elbow and inlet flange.
Page 15 of 52 flowserve.com
DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12
e) Fitting an isolation valve will allow easier
maintenance.
f) Never throttle pump on suction side and never
place a valve directly on the pump inlet nozzle.
4.6.2.3
Suction strainer
In a new installation, great care should be taken to
prevent dirt, scale, welding beads and other items
from entering the pump, as it is particularly important
to protect the numerous close running fits from
abrasive matter present in new piping
The suction system should be thoroughly flushed
before installing the suction strainer and making up
suction piping to the pump.
The suction strainer should be installed between 5 to
20 pipe diameters upstream from the pump suction
flange.
The open area of the strainer should
have a minimum of a 3 to 1 ratio to the area of the
pump suction.
A spool piece should be installed in
suction line so that the suction strainer may be
installed and removed with a pressure gauge
between the strainer and pump.
4.6.3 Discharge piping
4.6.3.1
Non self-primer casing discharge piping
a) A non-return valve should be located in the
discharge pipework to protect the pump from
excessive back pressure and hence reverse
rotation when the unit is stopped.
b) Fitting an isolation valve will allow easier
maintenance.
4.6.3.2
Self-priming casing discharge piping
a) In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose
pipework that is one or two sizes larger than the
pump discharge. Typically main pipework velocities
should not exceed 3 m/s (9 ft/sec) on the discharge.
Pipework expanders should have a maximum angle
of divergence of 9 degrees.
b) If a non-return valve is located in the discharge
pipework then a vent/bleed pipe should be fitted
from the discharge pipe back to the sump or
source tank.
c) A regulating valve should be fitted in the discharge
pipework unless pump flow is controlled by the
delivery system design.
Figure 4.14
Cone Type Strainer
The FLOWSERVE recommendation for suction
strainers consists of a conical shaped steel plate. The
plate has 1.6 mm (1/16 in.) perforations and is of
sufficient size and thickness for the required flow.
See Figure above.
Other type of strainers may be used as long as they
conform to the requirements stated above.
Pressure gauges should be installed on both sides of
the screen so that the pressure drop across the
screen can be measured.
When the unit is being started, the gauges on each
side of the screen should be carefully watched. An
increase in the differential pressure between the two
gauges indicates that the screen is becoming clogged
with dirt and scale. At this point, the pump should be
shut down, and the screen cleaned and/or replaced.
Page 16 of 52 flowserve.com
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