Flowserve Durco Mark 3 ISO Frame Mounted User Manual

USER INSTRUCTIONS

Durco® Mark 3™ ISO frame mounted

Installation

Operation

Maintenance

Standard two piece bearing frame foot mounted, centerline mounted and unitized self-priming chemical process pumps

PCN= 85392719 12-14 (E). Original instructions.

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 12-14

CONTENTS

Page

1 INTRODUCTION AND SAFETY ........................ 4

1.1 General ......................................................... 4

1.2 CE marking and approvals ........................... 4

1.3 Disclaimer ..................................................... 4

1.4 Copyright....................................................... 4

1.5 Duty conditions ............................................. 4

1.6 Safety ............................................................ 5

1.7 Nameplate and safety labels ........................ 9

1.8 Specific machine performance ..................... 9

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

2 TRANSPORT AND STORAGE ........................ 10

2.1 Consignment receipt and unpacking .......... 10

2.2 Handling ...................................................... 10

2.3 Lifting .......................................................... 10

2.4 Storage ....................................................... 11

2.5 Recycling and end of product life ............... 11

3 DESCRIPTION ................................................ 11

3.1 Configurations ............................................. 11

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

3.3 Design of major parts .................................. 12

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

4 INSTALLATION ................................................ 13

4.1 Location ...................................................... 13

4.2 Part assemblies .......................................... 13

4.3 Foundation .................................................. 13

4.4 Grouting ...................................................... 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

Page

6 MAINTENANCE .............................................. 25

6.1 General ....................................................... 25

6.2 Maintenance schedule ............................... 26

6.3 Spare parts ................................................. 27

6.4 Recommended spares ............................... 27

6.5 Tools required ............................................. 27

6.6 Fastener torques ........................................ 28

6.7 Setting impeller clearance .......................... 28

6.8 Disassembly ............................................... 29

6.9 Examination of parts ................................... 30

6.10 Assembly .................................................... 31

6.11 Sealing arrangements ................................ 33

7 FAULTS; CAUSES AND REMEDIES .............. 36

8 PARTS LISTS AND DRAWINGS ..................... 38

8.1 Mark 3 ISO ................................................. 38

8.2 Centerline mounted, recessed impeller

and self-primer configurations .................... 40

8.3 Additional details ........................................ 43

8.4 Parts interchangeability .............................. 45

8.5 General arrangement drawing .................... 49

9 CERTIFICATION ............................................. 49

10 OTHER RELEVANT DOCUMENTATION AND

MANUALS ....................................................... 49

10.1 Supplementary User Instruction manuals .. 49

10.2 Change notes ............................................. 49

10.3 Additional sources of information ............... 49

5 COMMISSIONING, START-UP, OPERATION

AND SHUTDOWN ........................................... 20

5.1 Pre-commissioning procedure .................... 20

5.2 Pump lubricants .......................................... 21

5.3 Impeller clearance ...................................... 22

5.4 Direction of rotation ..................................... 22

5.5 Guarding ..................................................... 22

5.6 Priming and auxiliary supplies .................... 22

5.7 Starting the pump ....................................... 23

5.8 Running the pump ...................................... 23

5.9 Stopping and shutdown .............................. 24

5.10 Hydraulic, mechanical and electrical duty .. 25

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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 12-14

INDEX

Page

Additional sources (10.3) ......................................... 49

Alignment of shafting (see 4.3, 4.5 and 4.8)

Assembly (6.10) ....................................................... 31

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

Bearing sizes and capacities (5.2.2) ....................... 21

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

Certification (9) ........................................................ 49

Change notes (10.2) ................................................ 49

Clearances, impeller (6.7) ....................................... 28

Commissioning and operation (5) ........................... 20

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

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

Design of major parts (3.3) ...................................... 12

Direction of rotation (5.4) ......................................... 22

Disassembly (6.8) .................................................... 29

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

Dismantling (6.8, Disassembly) ............................... 29

Drawings (8) ........................................................... 38

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

Electrical connections (0) ........................................ 20

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

Examination of parts (6.9) ....................................... 30

Fastener torques (6.6) ............................................. 28

Faults; causes and remedies (7) ............................. 36

Foundation (4.3) ...................................................... 13

General arrangement drawing (8.5) ........................ 49

General assembly drawings (8) ............................... 38

Grouting (4.4)........................................................... 14

Guarding (5.5).......................................................... 22

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

Hydraulic, mechanical and electrical duty (5.10) ..... 25

Impeller clearance (see 5.3 and 6.7)

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

Installation (4) .......................................................... 13

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

Location (4.1) ........................................................... 13

Lubrication (see 5.1.1, 5.2 and 6.2.3) Lubrication schedule (see 6.2.3)

Maintenance (6) ....................................................... 25

Maintenance schedule (6.2) .................................... 26

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

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

Nozzle loads (4.6.4) ................................................. 16

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

Ordering spare parts (6.3.1) .................................... 27

Part assemblies (4.2) ............................................... 13

Parts interchangeability (8.4) ................................... 45

Parts lists (8) ............................................................ 38

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

Piping (4.6) .............................................................. 15

Pre-commissioning (5.1) .......................................... 20

Priming and auxiliary supplies (5.6) ........................ 22

Page

Protection systems (4.9) ..........................................20

Reassembly (6.10, Assembly) .................................31

Receipt and unpacking (2.1) ....................................10

Recommended fill quantities (see 5.2.2) ..................21

Recommended grease lubricants (5.2.3) .................22

Recommended oil lubricants (5.2.1) ........................21

Recommended spares (6.4) .....................................27

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

Replacement parts (6.3 and 6.4) ..............................27

Running the pump (5.8) ...........................................23

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) ....................................33

Sectional drawings (8) ..............................................38

Setting impeller clearance (6.7) ...............................28

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

Sources, additional information (10.3) .....................49

Spare parts (6.3) ......................................................27

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

Starting the pump (5.7).............................................23

Stop/start frequency (5.8.5) ......................................24

Stopping and shutdown (5.9) ...................................24

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

Storage, spare parts (6.3.2) .....................................27

Supplementary manuals or information sources ......49

Supplementary User Instructions (10.1)...................49

Thermal expansion (4.5.1) .......................................14

Tools required (6.5) ..................................................27

Torques for fasteners (6.6) .......................................28

Trouble-shooting (see 7) ..........................................36

Vibration (5.8.4) ........................................................24

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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 12-14

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, 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) 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 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

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.

If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty) you should seek the written

agreement of Flowserve before start up.

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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 12-14

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 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 80 ºC (175 ºF) or

below -5 ºC (23 ºF) in a restricted zone, or exceeds local regulations, action as above shall be taken.

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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 12-14

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.

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 2014/34/EU (previously 94/9/EC which remains valid until 20 April 2016 during the transition). 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.

Scope of compliance 1.6.4.1

Use equipment only in the zone for which it is

appropriate. Always check that the driver, drive

coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed.

Where Flowserve has supplied only the bare shaft pump, the Ex rating applies only to the pump. The party responsible for assembling the ATEX pump set shall select the coupling, driver and any additional equipment, with the necessary CE Certificate/ Declaration of Conformity establishing it is suitable for the area in which it is to be installed.

The output from a variable frequency drive (VFD) can cause additional heating effects in the motor and so, for pumps sets with a VFD, the ATEX Certification for the motor must state that it is covers the situation where electrical supply is from the VFD. This particular requirement still applies even if the VFD is in a safe area.

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.

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DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 12-14

Temperature class

to EN13463-1

Maximum surface

temperature permitted

Temperature limit of

liquid handled

T6 T5 T4 T3 T2 T1

85 °C (185 °F) 100 °C (212 °F) 135 °C (275 °F) 200 °C (392 °F) 300 °C (572 °F) 450 °C (842 °F)

65 °C (149 °F) *

80 °C (176 °F) * 115 °C (239 °F) * 180 °C (356 °F) * 275 °C (527 °F) * 400 °C (752 °F) *

Temperature class

to EN 13463-1

Maximum surface

temperature permitted

Temperature limit of

liquid handled

T6 T5 T4 T3 T2 T1

85 °C (185 °F) 100 °C (212 °F) 135 °C (275 °F) 200 °C (392 °F) 300 °C (572 °F) 450 °C (842 °F)

Consult Flowserve Consult Flowserve

110 °C (230 °F) * 175 °C (347 °F) * 270 °C (518 °F) * 350 °C (662 °F) *

Marking 1.6.4.2

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)

b = Control of ignition source

(in accordance with EN13463-6) Gas Group

IIA – Propane (typical) IIB – Ethylene (typical) IIC – Hydrogen (typical)

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

Avoiding excessive surface 1.6.4.3

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

Maximum permitted liquid temperature for pumps with self-priming casing

* 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.

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.

Pumps with threaded/locking screw on 1.6.4.4

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.

Pumps with key drive impellers only 1.6.4.5

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 12-14

Additional requirements for self-priming 1.6.4.6

pumps only

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.

Preventing the build-up of explosive 1.6.4.7

mixtures

ENSURE THE PUMP IS PROPERLY FILLED

AND VENTED AND DOES NOT RUN DRY

Ensure the pump and relevant suction and discharge pipeline system is totally filled with liquid at all times during the pump operation, so that an explosive atmosphere is prevented.

In addition it is essential to make sure that seal chambers, auxiliary shaft seal systems and any heating and cooling systems are properly filled.

If the operation of the system cannot avoid this condition, fit an appropriate dry run protection device (for example liquid detection or a power monitor).

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

Preventing sparks 1.6.4.8

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 baseplate must be properly grounded.

Avoid electrostatic charge: do not rub non-metallic

surfaces with a dry cloth; ensure cloth is damp.

For ATEX the coupling must be selected to comply with the requirements of European Directive

2014/34/EU (previously 94/9/EC which remains valid until 20 April 2016 during the transition). Correct coupling alignment must be maintained.

Additional requirement for metallic 1.6.4.9

pumps on non-metallic baseplates

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

Preventing leakage 1.6.4.10

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, install a liquid detection device.

Maintenance to avoid the hazard 1.6.4.11

CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION

The responsibility for compliance with maintenance instructions is with the plant operator.

To avoid potential explosion hazards during maintenance, the tools, cleaning and painting materials used must not give rise to sparking or adversely affect the ambient conditions. Where there is a risk from such tools or materials, maintenance must be conducted in a safe area.

It is recommended that a maintenance plan and schedule is adopted. (See section 6, Maintenance.)

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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.

The values in below table are valid for preferred range of pump operation, 80% to 110% of B.E.P.

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Motor size and speed

kW (hp)

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

3550 r/min

2900 r/min

1750 r/min

1450 r/min

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

<0.55 (<0.75)

0.75 (1)

1.1 (1.5)

1.5 (2)

2.2 (3)

3 (4)

4 (5)

5.5 (7.5)

7.5 (10)

11 (15)

15 (20)

18.5 (25)

22 (30)

30 (40)

37 (50)

45 (60)

55 (75)

75 (100)

90 (120)

110 (150)

150 (200)

200 (270)

① ① ①

①

300 (400)

–

 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.

2 TRANSPORT AND STORAGE

2.3 Lifting

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

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:

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.

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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.

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 = centerline mounted high pressure casing H = foot mounted high pressure casing

 200 = nominal impeller diameter  A = extended flow hydraulic (B = standard hydraulic)  RV = impeller design

(RV = reverse vane, OP = open)

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The typical nomenclature above is the general guide to the Durco Mark 3 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.)

Impeller locking 3.3.2.1

Most A-OP type impellers are available with the option of key drive impeller. Most RV type impellers are available with the option of an impeller locking screw to provide an additional protection from loosening of the impeller during a reverse run.

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.

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 IPS Beacon User Instructions (26999949) 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.

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3.4.2 Energy efficiency operation of pumps

The pump supplied will have been selected from

Flowserve’s extensive product line to have optimum

efficiency for the application. If supplied with an electric motor then the motor will meet or exceed current legislation for motor efficiency. However it is the way the pump is operated which has the greatest impact on the amount and cost of energy used during the operating life of the pump. The following are key points in achieving minimum operating cost for the equipment:

 Design the pipe system for minimum friction losses  Ensure that the control system switches off the

pump when not required

 In a multi-pump system run the minimum number

of pumps

 Try to avoid systems which by-pass excess flow  As far as possible avoid controlling pump flow by

using throttle valves

 When commissioned, check that the pump

operates at the duty specified to Flowserve

 If it has been found that the pump head and flow

exceed that required, trim the pump impeller diameter

 Ensure that the pump is operating with sufficient

NPSH available

 Use variable speed drives for systems that

require variable flow. A VFD for an induction motor is a particularly effective way of achieving speed variation and energy/cost reduction

 Notes for VFD usage:

o make sure that the motor is compatible with

VFD

o Do not over-speed the pump without

checking the power capability with Flowserve

o On systems with high static head, speed

reduction is limited. Avoid running the pump at a speed which gives low or zero flow

o Do not run a low speed and flow rate that lets

solids settle out of suspension in the pipework

o Do not use a VFD for a fixed flow requirement;

it will introduce power losses

 Select high efficiency motors  If replacing a standard motor with a high

efficiency motor it will run faster and the pump could take more power. Reduce the impeller diameter to achieve energy reduction

 If the pump system pipework or equipment is

changed or process duty is changed, check that the pump is still correctly sized

 Periodically check that the pipe system has not

become corroded or blocked

 Periodically check that the pump is operating at

the flow, head and power expected and that the efficiency has not reduced with erosion or corrosion damage

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.

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Pa ralle l

An gu lar

d) The pump and driver have been aligned before

dispatch however the alignment of pump and motor half coupling must be checked. If this is incorrect, it indicates that the baseplate has become twisted and should be corrected by 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, typically above 100 ºC (212 ºF), the unit should be run at the actual operating temperature, shut down and the alignment checked immediately.

4.5.2 Alignment methods

move the pump before recommencing the above procedure.

For couplings with narrow flanges use a dial indicator as shown. The alignment values are maximums for continuous service.

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

This is a check to ensure that there is no undue stress on the driver holding down bolts; due to non-level 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.

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For example, if the dial test indicator shows the foot lifting 0.15 mm (0.006 in.) then this is the thickness of shim to be placed under that foot. Tighten down and repeat the same procedure on all other feet until all are within tolerance.

Complete piping as below and see sections 4.8,

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.

Non self-primer casings 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.

Self-priming casing 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.

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

Non self-primer casing suction piping 4.6.2.1

a) The inlet pipe should be one or two sizes larger

than the pump inlet bore and pipe bends should be as large a radius as possible.

b) On suction lift the piping should be inclined up

towards the pump inlet with eccentric reducers incorporated to prevent air locks.

c) On positive suction, the inlet piping must have a

constant fall towards the pump.

d) The pipe next to the pump should be the same

diameter as the pump suction and have a minimum of two pipe diameters of straight section between the elbow and the pump inlet flange. Where the NPSH margin is not large, it is recommended that the pipe straight is 5 to 10 pipe diameter. (See section 10.3, Reference 1.) Inlet strainers, when used, should have a net 'free area' of at least three times the inlet pipe area.

e) Fitting isolation and non-return valves will allow

easier maintenance.

f) Never throttle pump on suction side and never

place a valve directly on the pump inlet nozzle.

Self-priming casing suction piping 4.6.2.2

a) The inlet pipe should be as short as possible,

airtight and the smallest volume as practical for the pump flow rate so as to be able to prime quickly. Where inlet pipe volume is large an inlet ball-foot valve or flap valve will be required.

b) It is recommended that the pump inlet pipe is no

larger than the pump inlet bore or such that the suction velocity is in the range of 3 to 5 m/s (10 to 16 ft/sec). The piping should slope down towards the pump casing suction flange.

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c) Take into account the available NPSH, which must

be higher than the required NPSH of the pump.

d) Allow a minimum of two pipe diameters of straight

section between the elbow and inlet flange.

e) Fitting an isolation valve will allow easier

maintenance.

f) Never throttle pump on suction side and never

place a valve directly on the pump inlet nozzle.

Suction strainer 4.6.2.3

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.

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.

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

Non self-primer casing discharge piping 4.6.3.1

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.

Self-priming casing discharge piping 4.6.3.2

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.

4.6.4 Allowable nozzle loads

The pump complies with ISO 5199 shaft deflection limits for the following flange loads. The values are presented in the ISO 5199/ISO 13709 (API 610) format. Please note that the values permitted may be higher or lower than those in ISO 5199; see those specified for the actual pump size.

The values permitted (50 mm and above) meet ISO 13709 (API610 11th edition) Table 5 values with grouted metallic baseplates. Individual forces and moments up to twice ISO 13709 (API610) Table 5 values may be permitted but only when applied in accordance with the conditions in ISO 13709 (API610) Annex F.

Values are presented in compliance with the ISO 1503 sign convention.

All individual values which are greater than the following values must be referred to Flowserve for approval.

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