Flowserve ESP2 User Manual

ESP2 Vertical Immersion Sump Pump

Installation

USER INSTRUCTIONS

Operation

HOC3 Hydraulics
PCN=71569292 – 4-12 (E) Original Instructions
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
CONTENTS
Page
1 INTRODUCTION AND SAFETY ........................... 3
1.1 General ........................................................... 3
1.2 CE marking and approvals .............................. 3
1.3 Disclaimer ....................................................... 3
1.4 Copyright ......................................................... 3
1.5 Duty conditions................................................ 3
1.6 Safety .............................................................. 4
1.7 Name plate and safety labels .......................... 7
1.8 Noise level ....................................................... 8
2 TRANSPORT AND STORAGE ............................. 9
2.1 Consignment receipt and unpacking............... 9
2.2 Handling .......................................................... 9
2.3 Lifting ............................................................... 9
2.4 Storage .......................................................... 10
2.5 Recycling and end of product life .................. 10
3 DESCRIPTION .................................................... 10
3.1 Configurations ............................................... 10
3.2 Nomenclature ................................................ 11
3.3 Design of major parts .................................... 11
3.4 Performance and operation limits ................. 11
4 INSTALLATION ................................................... 15
INSTALLA TION AND START-UP CHECKLIST .... 15
4.1 Location ......................................................... 16
4.2 Part assemblies............................................. 16
4.3 Foundation .................................................... 16
4.4 Pump Mounting ............................................. 16
4.5 Driver Mounting ............................................. 16
4.6 Piping ............................................................ 17
4.7 Electrical connections ................................... 19
4.8 Level controls ................................................ 19
APEX SWITCH .................................................... 26
4.9 Protection systems ........................................ 27
6.6 Setting impeller clearance and impeller
replacement .................................................. 38
6.7 Disassembly ................................................. 38
6.8 Examination of parts ..................................... 40
6.9 Assembly of pump and seal .......................... 42
7 FAULTS; CAUSES AND REMEDI ES ................. 45
8 PARTS LIST AND DRAWINGS .......................... 47
General arrangement drawing ............................. 59
9 CERTIFICATION ................................................. 59
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS .......................................................... 59
10.1 Supplementary User Instructions ............... 59
10.2 Change notes ............................................. 59
10.3 Additional sources of information................ 59
5 COMMISSIONING, STARTUP, OPERATION AND
SHUTDOWN ...................................................... 27
5.1 Pre-commissioning procedure ...................... 27
5.2 Bearing Lubrication ....................................... 29
5.3 Setting the Impeller Clearance ...................... 31
5.4 Direction of rotation ....................................... 32
5.5 Guarding ....................................................... 32
5.6 Priming and auxiliary supplies ....................... 32
5.7 Starting the pump .......................................... 32
5.8 Running or operation .................................... 33
5.9 Stopping and shutdown ................................. 34
5.10 Hydraulic, mechanical and electrical duty ... 34
6 MAINTENANCE ................................................... 35
6.1 Maintenance schedule .................................. 35
6.2 Spare parts .................................................... 36
6.3 Recommended spares and consumable items
....................................................................... 36
6.4 Tools required ................................................ 37
6.5 Fastener torques ........................................... 38
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ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12

1 INTRODUCTION AND SAFETY

1.1 General

These instructions must always be kept
close to the product's operating location o r 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 your service for any further information about the product in its installation and operation or about its support products, repair and diagnostic services.
These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements and applicable safety and health laws/regulations.
These instructions must be read prior to
installing, operating, using and maintaining the equipment in any region worldwide. The equipment must not be put into service u n til all the conditions relating to safety noted in the instructions, have been met.

1.2 CE marking and approvals

It is a legal requirement that machinery and equipment put into service withi n certai n regi ons of the worl d shall conform with the applicable CE Marking Directives covering Machinery and, w he re a ppli c able , Low V ol ta ge Equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED) and Equipment for Potentially Explosive Atmospheres (ATEX).
Where applicable, the Directiv es and any additi onal 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 t he se Di re ctive s a nd App rov al s.
To confirm the Approval s a pply ing an d i f th e p rodu c t i s CE marked, check the serial number plate markings and the Certification. (See section 9, Certification.)

1.3 Disclaimer

Information in these User Instructions is believed to be reliable. In spite of all the efforts of Flowserve Pump Division to provide sound and all necessary information the content of this manual may appear insufficient and is not guaranteed by Flowserve as to its completeness or accuracy.
Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, inst a ll or use authorized Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by the Flowserve warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in their use.

1.4 Copyright

All rights reserved. No part of these instructions may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior permission of Flowserve Pump Division.

1.5 Duty conditions

This product has been selected to meet the specifications of your purchaser order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.
The product must not be operated beyond
the parameters specified for the application. If there is any doubt as to the suitability of the product for the application intende d , contact Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order are going to be changed (for ex ample liquid pu mped, temperature or duty) it is requested that the user seeks the written agreement of Flowserve before start up.
Page 3 of 64
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12

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 invo lve a high risk to personal safety or the loss of life.
This symbol indicates safety instructio ns where non-compliance would affect persona l saf et y 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 hazardo us 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 hazardo us 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 operatio ns 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 an d d amage 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 (Lock out.)
DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous.
FLUOROELASTOMERS (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.
NEVER OPERATE THE PUMP WITHOUT THE COUPLING GUARD AND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED
GUARDS MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL
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 IMPEL L E R Trapped lubricant or vapor could cause an explosion.
HOT (and cold) PARTS If hot or freezing co mponents o r auxilia ry heating equipment can present a danger to operators and persons entering the immediate area, action must be taken to avoid acciden tal conta ct (such a s shieldi ng).
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ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
If complete prote ction is not possibl e, the machi ne access must be limited to maintenance staff only with clear visual w arni ng s a nd indi cato r s t o tho se e nte ring the immediate area. Note: bearing housings must not be insulated and drive motors and bearings may be hot.
If the temperature is greater than 68 °C (175 °F) or below 5 °C (20 °F) 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 pump placement, limiting personnel access and by operator training. If the liqu id is flammable and/or explosive, strict safety procedures must be applied.
Gland packing must not be used when pu mping 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.
THE PUMP SHAFT MUST TURN CLOCKWISE WHEN VIEWED FROM THE MOTOR END It is absolutely essential that the rotation of the motor be checked before installation of the coupling spacer and starting the pump. Incorrect rotation of the pump for even a short period can unscrew the impell er, which can cause significant damage.

1.6.4 Products used in potentially explosive atmospheres

Measures are required to:
Avoid excess temperature
Prevent buildup of explosive mixtures
Prevent the generation of spark s
Prevent leakages
Maintain the pump to avoid hazard
The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection. Both electrical and non-electrical equipment must meet the requirement s o f E ur ope an Dir e ctiv e 9 4/9/E C.
1.6.4.1 Scope of compliance
ENSURE CORRECT LUBRICA TION (See section 5, Commissioning, startup, operation and shutdown.)
NEVER EXCEED THE MAXIMUM DESIGN PRESSURE (MDP) AT THE TEMPERATURE SHOWN ON THE PUMP NAMEPLATE See section 3 for pressure versus temperature ratings based on the material of construction.
NEVER OPERATE THE PUMP WITH THE DISCHARGE VALVE CLOSED (Unless otherwise instructed at a specific point in the User Instructions.) (See section 5, Commissioning start-up, operation and shutdown.)
NEVER RUN THE PUMP DRY OR WITHOUT PROPER PRIME (Casing flooded)
NEVER OPERATE THE PUMP AT ZERO FLOW OR FOR EXTENDED PERIODS BELOW THE MINIMUM CONTINUOUS FLOW
Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft pump, the Ex rating applies only to the pump. The party responsible for assembling the pump set shall select the coupling, driver, seal 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 affects in the motor. On pump installations controlled by a VFD, the ATEX Certification for the motor must state that it covers the situation where electrical supply is from the VFD. This particular requirement still applies even if the VFD is in a safe area.
Page 5 of 64
Temperature
Maximum
permitted
Temperature limit of liquid
variant – check which is lower)
Temperature
T1
450 °C (842 °F)
350 °C (662 °F) *
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
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 135ºC (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 (Equipment Category 2 only) IIA – Propane (Typical) IIB – Ethylene ( T y pi cal) IIC – Hydrog en (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
Pump liquid temperature
Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate . These are ba sed on a maximum ambient temperature 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 te mperature depends on the temperature class and must not exceed the values in the table applicable below. The temperature rise a t the seal s and bearings and due to th e minimum pe rmitted flow rate is taken into account in the temperatures stated.
Maximum permitted liquid temperature for pumps
class to
EN 13463-1
T6 T5 T4 T3 T2 T1
surface
temperature
85 °C (185 °F) 100 °C (212 °F) 135 °C (275 °F) 200 °C (392 °F) 300 °C (572 °F) 450 °C (842 °F)
handled (* depending on
material and construction
Consult Flowserve Consult Flowserve
115 °C (239 °F) * 180 °C (356 °F) * 275 °C (527 °F) * 400 °C (752 °F) *
Maximum permitted liquid temperature fo r pumps with self-priming casing
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is lower)
Consult Flowserve Consult Flowserve
110 °C (230 °F) * 175 °C (347 °F) * 270 °C (518 °F) *
class to
EN 13463-1
T6 T5 T4 T3 T2
Maximum
surface
temperature
permitted
85 °C (185 °F) 100 °C (212 °F) 135 °C (275 °F) 200 °C (392 °F) 300 °C (572 °F)
The responsibility for compliance with the specified maximum liquid temperature is with the plant operator.
Temperature classification “Tx” is used when the liquid temperature varies and the pump could be installed in different hazardous atmospheres. In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in the particular hazardous atmosphere.
Do not attempt to check the dir ection of rotat ion with the coupling element/pins fitted due to the risk of severe contact between rot ating and stationa ry compon ents.
Where there is any risk of the pump being run against a closed valve generatin g high liqu id and ca sing exte rnal surface temperature, it is recommended that users fit an external surface temperature protection device.
Avoid mechan i cal , hy d raul ic o r electrical overload by using motor overload trips, temperature monitor or a power monitor and perform routine vibration monitoring.
In dirty or dusty environments, regular checks must be made and dirt removed from areas around close clearances, bearing housings and motors.
1.6.4.4 Preventing the buildup of explosive mixtures
ENSURE PUMP IS PROPERLY FILLED AND
VENTED AND DOES NOT RUN DRY Ensure that the pump and relevant suction and discharge
piping is totally filled with li quid at all ti mes du ring the pumps operation so tha t an expl osive at mosphere is prevented. In addition, i t is essential to make sure that seal chambers, auxiliary shaft seal systems and any heating and cooling systems are properly filled.
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ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
If the operation of the system can not avoid this condition it is recommended that you 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.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical contact, the coupling guard must be non-sparking for Category 2.
To avoid the potential hazard from random induced current generating a spark, the baseplate must be properly grounded.
Avoid electrostatic charge. Do not rub non­metallic surfaces with a dry cloth; ensure the cloth is damp.
The coupling must be selected to comply with 94/9/EC and correct alignment must be maintained.
Additional requirements for pumps on non­metallic baseplates
When metallic components are fitted on a non­metallic baseplate they must be individually earthed.
1.6.4.6 Preventing leakage
Avoid entrapment o f l iqui d 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 auxiliary systems.
Where there is the potenti al hazard of a lo ss of a seal barrier fluid or external flush, the fluid must be monitored. If leakage of liquid to atmosphere can result in a hazard, the installation of a liquid detection device is recommended.
1.6.4.7 Maintenance of the centrifugal pump to avoid a hazard
CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION
The responsibility for compliance with maintenance instructions is with the plant operator.
To avoid potential explosion hazards during maintenance, the tools, cleaning and painting materials used must not give rise to sparking o r adversely affect the ambient conditions. Where there is a risk from such tools or materials, maintenance must be conducted in a safe area.
It is recommended that a maintenance plan and schedule is adopted. (See section 6, Maintenance.)

1.7 Name plate and safety labels

1.7.1 Nameplate

For details of nameplate, see the Declaration of Conformity and section 3.

1.7.2 Safety labels

J218JZ250
ESSENTIAL PROCEEDURES BEFORE STARTING:
INSTALL AND OPERATE EQUIPM ENT IN ACCORDAND WITH THE INSTRUCTION MANUAL SUPPLIED SEPARATELY.
ENSURE GUARDS ARE SECURELY IN PLACE.
ENSURE CORRECT DIRECTION OF ROTATION.
ENSURE CORRECT DRIVER DIRECTION OR ROTATION WIT H COUPLING ELEMENT / PINS REMOVED: OTHERWISE SERIOUS DAMAGE MAY RESULT .
VERIFIER LE SENS CORRECT DE ROTATION DU MOTEUR. POMPE DESACCOUPLEE / ENTRETOISE DEMONTEE. NE PAS SUIVRE CETTE RECOMMANDATION PEUT CONDUIRE A DE GRAVES DOMMAGES POUR LA POMPE
CDC: 603 604 610 612 62 1 62 3 624
ENSURE ALL EXTERNAL CONNECTIONS TO THE PUMP / SHAFT SEALING AND DRIVER ARE CONNECTED AND OPERATIONAL
FULLY PRIME UNIT AND SYSTEM. DO NOT RUN UNIT DRY
FAILURE TO FOLLOW THESE PROCEEDURES MAY RESULT IN PERSONAL INJURY AND/ OR EQUIPMENT DAMAGE
J218JZ250
KONTROLLE VORGESCHRIEBENER DREHRICHTUNG ! HIERZU KUPPLUNGSZWISCHENSTÜCK / KUPPLUNGSBOLZEN ENTFERNEN. ANDERENFALLS ERNSTHAFTE SCHÄDEN !
ZORG VOOR JUISTE ROT ATIER ICHTING VAN DRIJFAS WAARBIJ DE KOPPELELELMENTEN / PENNEN VERWIJDERD ZIJN: VERZUM KAN ERNSTIGE SCHADE TOT GEVOLG HABBEN.
Page 7 of 64
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12

1.8 Noise level

When pump noise level exceeds 85 dB(A) attention must be given to prevailing Health and Safety Legislation, to limit the exposure of pla nt operat in g personnel to the noise. The usual approach is to control exposure time to the noise or to enclose the machine to reduce emitted sound. You may have already specified a limiting noise le ve l when the equipment was ordered, however if no noise requirements were defined then m ac hines abo ve a certain power level will exceed 85 dB(A). In such situations consideration must be given to the fitting of an acoustic enclosure to meet local regulations.
Pump noise level is dependen t on a numbe r of factors -
The values are based on the noisiest non-geared electric motors that are likely to be encountered. They represent sound pressure levels at 1 m (3.3 ft) from the directly driven pump, for "free field over a reflecting plane". For estimating L
sound power
wA
level (re 1 pW) add 14dBA to the sound pressure value.
If a pump unit only has been purchased, for fitting with your own driver, then the "pump only" noise levels from the table should be combined with the level for the driver obtained from the supplier. If the motor is driven by an inverter it may show an increase in noise level at some speeds. Consult a Noise Specialist for the combined calculation.
the type of motor fitted, the ope rating capa city, pipework design and acoustic characteristics of the building. Typical sound pressure levels measured in dB, and A-weighted are shown in the table below. The figures are indicative only, they are subject to a +3 dB
For units driven by equipment other than
electric motors or units contained within enclosures, see the accompanying information sheets and manuals.
tolerance, and cannot be guaranteed.
Ty pical sound pressure level, dBA, L
Motor size and speed
kW (hp)
<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) (1) 83 (1) 80 300 (400) - - - - (1) 84 (1) 81
(1) Motors in this range are generally job specific and noise levels should be calculated based on actual equipment installed. For 960 r/min reduce 1450 r/min values by 5 dBA.
3550 r/min 2900 r/min 1750 r/min 1450 r/min
Pump and
motor
dBA
71 66 64 62 64 62 63 62 74 66 67 62 67 62 63 62 74 68 67 64 67 64 65 64 77 70 70 66 70 66 66 66 78 72 71 68 71 68 68 68 81 74 74 70 74 70 70 70 82 75 75 71 75 71 71 71 90 77 83 73 76 73 72 71 90 78 83 74 77 74 73 72 91 80 84 76 78 76 74 73 92 83 85 79 80 79 76 75 92 83 85 79 80 79 76 75
92 83 85 79 81 79 77 75 100 85 93 81 84 80 80 76 100 86 93 82 84 80 80 76 100 87 93 83 84 80 80 76 100 88 95 84 86 81 82 77 100 90 95 86 88 81 83 78 100 90 95 86 90 81 85 78 100 91 95 87 91 83 86 79 101 92 96 88 91 83 86 79
Pump
only
dBA
at 1 m reference 20 μPa
pA
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
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ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
ESP2
Base Pump
Kg (lb) per 0.15m
Pump Size
Wt. Kg (lb)
Extra Length
Group 1
1.5x1x6
136 (300)
3.6 (8)
3x1.5x6
139 (305)
3.6 (8)
3x2x6K
145 (320)
4.1 (9)
1.5x1x8
148 (325)
3.6 (8)
3x1.5x8
150 (330)
3.6 (8)
Group 2
3x2x8
184 (405)
7.3 (16)
4x3x8
223 (490)
7.7 (17)
4x3x8L
223 (490)
7.7 (17)
2x1x10
182 (400)
6.8 (15)
3x1.5x10
223 (490)
6.8 (15)
3x2x10
232 (510)
7.3 (16)
4x3x10L
309 (680)
7.7 (17)
6x4x10
323 (710)
8.6 (19)
3x1.5x13
3x2x13
264 (580)
7.3 (16)
4x3x13
302 (665)
7.7 (17)
Group 3
6x4x13
407 (895)
11.4 (25)
8x6x13
545 (1200)
15 (33)
8x6x15
561 (1235)
15 (33)
10x8x15
645 (1420)

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be checked against the delivery/s hipping documents for its completeness and that there has been no damage in transportation. Any shortage and/or damage must be reported immediately to Flowserve Pump Division and must be received in writing within ten days 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 pallet, box, or equipment.
Each product has a unique serial number. Check that this number corresponds with the order. 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. The unit should be stored in a level position with no strains applied.

2.3 Lifting

Pump Weights
3x2x8
3x1.5x8
4x3x10
152 (335)
182 (400)
286 (630)
259 (570)
(6 in.)
4.1 (9)
6.8 (15)
7.7 (17)
6.8 (15)
Pumps and motors often have integral lifting lugs or eye bolts. These are intended for use in only lifting the individual piece of equipment.
Do not use eye bolts or cast-in lifting lugs to lift pump, motor and baseplate assemblies.
Care must be taken to lift components or assemblies above the center of gravity to prevent the unit from flipping. This is especially true with In-Line pumps.
Carefully sling ESP pumps so that bearing lubrication lines (3840.1) will not be bent or damaged when lifting.
It is advisable to raise the pump into the vertical position before uncrating. If this isn't possible, pumps over eight feet long must be supported at more than one place when raising to the vertical position. Use a support strap around the bottom column (1341.2) and on the motor support (3160).
10x8x13 616 (1355)
16.4 (36)
16.4 (36)
Base pump lengths are 0.61m (2 ft.) for Group 1 & Group 2 pumps and 0.91m (3 ft.) for Group 3 pumps.
On pumps equipped with grease lubricated shaft bearings, (3020.1 and 3020.2) take care not to flush the grease from the bearings.
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Figure 3-1: Nameplate mounted to housing

Serial No.

2.4 Storage

Store the pump in a clean, dry location away from vibration. Leave flange covers in place to keep dirt and other foreign material out of pump casing.
The pump may be stored as above for up to 6 months. Consult Flowserve for preservative actions when a longer storage period is needed.

2.4.1 Short term storage and packaging

Normal packaging is designed to protect the pump and parts during shipment and for dry, indoor storage for up to six months or less. The following is an overview of our normal packaging:
All loose unmounted items are pack aged in a
water proof plastic bag or box.
Inner surfaces of the bearing housing, shaft (area
through bearing ho u sing) and be a rings a re coat ed with Cortec VCI-329 rust inhibitor, or equal.
Regreaseable bearings in the pump are packed
with Keystone 81-EP-2 lithium-based grease for the thrust bearing (and the line shaft bearings when grease lubrication is used).
The internal surfaces of ferrous casings, covers,
flange faces, and the impeller surface are sprayed with Cortec VCI-389, or equal
Exposed shafts are taped with Polywrap
Flange covers are secured to both the suction
and discharge flanges
In some cases with assemblies ordered with
external piping, components may be disassembled for shipment
The pump must be stored in a covered, dry
location
Every three months the pump shaft should be
rotated several revolutions to prevent brinelling of the thrust bearing and sticking of the seal faces (if fit t ed).

2.4.2 Long term storage and packagin g

Long term storage is defined as more than six months, but less than 12 months. The procedure Flowserve follows for long term storage of pumps is given below. These procedures are in addition to the short term procedure.
Each assembly is hermetically (heat) sealed
from the atmosphere by means of tack wrap sheeting and rubber bushings (mounting holes)
Desiccant bags are placed inside the tack
wrapped packaging
A solid wood box is used to cover the assembly
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
This packaging will provide protection for up to twelve months from humidity, salt laden air, dust etc.
After unpacking, protection will be the responsibility of the user. Addition of oil to the bearing housing will remove the inhi bit or . If uni t s a re to be idle for extended periods after addition of lubricants, inhibitor oils and greases should be used.

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 in accor danc e with loca l regulations. If the product contains substances that are harmful to the environment, these should be removed and disposed of in accordance with current local 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 local regulations at all times.

3 DESCRIPTION

3.1 Configurations

The ESP2 vertical imm ersion sump pumps are separately coupled, metallic construction, single stage, centrifugal pumps for wet pit applications. The ESP2 wetted parts are available in a wide rang e of materials to handle most fluids. Vapor tight, vapor proof, and pressurized options are available.
Equipment No.
Purchase Order
Model
Size
MDP
Material
Date DD/MMM/YY
ESP2 6X4X10
Page 10 of 64
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
MCF % of BEP
r/min
r/min
r/min
Group 1
1.5x1x6
10
10
10
3x1.5x6
10
10
10
3x2x6K
10
10
10
1.5x1x8
10
10
10
3x1.5x8
n.a.
10
10
3x2x8
n.a.
10
10
Group 2
3x1.5x8
10
10
10
3x2x8
10
10
10
4x3x8
25
10
10
4x3x8L
n.a.
25
10
2x1x10
n.a.
25
10
3x1.5x10
n.a.
25
10
3x2x10
n.a.
25
10
4x3x10
n.a.
25
10
4x3x10L
n.a.
25
10
6x4x10
n.a.
25
10
3x1.5x13
n.a.
25
10
3x2x13
n.a.
25
10
4x3x13
n.a.
25
10
Group 3
6x4x13
n.a.
25
10
8x6x13
n.a.
25
10
10x8x13
n.a.
25
10
8x6x15
n.a.
n.a.
25
10x8x15
n.a.
n.a.
25

3.2 Nomenclature

The pump size will be engraved on the nameplate typically as below:
6 X 4 X 10
“6” = nominal suction port size (in.)
“4” = Nominal discharge port size (in.)
Nominal maximum impelle r diamete r. “10” = 10 in.
Actual impeller size
“9.5” = 9 ½ in. diameter; “8.13” = 8 ⅛ in; ”7.75” = 7 ¾ in

3.3 Design of major parts

3.3.1 Pump casing

Casings are either a single or double volute design with a centerline discharge.

3.3.2 Impeller

The impeller is an open design and is threaded to the end of the shaft.

3.3.3 Shaft

Solid shafting is supported on plain bear ings with a thrust bearing located above the sump level.

3.3.4 Pump bearings and lubrication

Grease lubricated double row angular contact ball bearings are fitted as standard for the external thrust bearings. The plain bearings that support the shaft against radial loads can be lubricated either by external flush, product, or grease (see Fig. 3-4).

3.3.5 Bearing housing

The external bearing housing holds the thrust bearing and has lip seals to prevent ingress of contaminates to the bearing grease.

3.3.6 Shaft seal

There is no shaft seal required near the impeller since the pump is submerged. Only a small amount of pressurized fluid escapes through controlled leak paths from the backside of the impeller. Packing or a mechanical seal can be fitted above the sump level to provide vapor proof or pressurized options for the application.

3.3.7 Driver

The driver is normally a vertical electric motor.

3.3.8 Accessories

Accessories may be fitted when specified by the customer.

3.4 Performance and operation limits

This product has been selected to meet the specification of your purchase order. See se cti on 1. 5.
The following data is included as additional information to help with y our in stal l ati on . I t i s ty pi cal, a nd facto r s such as liquid being pumped, temperature, material of construction, an d se al ty pe may i n fluen ce this data. If required, a definitive statement for your application can be obtained from Flowse rve.

3.4.1 Minimum continuous flow

The minimum continuous flow (MCF) is based on a percentage of the best efficiency point (BEP). Figure 3-2 identifies the MCF for all ESP pump models.
FIGURE 3-2: Minimum continuous flow
Pump size
3500/2900
1750/1450
1180/960
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ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
Suct.
Flow
(m3/hr.)
Size
6.8
11.4
20.5
45.5
79.5
136
273
341
500
568
727
1023
1250
1.5 in
0.30
0.55
1.07
2.65 2 in
0.30
0.58
1.40
2.74
3 in
0.30
0.79
1.52
2.38 4 in 0.30
0.55
1.07
2.13
6 in 0.43
0.76
1.19
1.83
8 in 0.55
0.94
1.19
1.65
10 in 0.64
0.85
1.22
1.52
Suct.
Flow
(GPM) Size
30
50
90
200
350
600
1200
1500
2200
2500
3200
4500
5500
1.5 in
1.0
1.8
3.5
8.7 2 in
1.0
1.9
4.6
9.0
3 in
1.0
2.6
5.0
7.8 4 in 1.0
1.8
3.5
7.0
6 in 1.4
2.5
3.9
6.0
8 in 1.8
3.1
3.9
5.4
10 in 2.1
2.8
4.0
5.0

3.4.2 Minimum suction pipe submergence

The minimum submergence is shown in Figures 3­3A and 3-3B below.
FIGURE 3-3A
Minimum submergence (meters)
FIGURE 3-3B
Minimum submergence (feet)
Page 12 of 64
Bearing Material
Max. Product
Pumped Liquid
Lubricant
Shaft Material
Most clean acids,
External Flush
Steel or SS
BRONZE
82°C
Water and other
External Flush
Steel only
CAST IRON
82°C
Water and other
External Flush
Steel
RUBBER
71°C
General abrasive liquids
External Flush
SS only
TEFLON
177°C
Clean acids not
External Flush
SS only
Grease Lube
Clean acids not
Grease
SS only
VITON
149°C
Dirty acids not
External Flush
SS only

3.4.3 ESP2 Bearing Materials

CARBON - Carbon graphite, especially developed
for sump p ump appl ications , is chem icall y inert. The self lubricating properties of graphite present in the carbon bearings enhances its dry running capabilities.
BRONZE - SAE 660 Bron ze (grooved when grease lubricated).
CAST IRON - ASTM A48 Class 30 iron (grooved when grease lubricated). RUBBER - Resilient compounded rubber, fluted to
allow abrasive s t o wa sh away.
FIGURE 3-4: ESP2 Bearing selection
Temp.
CARBON
177°C (350°F)
genera! chemical, cold or hot water, cl eani ng fluids, gasol ine, kerosene, jet fuels
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
VITON - Resilient Viton, fluted to allow handling of
dirty corrosive liquids not able to be handled by carbon or rubber.
TEFLON - Fiberglass & moly-disulphide-filled, with
low cold flow, high tensile and elongation char­acteristics.
All bearing materials are enclosed in an AISI-316 shell (ex. Bronze & Cast Iron). Higher alloys ar e available (grooved when grease lubricated).
Product Lube
Steel or SS
Liquid Lube
TEFLON 82°C
180°F
(180°F)
(160°F)
(350°F)
(180°F)
(300° F)
compatible liquids
compatible liquids including alkaline caustics
compatible w ith rubber
compatible with carbon
compatible with carbon
compatible with carbon or rubber
Product Lube Grease
Product Lube Grease
Product Lube
Product Lube
Product Lube
Steel only Steel only
Steel Steel
SS only
SS only
SS only
Page 13 of 64
FIGURE 3-5: Engineering information
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
Page 14 of 64
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12

4 INSTALLATION INSTAL LAT ION AND S TART-UP

CHECKLIST
1. Check that the sump design will keep the liquid level within the proper range.
2. Check that the pump location is accessible and
has adequate ventilation.
3. Verify that the pump and motor are suitable for
the pump environment.
4. Check the sump design to be sure it is adequate to support the complete pumping assembly,
5. Verify the discharge piping meets Hydraulic Institute Standards for design and is properly supported.
6. Install the suction strainer
7. Install the liquid level controls.
8. If pump was ordered for vapor proof or pressurized design, install sealing device.
9. Lift the pump into place, level and tighten the
mounting plate bolts.
10. Install the motor on the pump , but do not connect the coupling or electric power.
1 _________ __________
2 _________ __________ 3 _________ __________
4 _________ __________
5 _________ __________
6 _________ __________ 7 _________ __________
8 _________ __________
9 _________ __________
10 _________ __________
11. Connect the wiring to the liquid level indicators and pump controls, as required.
12. Connect t he di sch arge pip ing ,
13. Check that all auxiliary piping is connected
14. Verify the pump is free of pipe strain by turning
the shaft by hand.
15. Verify the impeller setting.
16. Lubricate the driver, pump thrust and lineshaft
bearings as required using approved lubricants.
17. Connect the wiring for the motor.
18. Turn power ON and jog the driver to verify proper rotation; clockwise looking down.
19. Turn power OFF and assemble coupling and install coupling guard. Then turn power ON, but do not start the driver.
11 _________ __________ 12 _________ __________
13 _________ __________ 14 _________ __________
15 _________ __________
16 _________ __________ 17 _________ __________
18 _________ __________
19 _________ __________
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ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12

4.1 Location

The pump should be located to allow room for installation, access, ventilation, maintenance, and inspection with ample headroom for lifting. Refer to the general arrangement drawing for the pump set. If pump is furnished with external flush-lubricated bearings, the fluid lines must be accessible from the pump location. Also important, especially in the larger flow units, is proper sump design. Liquid velocity approaching the pump should be one foot per second or less. When more than one pump is installed and used at the same time in the same sump, the location and spacing of the pumps are important. The guidelines for sump design and pump placement as outlined in the "Hydraulic Institute Standards" are recommended.

4.2 Part assemblies

Pumps are shipped completely assembled
except for driver, strainer (6531), float controls (if furnished), pit cover, and the mechanical seal (4200) or packing (4130) for the stuffing box on a vapor proof or pressurized design pump.
When mechanical seals are furnished, they
should be installed before the motor is put in place. Refer to seal installation instructions in section 5.1.
Vapor Proof and Pressurized design pumps
are furnished with an upper stuffing box (4100). If the stuffing box does not already have the packing (4130) or seal (4200) installed, then they should be installed before the motor is mounted. See section 5.1.
The driver will be mounted after the pump is
installed.
When the pump is shipped, all threads and all
openings are covered. This protection should not be removed until installation. If the pump is removed from service, this protection should be reinstalled.

4.3 Foundation

There should be adequate space for workers to install, operate, and maintain the pump. The foundation should be sufficient to absorb any vibration and should provide a rigid support for the pump and motor. Recommended mass of a concrete foundation should be three times that of the pump, motor and mounting plate. Supporting members must be sufficiently strong to prevent spring action and/or lateral movement.

4.4 Pump Mounting

The pump may be mounted directly on the pit using the pum p mountin g plate ( 6110) or in conjunction with a pit cover. a) The pump was checked during assembly at
the factory to make sure the pump shaft (2100) rotated freely by hand. Handling during shipment, storage, or preparation for installation could have caused distortions resulting in pump shaft binding. Check the shaft to make sure that it will rotate freely by hand.
b) Check all bolts and nuts for tightness, then
carefully lower the assembled pump into the pit, taking care not to damage lube lines or float control equipment. Make sure that any equipment used to lift the pum p or any of its components is capable of supporting the weights encountered. Make su re that all parts are properly rigged before attempting to lift.
c) Pump mounting plate and/or pit cover mus t
maintain a tolerance of 2.5mm/m (0.03in/ft) level from one side of the plate to the other, and be supported evenly at all points before being bolted down.
d) If the sump doesn't provide a level mounting
surface for the pump, driv e wedges under the mounting plate/pit cover until pump levels out. The wedges m ust be able to support the weight of th e entir e pum ping assembly and hold the assembly steady enough that no excess vibration occurs.
e) Do not bolt the discharge flange of the pump
to the piping until the baseplate foundation is completely installed.
f) Run piping to the discharge of the pump.
There should be no piping loads transmitted to the pump after connection is made.

4.5 Driver Mounting

a) Before the motor is installed, be sure to
connect the motor half coupling and the pump half coupling onto their respective shafts.
b) Carefully lift the motor and place it on the
support head (3160) of the pump.
c) Turn the motor frame to one of the four
positions where the motor bolt hol e s li ne up to the support head (3160). Select the position of the motor to suit the desired conduit box location. Install the motor hold down bolts (6570.1). In some instances a motor adapter may be furnished. In this case the adapter must be installed before the motor can be mounted.
Page 16 of 64
PLATE
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12
d) L ocate the coupli ng and source of electri cal
power but DO N OT ASSEMBLE THE COUPLING AT THIS TIME.
e) Connect the motor terminals to the leads from
the starter panel. Make sure the motor shaft and/or coupling is not touching any part of the pump shaft or pump half coupling. Rotate the motor shaft by hand to make sure it is free to rotate when energized.
Never check driver rotation unless the
pump and driver are disconnected and physically separated. Failure to follow this instruction can result in serio u s damage to the pump and driver if rotation is in the wrong direction.
f) Jog the motor and check for proper rotation
which should be clockwise when looking down on top of the motor. If rotation is wrong,
interchange any two moto r connections on three-phase motors. On single-phase motors, follow the motor manufacturer’s instructions. After changing the connections, again check the rotation to ensure that the direction is correct.
g) Disconnect and loc kout the power supply to the
driver.
h) The coupling can now be fully installed and
join the driver and pump shafts t ogether (see section 5.4.2).
i) Install the coupling guarding ( see s ec tion
5.5).

4.6 Piping

4.6.1 Discharge piping

All piping must be ind epe nde ntly supported, accurately aligned and pre ferably connecte d to the pump by a short length of flex ible pipi ng. The pu mp should not hav e to supp o rt th e w eig ht o f the pi pe. It should be possible to install dis cha rge b ol ts t hrou gh mating flanges without pulling or prying either of the flanges. All piping must be tight .
Protective cov er s are fitted to both the suction and discharge flanges of the casing and must be removed prior to connecting the pump to any pipes.
a) Use discharge piping one size larger than the
pump discharge.
b) Discharge piping should be well supported
and connected to the pump such that no strain or weight of the piping is carried by the pump.
c) Check pump shaft for freedom of rotation by
hand to make sure any discharge piping strain is not causing binding.
d) After the pump discharge, the increaser
should be the first item in the discharge line, followed by the check valve and gate valve, respectively. See Figure 4-1.
e) It is recommended that pressure indicating
devices be installed before and after the valves in the discharge line to verify the pump is not being run dry and that the discharge valves are not closed.
The check valve is required to prevent back-flow through the pump on shut-down. This flow could cause the impeller to unscrew from the shaft and should be avoided.
When fluid velocity in the pipe is high, for example, 3 m/s (10 ft/sec) or higher, a rapidly closing discharge valve can cause a damaging pressure surge. A dampening arrangement should be provided in the pi pin g.
FIGURE 4-1
GATE
VALVE
CHECK VALVE
CONCENTRIC
INCREASER
PUMP.
DISCHARGE
MOUNTING,

4.6.2 Suction piping

ESP pumps typic ally only have strainers attached to the suction flange of the pump casing. An option for an extension from the suc tion flang e is availab le and is called a tailpipe ( see sectio n 8 for cross-sectional drawing). A tailpipe is useful for applications where there is adequa te NPS H at th e l ow est s ump l ev el but the discharge pressure is critical and must be maintained at a maximum value compared to using a longer column and shaft.
Page 17 of 64
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12

4.6.3 Allowable piping loads

Discharge piping should be constructed to fit to the ESP discharge piping flange. The ESP design can accommodate large piping loads without affecting the operation of the pump, but the installation
FIGURE 4-2 ESP2 nozzle loading
should not impose unnecessary loads to the discharge flange. The allowable piping loads are shown in Figure 4.2.
Page 18 of 64
ESP2 USER INSTRUCTIONS ENGLISH PCN-(71569292) 4-12

4.6.4 Final pump rotation check

After connecting the piping, rotate the pump drive shaft clockwise (viewed from motor end) by hand several complete revolutions to be sure there is no binding and that all parts are free. If piping caused unit to be in a bind, correct piping to relieve strain on the pump.

4.6.5 Auxiliary piping

Check to see if any other connections need to be made to pump, such as injection water to stuffing box for seal or packing lubrication (when furnished) and make the required connections.
4.6.6 Mechanical seal and packing
Pumps supplied with vapor proof construction or pressurized design are furnished with an upper stuffing box (4100) equipped to take mechanical seals or packing (see vapor proof and pressurized design cross-sections in section 8). Installation instructions are in section 5.1.

4.7 Electrical connections

See section 5.4, Direction of rotation before connecting the motor to the electrical supply.

4.8 Level controls

Assemble float control equipment per Figure 4-3 below. Wire the float controls following the diagrams on the next several pages. The stops should be set in accordance with maximum and minimum liquid levels desired and required. Float rods are furnished in kits of a standard length. The rod might have to be cut off to fit the particular installation.
FIGURE 4-3
Electrical connections must be made by a qualified Electrician in accor dance w ith relevant local national and internat io na l regula tio ns .
It is important to be aware of the EUROPEAN DIRECTIVE on potentially explosive areas wher e compliance with IEC60079-14 is an additional requirement for making electrical connections.
It is import ant to be aw are of the EUR OPEAN DIRECTIVE on ele ct ro magne ti c c o mpat i bili ty w hen wiring up and installing equipment on site.
Attention mus t be pai d to ensure tha t the te chniques used during wiring/installation do not increase electromagnetic emissions or decrease the electromagnetic immunity of the equipment, wiring or any connected d evi ce s. I f i n any do ubt contact Flowserve for advice.
The motor must be wired up in accordance with the motor m anuf ac tur er' s instructions (normally supplied within the terminal box) including any temperature, earth leakage, current and other protective devices as appropriate. The identification nameplate should be checked to ensure the power supply is appropriate.
Some of the wiring diagrams are included on the following pages. If the wiring diagram needed is not included, contact control manufacturer for wiring instructions.
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