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).
Page 4 of 64
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.
Page 6 of 64
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
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.
(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.
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.
Page 9 of 64
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
Page 11 of 64
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 _________ __________
Page 15 of 64
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.
Page 19 of 64
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