Flowserve ESP3 User Manual

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USER INSTRUCTIONS

ESP3 Vertical Immersion Sump Pump

Mark 3 Standard, Lo-Flo and Recessed Impeller Hydraulics

PCN=26999943 – 08-11 (E) Original Instructions

Installation

Operation

Maintenance

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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 Specific machine performance........................7

1.9 Noise level.......................................................7

2 TRANSPORT AND STORAGE.............................9

2.1 Consignment receipt and unpacking...............9

2.2 Handling..........................................................9

2.3 Lifting...............................................................9

2.4 Storage............................................................9

2.5 Recycling and end of product life..................10

3 DESCRIPTION ....................................................10

3.1 Configurations...............................................10

3.2 Nomenclature................................................10

3.3 Design of major parts.................................... 11

3.4 Performance and operation limits.................. 11

4 INSTALLATION ................................................... 17

4.1 Location.........................................................18

4.2 Part assemblies.............................................18

4.3 Foundation .................................................... 18

4.4 Pump Mounting.............................................18

4.5 Mechanical seals and packing......................18

4.6 Driver Mounting.............................................19

4.7 Piping ............................................................ 19

4.8 Final free rotation check................................23

4.9 Auxiliary piping..............................................23

4.10 Electrical connections .................................23

4.11 Level controls ..............................................23

4.12 Protection systems......................................31

6 MAINTENANCE ...................................................37

6.1 Maintenance schedule...................................37

6.2 Spare parts.....................................................38

6.3 Recommended spares and consumable items

7 FAULTS; CAUSES AND REMEDIES..................51

8 PARTS LIST AND DRAWINGS...........................53

9 CERTIFICATION..................................................62

10 OTHER RELEVANT DOCUMENTATION AND

.......................................................................38

6.4 Tools required................................................38

6.5 Fastener torques............................................39

6.6 Setting impeller clearance and impeller

replacement ...................................................40

6.7 Disassembly ..................................................41

6.8 Examination of parts......................................43

6.9 Assembly of pump and seal...........................46

8.1 General arrangement drawing.......................62

MANUALS...........................................................62

10.1 Supplementary User Instructions ................62

10.2 Change notes ..............................................62

10.3 Additional sources of information ................62

Page

5 COMMISSIONING, STARTUP, OPERATION AND

SHUTDOWN ......................................................31

5.1 Pre-commissioning procedure......................31

5.2 Bearing Lubrication ....................................... 31

5.3 Impeller clearance.........................................34

5.4 Direction of rotation.......................................34

5.5 Guarding .......................................................34

5.6 Priming and auxiliary supplies ......................34

5.7 Starting the pump..........................................34

5.8 Running or operation ....................................35

5.9 Stopping and shutdown.................................36

5.10 Hydraulic, mechanical and electrical duty...36

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1 INTRODUCTION AND SAFETY

1.1 General

These instructions must always be kept

close to the product's operating location or directly with the product.

Flowserve 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 until all the conditions relating to safety noted in the instructions, have been met. Failure to follow and apply the present user instructions is considered to be misuse. Personal injury, damage, delay or failure caused by misuse is not covered by the Flowserve warranty.

1.2 CE marking and approvals

It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and, where applicable, Low Voltage Equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED) and Equipment for Potentially Explosive Atmospheres (ATEX).

Where applicable, the Directives and any additional Approvals, cover important safety aspects relating to machinery and equipment and the satisfactory provision

of technical documents and safety instructions. Where applicable this document incorporates information relevant to these Directives and Approvals. To confirm the Approvals applying and if the product is CE marked, check the serial number plate markings and the Certification. (See section 9, Certification.)

1.3 Disclaimer

Information in these User Instructions is believed to be complete and reliable. However, in spite of all of the efforts of Flowserve Corporation to provide comprehensive instructions, good engineering and safety practice should always be used.

Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorized Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by the Flowserve warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in their use.

1.4 Copyright

1.5 Duty conditions

This product has been selected to meet the specifications of your purchaser order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.

The product must not be operated beyond

the parameters specified for the application. If there is any doubt as to the suitability of the product for the application intended, contact Flowserve for advice, quoting the serial number.

If the conditions of service on your purchase order are going to be changed (for example liquid pumped,

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temperature or duty) it is requested that the user seeks the written agreement of Flowserve before start up.

1.6 Safety

1.6.1 Summary of safety markings

These User Instructions contain specific safety markings where non-observance of an instruction would cause hazards. The specific safety markings are:

This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life.

This symbol indicates safety instructions where non-compliance would affect personal safety and could result in loss of life.

This symbol indicates “hazardous and toxic fluid” safety instructions where non-compliance would affect personal safety and could result in loss of life.

This symbol indicates safety instructions where non-compliance will involve some risk to safe operation and personal safety and would damage the equipment or property.

This symbol indicates explosive atmosphere zone marking according to ATEX. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.

1.6.3 Safety action

This is a summary of conditions and actions to help prevent injury to personnel and damage to the environment and to equipment. For products used in potentially explosive atmospheres section 1.6.4 also applies.

NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER (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.

This symbol is used in safety instructions to remind not to rub non-metallic surfaces with a dry cloth; ensure the cloth is damp. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.

This sign is not a safety symbol but indicates

an important instruction in the assembly process.

1.6.2 Personnel qualification and training

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

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

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 IMPELLER Trapped lubricant or vapor could cause an explosion.

HOT (and cold) PARTS If hot or freezing components or auxiliary heating equipment can present a danger to operators and persons entering the immediate area, action must be taken to avoid accidental contact (such as shielding). If complete protection is not possible, the machine access must be limited to maintenance staff only with clear visual warnings and indicators to those entering the

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immediate area. Note: bearing housings must not be insulated and drive motors and bearings may be hot.

If the temperature is greater than 80 °C (176°F) or below -5 °C (23 °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 liquid is flammable and/or explosive, strict safety procedures must be applied.

Gland packing must not be used when pumping hazardous liquids.

PREVENT EXCESSIVE EXTERNAL PIPE LOAD Do not use pump as a support for piping. Do not mount expansion joints, unless allowed by Flowserve in writing, so that their force, due to internal pressure, acts on the pump flange.

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

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 WITH THE SUCTION VALVE CLOSED It should be fully opened when the pump is running.

NEVER OPERATE THE PUMP AT ZERO FLOW OR FOR EXTENDED PERIODS BELOW THE MINIMUM CONTINUOUS FLOW

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 drive element and starting the pump. Incorrect rotation of the pump for even a short period can unscrew the impeller, 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 sparks

• Prevent leakages

• Maintain the pump to avoid hazard

The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection. Both electrical and non-electrical equipment must meet the requirements of European Directive 94/9/EC.

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed.

Where Flowserve has supplied only the bare shaft pump, the Ex rating applies only to the pump. The party responsible for assembling the pump set shall select the coupling, driver, 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.

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Temperature

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

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

1.6.4.3 Avoiding excessive surface temperatures

ENSURE THE EQUIPMENT TEMPERATURE

CLASS IS SUITABLE FOR THE HAZARD ZONE

Pump liquid temperature

Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate. These are based 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 temperature depends on the temperature class and must not exceed the values in the table applicable below.

Maximum permitted liquid temperature for pumps

Maximum

class to

EN 13463-1

T6 T5 T4 T3 T2

T1 * The table only takes the ATEX temperature class into consideration. Pump design or material, as well as component design or material, may further limit the maximum working temperature of the liquid.

surface

temperature

permitted

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

Temperature limit of liquid

handled (* depending on

material and construction

variant – check which is lower)

Consult Flowserve Consult Flowserve

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

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

The 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 direction of rotation with the coupling element/pins fitted due to the risk of severe contact between rotating and stationary components.

Where there is any risk of the pump being run against a closed valve generating high liquid, casing and discharge pipe external surface temperatures, fit an external surface temperature protection device.

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

In dirty or dusty environments, make regular checks and remove dirt from areas around close clearances, bearing housings and motors.

1.6.4.4 Preventing the buildup of explosive mixtures

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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 liquid at all times during the pumps operation so that an explosive atmosphere is prevented. In addition, it is essential to make sure that seal chambers, auxiliary shaft seal systems and any heating and cooling systems are properly filled.

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

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

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

Pumps with mechanical seal: The pump must only be used to handle liquids for which it has been approved to have the correct corrosion resistance.

Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves, which could cause dangerous excessive pressures to occur if there is heat input to the liquid. This can occur if the pump is stationary or running.

Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump and auxiliary systems.

Where there is the potential hazard of a loss of a seal barrier fluid or external flush, the fluid must be monitored.

If leakage of liquid to atmosphere can result in a hazard, install a liquid detection device.

1.6.4.7 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 or adversely affect the ambient conditions. Where there is a risk from such tools or materials, maintenance must be conducted in a safe area.

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

1.7 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 EQUIPMENT 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 WITH 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: 603 604 610 612 621 623 624

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 PR OCEEDURES MAY RESULT IN PERSONAL INJURY AND/ OR EQUIPMENT DAMAGE

J218JZ250

KONTROLLE VORGESCHRIEBENER DREHRICHTUNG ! HIERZU KUPPLUNGSZWISCHENSTÜCK / KUPPLUNGSBOLZEN ENTFERNEN. ANDERENFALLS ERNSTHAFTE SC HÄDEN !

ZORG VOOR JUISTE ROTATIERICHTING VAN DRIJFAS WAARBIJ DE KOPPELELELMENTEN / PENNEN VERWIJDERD ZIJN: VERZUM KAN ERNSTIGE SCHADE TOT GEVOLG HABBEN.

1.8 Specific machine performance

For performance parameters see section 1.5, Duty conditions. Where performance data has been supplied separately to the purchaser these should be obtained and retained with these User Instructions if

required

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1.9 Noise level

Attention must be given to the exposure of personnel to the noise, and local legislation will define when guidance to personnel on noise limitation is required, and when noise exposure reduction is mandatory. This is typically 80 to 85 dBA.

The usual approach is to control the exposure time to the noise or to enclose the machine to reduce emitted sound. You may have already specified a limiting noise level when the equipment was ordered, however if no noise requirements were defined, then attention is drawn to the following table to give an indication of equipment noise level so that you can take the appropriate action in your plant.

Pump noise level is dependent on a number of operational factors, flow rate, pipe work design and acoustic characteristics of the building, and so the values given are subject to a 3 dBA tolerance and cannot be guaranteed. Similarly the motor noise assumed in the “pump and

and high efficiency motors when on load directly driving the pump. Note that a motor driven by an inverter may show an increased noise at some speeds. If a pump unit only has been purchased for fitting with your own driver then the “pump only” noise levels in the table should be combined with the level for the driver obtained from the supplier. Consult Flowserve or a noise specialist if assistance is required in combining the values.

It is recommended that where exposure approaches the prescribed limit, then site noise measurements should be made.

The values are in sound pressure level LpA at 1 m (3.3 ft) from the machine, for “free field conditions over a reflecting plane”. The values are representative of a non-submerged wet end.

For estimating sound power level LWA (re 1 pW) then add 14 dBA to the sound pressure value.

motor” noise is that typically expected from standard

Motor size and speed

kW (hp)

<0.55(<0.75) 72 72 64 65 62 64 62 64

0.75 (1) 72 72 64 66 62 64 62 64

1.1 (1.5) 74 74 66 67 64 64 62 63

1.5 (2) 74 74 66 71 64 64 62 63

2.2 (3) 75 76 68 72 65 66 63 64 3 (4) 75 76 70 73 65 66 63 64 4 (5) 75 76 71 73 65 66 63 64

5.5 (7.5) 76 77 72 75 66 67 64 65

7.5 (10) 76 77 72 75 66 67 64 65 11(15) 80 81 76 78 70 71 68 69

15 (20) 80 81 76 78 70 71 68 69

18.5 (25) 81 81 77 78 71 71 69 71 22 (30) 81 81 77 79 71 71 69 71 30 (40) 83 83 79 81 73 73 71 73 37 (50) 83 83 79 81 73 73 71 73 45 (60) 86 86 82 84 76 76 74 76 55 (75) 86 86 82 84 76 76 74 76

75 (100) 87 87 83 85 77 77 75 77 90 (120) 87 88 83 85 77 78 75 78

110 (150) 89 90 85 87 79 80 77 80 150 (200) 89 90 85 87 79 80 77 80 200 (270) 300 (400) 87 90 85 86

`1 The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are inappropriate. Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.

Pump

only

1 1 1 1

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

3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min

Pump and

motor

Pump

only

Pump and

motor

Pump

only

85 87 83 85

Pump and

motor

Pump

only

Pump and

motor

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2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be checked against the delivery/shipping documents for its completeness and that there has been no damage in transportation. Any shortage and/or damage must be reported immediately to Flowserve Pump Division and must be received 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 sidewalls of the box or equipment.

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

2.2 Handling

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

2.3 Lifting

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 or cast-in lifting lugs to lift pump, motor and mounting plate assemblies.

Care must be taken to lift components or assemblies above the center of gravity to prevent the unit from flipping.

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]. Or lift use optionally supplied lifting eyes [6820] installed on mounting plate [6130].

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. Turn the pump shaft at regular intervals to prevent brinelling of the bearings and the seal faces, if fitted, from sticking.

The pump may be stored as above for up to 6 months. Consult Flowserve for preservative actions when a longer storage period is needed.

2.4.1 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 un-mounted items are packaged in a

water proof plastic bag and secured to the pallet.

• Inner surfaces of the bearing housing, shaft (area

through bearing housing) and bearings are coated with Cortec VCI-329 rust inhibitor, or equal.

Bearing housings are not filled with oil

prior to shipment

• Regreasable bearings are packed with grease

• 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

2.4.2 Long term storage and packaging

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 This packaging will provide protection for up to twelve

months from humidity, salt laden air, dust etc.

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After unpacking, protection will be the responsibility of the user. If units are to be idle for extended periods after addition of lubricants, inhibitor oils and greases should be used. Every three months, the pump shaft should be rotated approximately 10 revolutions.

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 accordance with local 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 ESP3 vertical immersion sump pumps are separately coupled metallic construction single stage centrifugal pumps for wet pit applications. The ESP3 wetted parts are available in a wide range of materials to handle most fluids. Vapor-tight, vaporproof, and pressurized construction options are available. The hydraulics utilized are from Mark 3 chemical process pumps.

Figure 3-1: Nameplate mounted to housing

3.2 Nomenclature

The pump size will be engraved on the nameplate typically as below:

2 E 6 X 4 SP - 13 A /12.5 RV

• Frame size “2" indicates a medium size pump frame (in this example, a Group 2) 1 = Group 1 (small frame) 2 = Group 2 (medium frame) 3 = Group 3 (large frame)

• Power end E = ESP3 Pump

• “6” = nominal suction port size (in.)

• “4” = Nominal discharge port size (in.)

• Modifier for “specialty pumps”

SP = standard sump pump RSP = recessed impeller pump LFSP = Lo-Flo pump

• Nominal maximum impeller diameter. “13” = 13 in.

• Pump design variation

A = This pump has been redesigned from an earlier

version. The impeller and casing are no longer interchangeable with the earlier version.

H = This pump is designed for a higher flow capacity

than another pump with the same basic designation. (Examples: 4X3-10 and 4X3-10H; 6X4-10 and 6X4-10H; 10X8-16 and 10X8-16H.

HH = This pump is designed for a higher head than

another pump with the same basic designation. (Example: 4X3-13 and 4X3-13HH.)

• Actual impeller size “12.5” = 12 ½ in. diameter; 8.13 = 8 ⅛ in.;

10.75 = 10 ¾ in. (Previous annotation: 124 = 12 4/8 or 12 ½ in. diameter; 83 = 8 ⅜ in.)

• Impeller style RV = reverse vane impeller; OP = Open impeller

Serial No.

Equipment No.

Purchase Order

Material

Date DD/MMM/YY

Page 10

Model

Size

MDP

2E6X4 SP-13A/12.5 RV

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3.3 Design of major parts

3.3.1 Pump casing

As used by the Mark 3 Product Line. Depending upon the installation, the casing feet may have been removed. Axial bolting retains the casing to the cover and compresses the sealing gasket.

3.3.2 Impeller

Depending on the product, the impeller is either reverse vane or open. The impeller is threaded to the end of the shaft

3.3.3 Shaft/sleeve

Solid and sleeved shafts are available. The shaft is threaded on the impeller end and keyed on the drive end.

3.3.4 Pump bearings and lubrication

The external thrust bearing is a grease-lubricated duplex angular contact ball bearing. The radial load line bearings are sleeve plain bearings lubricated by product, external flush or grease.

3.3.5 Bearing housing

The external housing contains grease ports and is sealed with lip seals.

3.3.6 Cover plate

The cover plate has a spigot (rabbet) fit between the pump casing and adapter for optimum concentricity. The cover plate holds the throttle bushing at the back of the impeller.

3.3.7 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.

3.3.8 Driver

The standard driver is a NEMA C-Face vertical electric motor. The motor must be equipped with a drip-cap when installed outdoors.

3.3.9 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 section 1.5.

The following data is included as additional information to help with your installation. It is typical, and factors such as liquid being pumped, temperature, material of construction, and seal type may influence this data. If required, a definitive statement for your application can be obtained from Flowserve.

3.4.1 Alloy cross reference chart

Figure 3-3 is the Alloy cross-reference chart. The chart is used to material group number which can be used to establish the pressure-temperature rating as discussed below. Not all materials may be available

3.4.2 Pressure-temperature ratings

The pressure–temperature (P-T) ratings for ESP3 pumps are shown in figures 3-4 and 3-5. Determine the appropriate casing “Material Group No.” in Figure 3-3. Interpolation may be used to find the pressure rating for a specific temperature.

Example: The pressure temperature rating for a standard GP210” pump with Class 150 flanges and CF8M construction at an operating temperature of 149˚C is found as follows: a) The correct pressure-temperature chart is Figure

3-4.

b) From Figure 3-3, the correct material group for

CF8M is 2.2

c) From Figure 3-4, the pressure-temperature rating

is 14.8 bar.

The maximum discharge pressure must be less than or equal to the P-T rating. Discharge pressure may be approximated by adding the suction pressure and the differential head developed by the pump.

3.4.3 Suction pressure limits

Pump suction pressure is limited by the maximum pump length and the maximum sump pressure of 3.45 bar (50 psi).

3.4.4 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 ESP3 pump models with the exception of the Lo-Flo pump line; there is no MCF associated with this product line.

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Figure 3-2: Minimum continuous flow

Pump size

1E3x2SP-62 20% 10% 10% 2E3x2SP-82 20% 10% 10% 2E4x3SP-82 20% 10% 10% 2E3x2SP-10A 30% 10% 10% 2E4x3SP-10 30% 10% 10% 2E6x4SP-10 40% 10% 10% 2E6x4SP-10H n.a. 20% 10% 2E3x1.5SP-13 30% 10% 10% 2E3x2SP-13 40% 10% 10% 2E4x3SP-13 40% 20% 10% 2E4x3SP-13HH n.a. 50% 30% 2E6x4SP-13A 60% 40% 10% 3E8x6SP-14A n.a. 40% 15% 3E10x8SP-14 n.a. 40% 10% 3E6x4SP-16 n.a. 50% 10% 3E8x6SP-16 n.a. 50% 10% 3E10x8SP-16 n.a. 50% 10% All other sizes 10% 10% 10%

3500/2900

r/min

MCF % of BEP

1750/1450

r/min

1180/960

r/min

Figure 3-3: Alloy cross-reference chart

Flowserve

Material Code

E3020 Ductile iron DCI A395, Gr. 60-40-18 1.0 C3009 Carbon steel DS A216 Gr. WCB 1.1 C3062 304 D2 A744, Gr. CF8 2.1 C3069 304L D2L A744, Gr. CF3 2.1 C3063 316 D4 A744, Gr. CF8M 2.2 C3067 316L D4L A744, Gr. CF3M 2.2 C4029 Durcomet 5 DV None 2.2 C3107 Duplex Stainless CD4M A995, Gr. CD4MCuN 2.8 C4028 Alloy 20 D20 A744, Gr. CN7M 3.17 K3008 Nickel DNI A494, Gr. CZ100 3.2 K3007 K3005 K4007 K4008 D4036 Durco DC8 DC8 None H3004 Titanium Ti B367, Gr. C3 Ti H3005 Titanium-Pd TiP B367, Gr. C8A Ti H3007 Zirconium Zr B752, Gr. 702C Ti E3033 High chrome iron CR28 A532 class 3 Cr E4027 High chrome iron CR29 None Cr E4028 High chrome iron CR35 None Cr

 Duriron, Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation.  Hastelloy is a registered trademark of Haynes International, Inc.  Inconel and Monel are registered trademarks of International Nickel Co. Inc.

Generic

Designation

Monel400 Inconel600

HastelloyB HastelloyC

Durco Legacy

DMM A494, Gr. M35-1 3.4 DINC A494, Gr. CY40 3.5 DC2 A494, Gr. N7M 3.7 DC3 A494, Gr. CW6M 3.8

Codes

ASTM

Specifications

Material

Group No.

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700 325 266 269

277 313 342 342 144

Figure 3-4 Class 150 Flanges

Material Group No.

˚C

-73 19.0 19.0 19.7 15.9 9.7 15.9 15.2 20.0 20.0 20.0

-29 17.2 19.7 19.0 19.0 19.7 15.9 9.7 15.9 15.2 20.0 20.0 20.0

-18 17.2 19.7 19.0 19.0 19.7 15.9 9.7 15.9 15.2 20.0 20.0 20.0 12.6 38 17.2 19.7 19.0 19.0 19.7 15.9 9.7 15.9 15.2 20.0 20.0 20.0 12.6 93 16.2 17.9 15.9 16.2 17.9 13.8 9.7 13.8 13.8 17.9 17.9 17.9 12.6

149 14.8 15.9 14.1 14.8 15.9 12.4 9.7 13.1 12.4 15.9 15.9 15.9 12.6 171 14.4 15.0 13.7 14.3 15.0 11.9 9.7 13.0 12.1 15.0 15.0 15.0 12.6 204 13.8 13.8 13.1 13.4 13.8 11.0 9.7 12.8 11.7 13.8 13.8 13.8 260 11.7 11.7 11.7 11.7 11.7 10.3 9.7 11.7 11.0 11.7 11.7 11.7 316 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 343 8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.6 371 7.6 7.6 7.6 7.6 7.6 7.6 7.6 7.6

1.0 1.1 2.1 2.2 2.8 3.17 3.2 3.4 3.5 3.7 3.8 Ti Cr Temp bar

Material Group No.

˚F

-100 275 275 285 230 140 230 220 290 290 290

-20 250 285 275 275 285 230 140 230 220 290 290 290

100 250 285 275 275 285 230 140 230 220 290 290 290 183 200 235 260 230 235 260 200 140 200 200 260 260 260 183 300 215 230 205 215 230 180 140 190 180 230 230 230 183 340 209 218 199 207 218 172 140 188 176 218 218 218 183 400 200 200 190 195 200 160 140 185 170 200 200 200 500 170 170 170 170 170 150 140 170 160 170 170 170 600 140 140 140 140 140 140 140 140 140 140 140 140 650 125 125 125 125 125 125 125 125 125 700 110 110 110 110 110 110 110 110

1.0 1.1 2.1 2.2 2.8 3.17 3.2 3.4 3.5 3.7 3.8 Ti Cr Temp psi

0 250 285 275 275 285 230 140 230 220 290 290 290 183

Figure 3-5 Group2-13” Lo-Flo Pumps with Class 300 Flanges

Material Group No.

˚C

-73 31.0 31.0 31.0 24.1 17.4 24.1 27.6 31.0 31.0 31.0

-29 31.0 31.0 31.0 31.0 31.0 24.1 17.4 24.1 27.6 31.0 31.0 31.0

-18 31.0 31.0 31.0 31.0 31.0 24.1 17.4 24.1 27.6 31.0 31.0 31.0 38 31.0 31.0 31.0 31.0 31.0 24.1 17.4 24.1 27.6 31.0 31.0 31.0 93 29.1 28.3 25.9 26.7 29.8 20.9 17.4 21.3 26.1 31.0 31.0 27.5

149 27.4 27.5 23.3 24.1 27.5 18.7 17.4 19.9 24.4 30.2 30.2 24.0 204 25.5 26.6 21.3 22.2 25.4 16.9 17.4 19.3 22.7 29.2 29.2 20.5 260 24.0 25.2 19.7 20.7 23.8 15.7 17.4 19.1 22.1 27.5 27.5 17.0 316 22.5 23.1 18.7 19.4 23.0 14.5 17.4 19.1 21.9 25.0 25.0 13.4 343 21.8 22.4 18.5 19.2 19.1 21.8 24.4 24.4 11.7 371 22.4 18.3 18.5 19.1 21.6 23.6 23.6 9.9

1.0 1.1 2.1 2.2 2.8 3.17 3.2 3.4 3.5 3.7 3.8 Ti Temp bar

Material Group No.

˚F

-100 450 450 450 350 252 350 400 450 450 450

-20 450 450 450 450 450 350 252 350 400 450 450 450

100 450 450 450 450 450 350 252 350 400 450 450 450 200 422 410 375 388 432 303 252 309 379 450 450 399 300 397 398 338 350 399 271 252 289 354 438 438 348 400 369 386 309 322 369 245 252 280 330 423 423 297 500 348 365 285 300 345 228 252 277 320 399 399 246 600 327 334 272 281 333 210 252 277 318 363 363 195 650 316 325 269 278 277 316 354 354 170

1.0 1.1 2.1 2.2 2.8 3.17 3.2 3.4 3.5 3.7 3.8 Ti Temp psi

0 450 450 450 450 450 350 252 350 400 450 450 450

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3.4.5 Minimum suction pipe submergence

The minimum submergence is shown in Figure 3-6.

Figure 3-6

Minimum submergence (meters)

Flow (m3/hr.) Suct.

Size

1.5 0.30 0.55 1.07 2.65 2 0.30 0.58 1.40 2.74 3 0.30 0.79 1.52 2.38 4 0.30 0.55 1.07 2.13 6 0.43 .076 1.19 1.83 8 0.55 0.94 1.19 1.65

10 0.64 0.85 1.22 1.52

Minimum submergence (feet)

Size

1.5 1.0 1.8 3.5 8.7 2 1.0 1.9 4.6 9.0 3 1.0 2.6 5.0 7.8 4 1.0 1.8 3.5 7.0 6 1.4 2.5 3.9 6.0 8 1.8 3.1 3.9 5.4

10 2.1 2.8 4.0 5.0

6.8 11.4 20.5 45.5 79.5 136 273 341 500 568 727 1023 1250

Flow (USgpm) Suct.

30 50 90 200 350 600 1200 1500 2200 2500 3200 4500 5500

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3.4.6 ESP3 Bearing Materials

• CARBON - Carbon graphite, especially developed for sump pump applications, is chemically inert. The self-lubricating properties of graphite present in the carbon bearings enhance its dry running capabilities.

• BRONZE - SAE 660 Bronze (grooved when grease lubricated).

• CAST IRON - ASTM A48 Class 30 iron (grooved when grease lubricated).

• RUBBER - Resilient compounded rubber, fluted to allow abrasives to wash away.

• TEFLON - Fiberglass & molybdenum disulphide filled, with low cold flow, high tensile and elongation characteristics.

• ARHT - Chemical and wear resistant bearing material developed by Greene, Tween & Co. (grooved when grease lubricated).

All bearing materials are enclosed in an AISI-316 shell (ex. Bronze, Cast Iron & ARHT). Higher alloys are available (grooved when grease lubricated).

• VITON - Resilient Viton, fluted to allow handling of dirty corrosive liquids not able to be handled by carbon or rubber.

Figure 3-7: ESP3 Bearing selection

Bearing Material Max Temp Liquid Pumped Lubricant Shaft Material

Most clean acids,

Carbon

Bronze

Cast Iron

Rubber

Teflon

Viton

ARHT

177˚C 350˚F

82˚C

180˚F

82˚C

180˚F

71˚C

160˚F

177˚C 350˚F

Liquid Lube

82˚C

180˚F

Grease Lube

149˚C 300˚F

121˚C 250˚F

Liquid Lube

82˚C

180˚F

Grease Lube

general chemicals,

water, cleaning fluids,

gasoline, kerosene, jet

Water and compatible

liquids including alkaline

General abrasive liquids

compatible with rubber

compatible with carbon

Dirty acids, hot water

compatible with PEEK

chemicals compatible

fuels

liquids

caustics

Clean acids not

Dirty acids not

or rubber

and chemicals

Dirty acids and

with PEEK

External flush

Product Lube

External flush

Product Lube

Grease Lube

External flush

Product Lube

Grease Lube

External flush

Product Lube

External flush

Product Lube

Grease SS only

External flush

Product Lube

External flush

Product Lube

Grease SS only

Steel or SS Steel or SS

Steel only Steel only Steel only

Steel Steel Steel

SS only SS only

Page 15

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Figure 3-8: Engineering information

Pump Group Size GP1 – 1E GP2 – 2E GP3 – 3E Ball Bearing Size 1st Critical Speed @ 3550 span 1st Critical Speed @ 1750 span 1st Critical Speed @ 1180 span Std. Bearing Span @ 3550 rpm Std, Bearing Span @ 1750 rpm Standard Bearing Span @ 1180 rpm Shaft Diameter @ Sleeve Bearing Shaft Diameter @ Stuffing Box Shaft Diameter @ Coupling Keyway Size mm (in) Nominal Impeller Clearance Corrosion Allowance Minimum Pit Depth Maximum Pit Depth

28.58 mm (1.125 in.) 38.10 mm (1.500 in.) 53.98 mm (2.125 in.)

28.58 mm (1.125 in.) 38.10 mm (1.500 in.) 47.63 mm (1.875 in.)

25.4 mm (1.000 in.) 34.93 mm (1.375 in.) 41.28 mm (1.625 in.)

6.4 x 3.2 (1/4 x 1/8) 7.9 x 4.0 (5/16 x 5/32) 15.9 x 7.9 (5/8 x 5/16)

7308 7310 7313 6000 5555 n.a. 2344 2469 2833 2344 2469 2833

760 mm (30 in.) 915 mm (36 in.) n.a.

1220 mm (48 in.) 1220 mm (48 in.) 1520 mm (60 in.) 1220 mm (48 in.) 1220 mm (48 in.) 1520 mm (60 in.)

.46 mm (0.018 in.) .46 mm (0.018 in.) .64 mm (0.025 in.)

3.2 mm (0.125 in.) 3.2 mm (0.125 in.) 3.2 mm (0.125 in.) .61 m (2.0 ft) .61 m (2.0 ft) .91 m (3.0 ft)

6.10m (20.0 ft) 6.10 m (20.0 ft) 6.10 m (20.0 ft)

Page 16

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4 INSTALLATION

INSTALLATION AND START-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 and tighten the mounting plate bolts.

10. Install the motor on the pump, but do not connect the coupling or electric power.

11. Connect the wiring to the liquid level indicators and pump controls, as required.

12. Connect the discharge piping,

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 and pump as required using approved lubricants.

1 _________ __________ 2 _________ __________ 3 _________ __________

4 _________ __________

5 _________ __________

6 _________ __________ 7 _________ __________

8 _________ __________

9 _________ __________

10 _________ __________

11 _________ __________ 12 _________ __________

13 _________ __________

14 _________ __________ 15 _________ __________ 16 _________ __________ 17 _________ __________

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 install the coupling element and coupling guard. Then turn power ON, but do not start the driver.

Page 17

18 _________ __________

19_________ __________

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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 6.9.5.

• Vapor Proof and Pressurized design pumps

are furnished with an upper stuffing box [4110]. If the stuffing box doesn't already have the packing [4130] or seal [4200] installed, then they should be installed before the motor is mounted. See section 6.

• 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 pump mounting plate [6130] 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 pump or any of its components is capable of supporting the weights encountered. Make sure that all parts are properly rigged before attempting to lift.

c) Pump mounting plate and/or pit cover must

maintain level within 1/8in/ft. 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, drive wedges under the mounting plate/pit cover until pump levels out. The wedges must be able to support the weight of the entire pumping 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 Mechanical seals and packing

Pumps supplied with vapor proof construction or pressurized designs are furnished with an upper stuffing box [4110] equipped to take mechanical seals or packing (see vapor proof and pressurized design cross-sections in section 8). Gas seals are typically of a canister design, thus the stuffing box is omitted. The canister seals are mounted directly to the upper column [1341.1]. Installation instructions can be found in section 6.9.5

4.5.1 Mechanical seal

Mechanical seals [4200] are typically installed prior to shipment. Specific order requirements may specify that the seal be shipped separately, or none be supplied. It is the pump installer’s responsibility to determine if a seal was installed. Installation instruction can be found in section 6

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Failure to ensure that a seal is installed may result in serious leakage of vapor and of the pumped fluid.

Seal and seal support system must be installed and operational as specified by the seal manufacturer.

The stuffing box/seal chamber/gland may have ports that have been temporarily plugged at the factory to keep out foreign matter. It is the installer’s responsibility to determine if these plugs should be removed and external piping connected. Refer to the seal drawings and or the local Flowserve representative for the proper connections.

4.5.2 Packing

When the pump is intended to be equipped with shaft packing, it is NOT Flowserve standard practice to install the packing in the stuffing box prior to shipment. The packing is shipped with the pump. It is the pump installer’s responsibility to install the packing in the stuffing box. Installation instructions can be found in section 6.

Failure to ensure that the packing is installed may result in serious leakage of vapor and of the pumped fluid.

4.6 Driver Mounting

a) Before the motor is installed, be sure to

connect the motor half coupling hub and the pump half coupling hub 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 holes line 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 [1340.3] may be furnished. In this case the adapter must be installed before the motor can be mounted.

d) Motor to pump alignment is controlled by fits

within the adapter and cannot be adjusted.

e) Locate the coupling and source of electrical

power but DO NOT INSTALL THE COUPLING DRIVE ELEMENT AT THIS TIME.

f) 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

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

motor shaft by hand to make sure it is free to rotate when energized.

Never check driver rotation unless the

pump and driver shafts are disconnected and physically separated. Failure to follow this instruction can result in serious damage to the pump and driver if rotation is in the wrong direction.

g) 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 motor 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.

h) Disconnect and lockout the power supply to the

driver.

i) The coupling can now be fully installed and

join the driver and pump shafts together (see section 5.4.2).

j) Install the coupling guarding [7450.1-.2] (see

section 5.5).

4.7 Piping

Protective covers are fitted to both the suction and discharge flanges of the casing and must be removed prior to connecting the pump to any pipes.

4.7.1 General piping

If the pump flange(s) have tapped holes, select flange fasteners with thread engagement at least equal to the fastener diameter but that do not bottom out in the tapped holes before the joint is tight.

4.7.2 Suction piping

ESP pumps typically only have strainers attached to the suction flange of the pump casing. An option for an extension from the suction flange is available and is called a tailpipe (see section 8 for cross-sectional drawing). A tailpipe is useful for applications where there is adequate NPSH at the lowest sump level but the discharge pressure is critical and must be maintained at a maximum value compared to using a longer column and shaft. Pumps may air-bind if air is allowed to leak into the piping

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4.7.3 Discharge piping

Install a valve in the discharge line. This valve is required for regulating flow and/or to isolate the pump for inspection and maintenance.

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 piping.

All piping must be independently supported, accurately aligned and preferably connected to the pump by a short length of flexible piping. The pump should not have to support the weight of the pipe. It should be possible to install discharge bolts through mating flanges without pulling or prying either of the flanges. All piping must be tight.

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.

Figure 4-1

GATE

VALVE

CHECK VALVE

CONCENTRIC

INCREASER

PUMP.

DISCHARGE

MOUNTING,

PLATE

The check valve is required to prevent back-flow through the pump on shut-down. This flow can reverse rotation of the pump, potentially damaging the pump, motor and associated equipment.

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4.7.4 Allowable Nozzle Loads

Discharge piping should be constructed to fit to the ESP3 discharge piping flange. The ESP3 design can accommodate large piping loads without

installation should not impose unnecessary loads to the discharge flange. The allowable piping loads are shown in Figure 4.2.

affecting the operation of the pump, but the

Figure 4-2 ESP3 Nozzle Loading

≤+++++

maxmaxmaxmaxmaxmax

Force N Moments Nm Group Size Fx Fy Fz Mx My Mz

1E 1.5x1LFSP-4 760 1270 760 1E 1.5x1SP-62 760 1270 760 1E 3x1.5SP-62 930 1560 930 1E 3x2SP-62 1110 1870 1110 1E 1.5x1SP-8 760 1270 760 1E 1.5x1LFSP-8 760 1270 760 1E 3x1.5SP-82 930 1560 930 1E 3x2SP-82 1110 1870 1110 2E 3x1.5SP-82 930 1560 930 515 542 515 2E 3x2SP-82 1110 1870 1110 2E 4x3SP-82 1380 2310 1380 2E 2x1SP-10A 760 1270 760 2E 2x1LFSP-10 760 1270 760 2E 3x1.5SP-10 930 1560 930 2E 2x2RSP-10 1110 1870 1110 2E 3x2SP-10 1110 1870 1110 2E 3x3RSP-10 1380 2310 1380 2E 4x3SP-10 1380 2310 1380 2E 4x3SP-10H 1380 2310 1380 2E 6x4SP-10\H 1780 2980 1780 2E 3x1.5SP-13 930 1560 930 2E 3x1.5LFSP-13 930 1560 930 2E 3x2SP-13 1110 1870 1110 2E 4x3SP-13\HH 1380 2310 1380 2E 4x3RSP-13 1380 2310 1380 3E 6x4SP-13A 1780 2980 1780 976 1030 976 3E 6x4RSP-13 1780 2980 1780 3E 8x6SP-14A 2340 3890 2340 3E 10x8SP-14 2800 4670 2800 3E 6x4SP-16\A 1780 2980 1780 3E 8x6SP-16 2340 3890 2340 3E 10x8SP-16\H 2800 4670 2800

414 441 414 414 441 414 515 542 515 610 644 610 414 441 414 414 441 414 515 542 515 610 644 610

610 644 610 759 800 759 414 441 414 414 441 414 515 542 515 610 644 610 610 644 610 759 800 759 759 800 759 759 800 759 976 1030 976 515 542 515 515 542 515 610 644 610 759 800 759 759 800 759

976 1030 976 1281 1356 1281 1539 1620 1539

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Force lbf Moments lbf▪ft Group Size Fx Fy Fz Mx My Mz

1E 1.5x1LFSP-4 170 285 170 305 325 305 1E 1.5x1SP-62 170 285 170 305 325 305 1E 3x1.5SP-62 210 350 210 380 400 380 1E 3x2SP-62 250 420 250 450 475 450 1E 1.5x1SP-8 170 285 170 305 325 305 1E 1.5x1LFSP-8 170 285 170 305 325 305 1E 3x1.5SP-82 210 350 210 380 400 380 1E 3x2SP-82 250 420 250 450 475 450 2E 3x1.5SP-82 210 350 210 380 400 380 2E 3x2SP-82 250 420 250 450 475 450 2E 4x3SP-82 310 520 310 560 590 560 2E 2x1SP-10A 170 285 170 305 325 305 2E 2x1LFSP-10 170 285 170 305 325 305 2E 3x1.5SP-10 210 350 210 380 400 380 2E 2x2RSP-10 250 420 250 450 475 450 2E 3x2SP-10 250 420 250 450 475 450 2E 3x3RSP-10 310 520 310 560 590 560 2E 4x3SP-10 310 520 310 560 590 560 2E 4x3SP-10H 310 520 310 560 590 560 2E 6x4SP-10\H 400 670 400 720 760 720 2E 3x1.5SP-13 210 350 210 380 400 380 2E 3x1.5LFSP-13 210 350 210 380 400 380 2E 3x2SP-13 250 420 250 450 475 450 2E 4x3SP-13\HH 310 520 310 560 590 560 2E 4x3RSP-13 310 520 310 560 590 560 3E 6x4SP-13A 400 670 400 720 760 720 3E 6x4RSP-13 400 670 400 720 760 720 3E 8x6SP-14A 525 875 525 945 1000 945 3E 10x8SP-14 630 1050 630 1135 1195 1135 3E 6x4SP-16\A 400 670 400 720 760 720 3E 8x6SP-16 525 875 525 945 1000 945 3E 10x8SP-16\H 630 1050 630 1135 1195 1135

≤+++++

maxmaxmaxmaxmaxmax

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4.8 Final free 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.

4.9 Auxiliary piping

Check to see if any other connections need to be made to pump, such as fluid injection to stuffing box for seal or packing lubrication (when furnished) and make the required connections.

Check to see that connections are made to the lubrication fittings at pump manifold [3869] on mounting plate [6130]

4.10 Electrical connections

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

It is important to be aware of the EUROPEAN DIRECTIVE on potentially explosive areas where compliance with IEC60079-14 is an additional requirement for making electrical connections.

4.11 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

It is important to be aware of the EUROPEAN DIRECTIVE on electromagnetic compatibility when wiring up and installing equipment on site.

Attention must be paid to ensure that the techniques used during wiring/installation do not increase electromagnetic emissions or decrease the electromagnetic immunity of the equipment, wiring or any connected devices. If in any doubt contact Flowserve for advice.

The motor must be wired up in accordance with the motor manufacturer's instructions (normally supplied within the terminal box) including any temperature, earth leakage, current and other protective devices as appropriate. The identification nameplate should be checked to ensure the power supply is appropriate.

See section 5.4, Direction of rotation

before connecting the motor to the electrical supply.

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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SQUARE "D" CLASS 9036 TYPE GG, DR, DW, GR AND GW - FLOAT SWITCH (Typical Only)

SQUARE "D" CLASS 9038 TYPE AG, AW, AR - MECHANICAL ALTERNATOR (Typical Only)

OPTIONAL SQUARE "D" FORM N5 HIGH LEVEL ALARM FOR USE WITH CLASS 9038 MECHANICAL ALTERNATOR (Typical Only)

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MAGNATROL®

FOR SINGLE FUNCTION (A10) SWITCHES

(Typical Only)

MAGNATROL®

FOR DOUBLE FUNCTION (B10) SWITCHES

(Typical Only)

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MAGNATROL®

FOR DOUBLE FUNCTION (B10) SWITCHES

(Typical Only)

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MAGNATROL®

FOR DOUBLE FUNCTION (B10) SWITCHES

(Typical Only)

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MAGNATROL®

FOR TRIPLE FUNCTION (C10) SWITCHES

(Typical Only)

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MAGNATROL®

FOR TRIPLE FUNCTION (C10) SWITCHES

(Typical Only)

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APEX SWITCH

(Typical Only)

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4.12 Protection systems

The following protection systems are recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous liquid. If in doubt consult Flowserve.

If there is any possibility of the system allowing the pump to run against a closed valve or below minimum continuous safe flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsafe level.

If there are any circumstances in which the system can allow the pump to run dry, or start up empty, a power monitor should be fitted to stop the pump or prevent it from being started. This is particularly relevant if the pump is handling a flammable liquid.

If leakage of product from the pump or its associated sealing system can cause a hazard it is recommended that an appropriate leakage detection system is installed.

To prevent excessive surface temperatures at bearings it is recommended that temperature or vibration monitoring is carried out.

5 COMMISSIONING, STARTUP, OPERATION AND SHUTDOWN

These operations must be carried

out by fully qualified personnel.

5.1 Pre-commissioning procedure

5.1.1 Pre start-up checks

Prior to starting the pump it is essential that the following checks be made. These checks are all described in detail in the Maintenance section of this manual.

• Motor properly secured to the support head

• All fasteners tightened to the correct torque

• Coupling guard in place and not rubbing

• Rotation check, see section 5.4.

This is absolutely essential

• Impeller clearance setting

• Shaft seal properly installed

• Seal support system operational

• Bearing lubrication

• Pump instrumentation is operational

• Rotation of shaft by hand

As a final step in preparation for operation, it is important to rotate the shaft by hand to be certain that

all rotating parts move freely, and that there are no foreign objects in the pump casing.

5.2 Bearing Lubrication

Two types of bearings are used in the ESP3. Line shaft bearings are used to support pump shaft within the column. These plain bearings are lubricated by external flush, product lubrication or grease. Duplex angular contact bearings are used to support the coupling end of the shaft. These ball bearings support coupling loads and pump thrust. They are lubricated by bearing grease. See (5.2.3)

Operation of the unit without proper lubrication can result in bearing failures, pump seizures and pump failure.

5.2.1 Line Shaft Bearings

Check to see that no damage has occurred to any lubrication lines above the mounting plate [6130] during shipment or installation. For number of bearings, refer to Figure 5-6. Check to see that connections are made to lubrication fittings at pump manifold [3869] on mounting plate [6130].

5.2.1.1 External Flush Lubrication

a) Clean liquid from an external source must be

used when pumps are furnished with external flush lubrication connections. Liquid is typically supplied continuously during operation. Some bearings (such as carbon) can run without lubrication for short periods but lubrication is needed to dissipate heat and abrasives.

b) Check to see that connections are made to

lubrication fittings on pump manifold [3869] on mounting plate [6130] and that 1.9 LPM (0.5 gpm) of flushing fluid per bearing, 3.0 LPM (0.8 gpm) for Group 3, (See Figure 5-6) at 1.4 kg/cm2 to 5.6 kg/cm2 (20 PSIG to 80 PSIG) above sump pressure.

It is absolutely necessary that rubber bearings be wet at all times during operation.

5.2.1.2 Product Lubrication

When conditions warrant, the pump can be furnished with provisions for pumped product bearing lubrication. This is accomplished by means of a lubrication line from the discharge flange of the pump casing [1100] to the adapter bearing [3020.2], while the rest of the lines are run from the manifold [3869] on the pump mounting plate [6130]. In the case of a pumped-product lubricated pump with separators furnished, all lube lines will be run from the pump manifold [3869].

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a) Check to see that connections are made to

lubrication fittings at pump manifold [3869] on mounting plate [6130] and for the adapter [1340.1] bearing [3020.2].

b) Check that 1.9 LPM (0.5 gpm), 3.0 LPM (0.8

gpm) for Group 3, of pumped liquid per bearing (See Figure 5-5) at 1.4 kg/cm2 (20 PSIG) for standard product lubricated pumps or 1.8 kg/cm2 (25 PSIG) for product lubricated pumps with separators is available.

c) Changes in noise and vibration may indicate

insufficient lubrication.

5.2.1.3 Grease Lubrication

Pumps furnished with grease-lubricated shaft bearings [3020.1-.2] will leave the factory with lube lines [3840.1] and bearings [3020.1-.2] already packed with grease. The grease used will be of a water-resistant nature. Each bearing should be regreased prior to start-up through the grease fittings located in the manifold [3869] on the pump mounting plate [6130]. Grease must be insoluble in the liquid being pumped. The recommended grease to be used is Mobil Polyrex EP 2 or an equivalent. Bearing lubrication lines are filled with Polyrex EP 2 before the pump leaves the factory. Consult local lubricant suppliers for the type of grease most compatible with the liquid being pumped. The grease lubrication system is the same as the external flush system with the exception of the manifold [3869]. For grease lubrication the manifold contains grease fittings while the external flush manifold contains fluid line taps.

Grease lubricated line bearings require frequent lubrication. Grease lubricating systems may be utilized. Follow the manufacturer’s instruction for proper use. Lubrication intervals and amounts can be found in Figures 5-2 and 5-3.

Flowserve offers two lubrication systems that significantly extend the line shaft bearing lubrication intervals. Individual 2 oz. grease cups per line shaft bearing and a fully automated progressive lubrication system. Consult your Flowserve representative for additional information.

5.2.2 Thrust Bearing

The external duplex angular contact thrust bearing [3031] may be lubricated through the grease fitting [3853.2]. Lubrication type, intervals and amount may be found in Figures 5-1, 5-4 and 5-5. The bearing will leave the factory with grease already packed.

A greased for-life option may be selected. In this case, NYLOS® rings will be added to control grease movement and the grease port will be plugged. A

shielded bearing will not need to be re-greased, but will need to be replaced when it becomes excessively worn.

Grease for life bearings The replacement interval for these bearings is greatly affected by their operating temperature and speed.

5.2.3 Driver Bearings

Driver Bearings should be re-greased before starting the pump. Consult the manufacturer's directions for lubricating instructions.

Figure 5-1: Recommended Grease

Line Shaft

Bearings

Thrust

Bearing

Motor

Mobil Polyrex EP 2, ConocoPhilips Polytac® EP

or equivalent

Mobil Polyrex EP 2, ConocoPhilips Polytac® EP

(or compatible Polyurea with mineral oil)

Mobil Polyrex EM 2, ConocoPhilips Polytac® or

equivalent

Figure 5-2: Line bearing lubrication intervals*

Service Clean Contains abrasives Interval

*Interval depends upon process conditions

8 Hours 4-6 hours

Figure 5-3: Line bearing lubrication amounts

Location Amount

Intermediate Bearings [3020.1]

Bottom Bearing [3020.2]

18 grams (0.625 oz.)

21 cm

(1.3 in.3)

11 grams (0.375 oz.)

47 cm

(2.9 in.3)

Figure 5-4: Ball bearing lubrication intervals*

Bearing Temperature

Interval 6 months 3 months 1.5 months *Assuming good maintenance and operation practices, and no contamination. * Bearing Temperatures up to 16°C (30 °F) higher th an housing

Under 71 °C (160 °F)

71-80 °C (160-175 °F)

80-94 °C (175-200 °F)

Figure 5-5: Ball bearing lubrication amounts

Group Size Initial lube Re-lubrication

Group 1 50 g (1.8 oz.) 20 g (0.7 oz.) Group 2 75 g (2.7 oz.) 30 g (1.1 oz.)

Group 3 115 g (4.1 oz.) 45 g (1.6 oz.) *If new bearings are not lubricated, they should be packed prior to installation and the housing lubricated as described above.

Do not overfill the motor or pump thrust bearings with grease. If too much grease is pumped into the bearings, they can overheat. The maximum temperature that a rolling element bearing should be exposed to is 105 °C (220 °F).

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2'-6" 1 1 1 1

3'-0" 1 1 1 1 1 1

3'-6" 1 1 1 1 1 1 1 1

4'-0" 2 1 1 1 1 1 1 1

4'-6" 2 1 2 1 1 1 1 1

5’-0” 2 1 2 1 1 1 1 1

5'-6" 2 2 2 2 1 1 1 1

6’-0” 2 2 2 2 1 1 1 1

6'-6" 3 2 2 2 1 1 1 1

7’-0” 3 2 2 2 1 1 2 2

7'-6" 3 2 3 2 2 2 2 2

8'-0" 3 2 3 2 2 2 2 2

8'-6" 3 2 3 2 2 2 2 2

9'-0" 4 2 3 2 2 2 2 2

9'-6" 4 3 3 3 2 2 2 2

10'-0" 4 3 3 3 2 2 2 2

10'-6" 4 3 4 3 2 2 2 2

11'-0" 4 3 4 3 2 2 2 2

11'-6" 5 3 4 3 2 2 2 2

12’-0” 5 3 4 3 2 2 3 3

12'-6" 5 3 4 3 3 3 3 3

13'-0" 5 3 4 3 3 3 3 3

13'-6" 5 4 5 4 3 3 3 3

14'-0" 6 4 .5 4 3 3 3 3

14'-6" 6 4 5 4 3 3 3 3

15'-6" 6 4 5 4 3 3 3 3

16'-0" 6 4 5 4 3 3 3 3

16'-6" 7 4 6 4 3 3 3 3

17'-0" 7 4 6 4 3 3 4 4

17'-6" 7 5 6 5 4 4 4 4

18’-0” 7 5 6 5 4 4 4 4

18'-6" 7 5 6 5 4 4 4 4

19'-0" 8 5 6 5 4 4 4 4

19'-6" 8 5 7 5 4 4 4 4

20'-0" 8 5

5 4 4 4 4

Figure 5-6: Number of line shaft bearings for standard span

GROUP 1 GROUP 2 GROUP 3 GROUP 3

PIT EXCEPT 6X4X13 6X4X13

DEPTH

2’-0" 1 1 1 1

3600 RPM 1800 RPM 3600 RPM 1800 RPM 1800 RPM 1200 RPM 1800 RPM 1200 RPM

15'-0"

6 4 5 4 3 3 3 3

MAX. BRG.

SPAN

The above numbers include the bottom adapter bearing. For determining the required number of line

shaft bearing lubrication points, use the total quantity of line shaft bearings on this sheet. These spans meet the requirements of ANSI/API STANDARD 610, 11th Edition, Figure 37.

30"

48"

36"

48"

60"

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5.3 Impeller clearance

The impeller clearance was set at the factory. For reverse-vane and recessed impellers, the clearance is set to the cover while the open impeller clearance is set to the casing The impeller setting may be checked or change due to wear. See Section 6.6.

5.4 Direction of rotation

5.4.1 Rotation check

It is absolutely essential that the rotation of the motor be checked before installing the coupling drive element. Incorrect rotation of the pump, for even a short time, can dislodge and damage the impeller, casing, shaft and shaft seal. All ESP3 3 pumps turn clockwise as viewed from the motor end (top). A direction arrow is cast on the support head [3160].

5.4.2 Coupling installation

Turn off the driver power and lock it out so that the driver cannot be started during the coupling assembly. Non-spacer couplings are used. Mount coupling hubs/sheaves on pump and motor shafts prior to attaching motor to the support head.

The coupling should be installed as advised by the coupling manufacturer. Pumps are shipped without the sleeve installed. If the sleeve has been installed then it must be removed prior to checking rotation. Remove all protective material from the coupling and shaft before installing the coupling.

5.5 Guarding

Power must never be applied to the driver when

the coupling guard is not installed.

In member countries of the EU and EFTA, it is a legal requirement that fasteners for guards must remain captive in the guard to comply with the Machinery Directive 2006/42/EC. When releasing such guards, the fasteners must be unscrewed in an appropriate way to ensure that the fasteners remain captive.

Flowserve coupling guards are safety devices intended to protect workers from inherent dangers of the rotating pump shaft, motor shaft and coupling. It is intended to prevent entry of hands, fingers or other body parts into a point of hazard by reaching through, over, under or around the guard. No standard coupling guard provides complete protection from a disintegrating coupling.

Flowserve cannot guarantee their guards will completely contain an exploding coupling.

5.6 Priming and auxiliary supplies

A pump is said to be “primed” when the casing is submerged and completely filled with liquid. Open discharge valves a slight amount. This will allow any entrapped air to escape and will normally allow the pump to prime, if the liquid level is above the pump casing. When a condition exists where the suction pressure may drop below the pump’s capability, it is advisable to add a low-pressure control device to shut the pump down when the pressure drops below a predetermined minimum.

Depending upon the bearing lubrication and shaft seal option, some auxiliary supply lines may need to be brought to the pump. Check to see if any other connections need to be made to pump, such as fluid injection to stuffing box for seal or packing lubrication (when furnished) and make the required connections. Check to see that connections are made to the lubrication fittings at pump manifold [3869] on mounting plate [6130]

Seals must never be run without lubrication. Abrasive lubrication will greatly reduce seal life.

5.7 Starting the pump

To avoid pump damage or injury to operating

personnel during start-up and operation:

• DO NOT operate the pump outside of design

parameters.

• DO NOT run with a closed discharge for more than

one minute.

• DO NOT operate with safety devices (i.e. coupling

guard) removed.

• DO NOT run the pump dry. a) Ensure the pump is primed. (See section 5.6.)

The sump liquid level must cover the casing and adapter. Minimum submergence number can be

found in Figure 3-6. b) All flush lines must be started and regulated. c) Start the driver (typically, the electric motor). d) Slowly open the discharge valve until the desired

flow is reached, keeping in mind the minimum

continuous flow listed in Figure 3-2. e) Check all joints and mechanical seal (if

furnished) for leakage.

f) If packing is furnished, adjust the packing gland

and flush flow. g) Check for excessive vibration. h) Monitor bearing temperature until it stabilizes.

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It is important that the discharge valve be opened within a short interval after starting the driver. Failure to do this could cause a dangerous buildup of heat, and possibly an explosion.

5.8 Running or operation

5.8.1 Minimum continuous flow

Minimum continuous stable flow is the lowest flow at which the pump can operate and still meet the bearing life, shaft deflection and bearing housing vibration limits documented in the latest version of ASME B73.1M. Pumps may be operated at lower flows, but it must be recognized that the pump may exceed one or more of these limits. For example, vibration may exceed the limit set by the ASME standard. The size of the pump, the energy absorbed, and the liquid pumped are some of the considerations in determining the minimum continuous flow (MCF).

The minimum continuous flow (capacity) is established as a percentage of the best efficiency point (BEP). (See section 3.4.4.)

5.8.2 Minimum thermal flow

All ESP3 pumps also have a minimum thermal flow. This is defined as the minimum flow that will not cause an excessive temperature rise. Minimum thermal flow is application dependent.

Do not operate the pump below minimum thermal flow, as this could cause an excessive temperature rise. Contact a Flowserve sales engineer for determination of minimum thermal flow.

Avoid running a centrifugal pump at drastically reduced capacities or with discharge valve closed for extended periods of time. This can cause severe temperature rise and the liquid in the pump may reach its boiling point. If this occurs, the bearings and any equipment flushed with process fluid will be exposed to vapor, with no lubrication, and may score or seize to the stationary parts.

Thermostats may be used to safeguard against overheating by shutting down the pump at a predetermined temperature.

Safeguards should also be taken against possible operation with a closed discharge valve, such as installing a bypass back to the suction source. The size of the bypass line and the required bypass flow rate is a function of the input horsepower and the allowable temperature rise.

5.8.3 Reduced head

Note that when discharge head drops, the pump’s flow rate usually increases rapidly. Check motor for temperature rise as this may cause overload. If overloading occurs, throttle the discharge.

5.8.4 Surging condition

A rapidly closing discharge valve can cause a damaging pressure surge. A dampening arrangement should be provided in the piping.

5.8.5 Operation in sub-freezing conditions

When using the pump in sub-freezing conditions where the pump is periodically idle, the sump should be properly drained or protected with thermal devices which will keep the liquid in the sump from freezing. External bearing and seal lubrication lines must be protected with thermal devices. High chrome iron pumps are not recommended for applications below 18 °C (0 °F).

5.8.6 Operating Checks

Costly shutdowns will be avoided by making routine checks on pump operation. a) Check to see if liquid is being discharged. A

discharge pressure gauge is an easy way to check whether or not the liquid is being pumped. If, at any time, the gauge should drop near or to zero, or register an abnormally high pressure, shut down the pump immediately.

b) Observe pump for any abnormal noise or

vibration. Especially check for any CHANGE in pump noise or vibration.

c) Bearing lubricating liquid, and sealing and

cooling liquid flows, should be checked frequently.

5.8.7 Normal vibration levels, alarm and trip

Alarm and trip values for installed pumps should be based on the actual measurements (N) taken on site on the motors of vertical pumps in fully commissioned as new condition. The example (N) value is given for the preferred operating flow region (typically this may extend to 70 to 120% of the pump best efficiency point); outside the preferred flow region the actual vibration experienced may be multiplied by up to two.

These standard values can vary with the rotational speed and the power absorbed by the pump. For any special case, contact your nearest Flowserve office.

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

Vibration velocity – unfiltered

Normal N Alarm N x 1.25 Shutdown N x 2.0

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

5.6 (0.22) 8.0 (0.31)

7.0 (0.28) 9.9 (0.39)

11.3 (0.45) 16.0 (0.63)

mm/s (in./s) Peak value

5.9 Stopping and shutdown

5.9.1 Shutdown considerations

When the pump is being shutdown, the procedure should be the reverse of the start-up procedure. First, slowly close the discharge valve and shut down the driver.

The pump should be brought to zero speed rapidly, especially on pumps equipped with product-lubricated bearings.

Pumps driven by electric motors do not require any special shutdown procedure. If turbine drive is used, the operator must manually trip the over speed trip to obtain rapid shutdown

5.10 Hydraulic, mechanical and electrical duty

5.10.1 Net positive suction head (NPSH)

Net positive suction head - available (NPSHA) is the measure of the energy in a liquid above the vapor pressure. It is used to determine the likelihood that a fluid will vaporize in the pump. It is critical because a centrifugal pump is designed to pump a liquid, not a vapor. Vaporization in a pump will result in damage to the pump, deterioration of the Total differential head (TDH), and possibly a complete stopping of pumping.

Net positive suction head - required (NPSHR) is the decrease of fluid energy between the inlet of the pump, and the point of lowest pressure in the pump. This decrease occurs because of friction losses and fluid accelerations in the inlet region of the pump and particularly accelerations as the fluid enters the impeller vanes. The value for NPSHR for the specific pump purchased is given in the pump data sheet, and on the pump performance curve. For a pump to operate properly the NPSHA must be greater than the NPSHR. Good practice dictates that this margin should be at least 1.5 m (5 ft) or 20%, whichever is greater.

Ensuring that NPSHA is larger than NPSHR by the suggested margin will greatly enhance pump performance and reliability. It will also reduce

the likelihood of cavitation, which can severely damage the pump.

5.10.2 Specific gravity (SG)

Pump capacity and total head in meters (feet) of liquid do not change with SG; however pressure displayed on a pressure gauge is directly proportional to SG. Power absorbed is also directly proportional to SG. It is therefore important to check that any change in SG will not overload the pump driver or over pressurize the pump.

5.10.3 Viscosity

For a given flow rate the total head reduces with increased viscosity and increases with reduced viscosity. Also for a given flow rate the power absorbed increases with the increased viscosity, and reduces with reduced viscosity. Product lubricated bearings require a minimum of viscosity of 0.4 cP; >0.6 cP is recommended for extended bearing life. Failure to maintain sufficient viscosity will result in a damaged shaft and bearings, and possibly a complete stopping of pumping. It is important that checks are made with your nearest Flowserve office if changes in viscosity are planned.

5.10.4 Pump speed

Changing the pump speed affects flow, total head, power absorbed, NPSHR, noise and vibration levels. Flow varies in direct proportion to pump speed. Head varies as speed ratio squared. Power varies as speed ratio cubed. If increasing speed it is important to ensure the maximum pump working pressure is not exceeded, the driver is not overloaded, NPSHA > NPSHR and that noise and vibration are within local requirements and regulations.

The number of line shaft bearings (bearing spans) has been selected based upon the motor speed. These spans impact the stability of the shaft and determine it natural frequencies. The number of line shaft bearings can be found in Figure 5-6. The bearing spans and critical speeds can be found in Figure 3-8. The pump should not be operated above it designed operating speed as this may result in severe and damaging vibration.

The minimum speed for pump with product lube bearings is dictated by the ability of the discharge pressure to deliver lube to the bearings. Pumps with product lube line shaft bearings should not be operated at speeds that deliver less than 20 PSIG at the mounting plate or 25 PSIG if equipped with separator(s).

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5.10.5 Minimum submergence

Each ESP3 pump has a minimum submergence depending on the design conditions of that pump. See Figure 3-6 to determine the minimum submergence based upon pump flow and suction size. All minimum submergence values are taken from the bottom of the strainer.

If a tailpipe [1428] is used, the sump (pit) liquid level must engulf the casing and adapter completely during start-up.

6 MAINTENANCE

It is the plant operator's responsibility to ensure that all maintenance, inspection and assembly work is carried out by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail. (See also section 1.6.)

Any work on the machine must be performed when it is at a standstill. It is imperative that the procedure for shutting down the machine is followed, as described in section 5.9.

On completion of work all guards and safety devices must be re-installed and made operative again. Before restarting the machine, the relevant instructions listed in section 5, Commissioning, start up, operation and shut down must be observed.

Oil and grease leaks may make the ground slippery. Machine maintenance must always begin and finish by cleaning the ground and the exterior of the machine.

If platforms, stairs and guardrails are required for maintenance, they must be placed for easy access to areas where maintenance and inspection are to be carried out. The positioning of these accessories must not limit access or hinder the lifting of the part to be serviced.

When air or compressed inert gas is used in the maintenance process, the operator and anyone in the vicinity must be careful and have the appropriate protection.

Do not spray air or compressed inert gas on skin. Do not direct an air or gas jet towards other people. Never use air or compressed inert gas to clean

clothes.

Before working on the pump, take measures to prevent the pump from being accidentally started. Place a warning sign on the starting device: "Machine under repair: do not start."

With electric drive equipment, lock the main switch open and withdraw any fuses. Put a warning sign on the fuse box or main switch: "Machine under repair: do not connect."

Never clean equipment with flammable solvents or carbon tetrachloride. Protect yourself against toxic fumes when using cleaning agents. Refer to the parts list shown in section 8 for item number references used throughout this section.

6.1 Maintenance schedule

It is recommended that a maintenance plan and schedule be implemented, in accordance with these User Instructions, to include the following: a) Any auxiliary systems installed must be monitored,

if necessary, to ensure they function correctly.

b) Gland packing must be adjusted correctly to give

visible leakage and concentric alignment of the gland follower to prevent excessive temperature of the packing or follower.

c) Check for any leaks from gaskets and seals. The

correct functioning of the shaft seal must be checked regularly.

d) Check bearing lubricant level, and the remaining

hours before a lubricant change is required.

e) Check that the duty condition is in the safe

operating range for the pump.

f) Check vibration, noise level and surface

temperature at the bearings to confirm satisfactory operation.

g) Check dirt and dust is removed from areas

around close clearances, bearing housings and motors.

6.1.1 Preventive maintenance

The following sections of this manual give instructions on how to perform a complete maintenance overhaul. However, it is also important to periodically repeat the Pre start-up checks listed in section 5.1. These checks will help extend pump life as well as the length of time between major overhauls.

6.1.2 Need for maintenance records

A procedure for keeping accurate maintenance records is a critical part of any program to improve pump reliability. There are many variables that can contribute to pump failures. Often long term and repetitive problems can only be solved by analyzing these variables through pump maintenance records.

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6.1.3 Cleanliness

One of the major causes of pump failure is the presence of contaminants in the bearing housing. This contamination can be in the form of moisture, dust, dirt and other solid particles such as metal chips. Contamination can also be harmful to the mechanical seal (especially the seal faces) as well as other parts of the pump. For example, dirt in the impeller threads could cause the impeller to not be seated properly against the shaft. This, in turn, could cause a series of other problems. For these reasons, it is very important that proper cleanliness be maintained. Some guidelines are listed below.

• After draining the oil from the bearing housing, periodically send it out for analysis. If it is contaminated, determine the cause and correct.

• The work area should be clean and free from dust, dirt, oil, grease etc.

• Hands and gloves should be clean.

• Only clean towels, rags and tools should be

used.

6.2 Spare parts

The decision on what spare parts to stock varies greatly depending on many factors such as the criticality of the application, the time required to buy and receive new spares, the erosive/corrosive nature of the application, and the cost of the spare part. Section 8 identifies all of the components that make up each pump addressed in this manual.

Prior to resizing impellers in high chrome iron and nickel, please consult your local Flowserve sales representative.

6.2.1 Ordering of spare parts

Flowserve keeps records of all pumps that have been supplied. Spare parts can be ordered from your local Flowserve sales engineer or from a Flowserve distributor or representative. When ordering spare parts the following information should be supplied:

1) Pump serial number

2) Pump size and type

3) Part name – see section 8

4) Part item number – see section 8

5) Material of construction (alloy)

6) Number of parts required The pump size and serial number can be found on the nameplate located on the support head. See figure 3-1.

6.3 Recommended spares and consumable items

Figure 6-2 shows the parts which are included in each of the following three classes of recommended spares: CLASS 1 - MINIMUM - Suggested for Domestic Service when pump is handling clean non-corrosive liquids and where interruptions in continuity of service are not objectionable. CLASS 2 - AVERAGE - Suggested for Domestic Service when pump is handling abrasive or corrosive liquids and where some interruptions in continuity of service are not objectionable. CLASS 3 - MAXIMUM - Suggested for Export Marine or Domestic Service where interruptions in service are objectionable.

Our Sales Representative in your area will gladly review the class of spares best suited to meet your requirements. When ordering recommended spares, please provide information specified in section in

6.2.1.

6.4 Tools required

A typical range of tools that will be required to maintain these pumps is listed below.

Standard hand tools SAE

• Hand wrenches

• Socket wrenches

• Allen wrenches

• Soft mallet

• Screwdrivers

Specialized equipment

• Bearing pullers

• Bearing induction heaters

• Dial indicators

• Snap ring pliers

• Spanner wrench

• Flowserve specialty tools (see below)

To simplify maintenance, it is recommended that specialty tools be purchased from Flowserve. Nose cones are available to ease assembly. These cones help guide assembly, protect threads and protect line shaft bearings. These tools can be ordered from your local Flowserve sales engineer or from a Flowserve distributor or representative.

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Figure 6-1: Recommended spare parts

(Reference Figure 8-11)

Part Number Description

Spare Parts Class

1 2 3 2100 Pump shaft (see note 2) 1 2200 Impeller 1 2500 Throttle Bushing for cover 1 1

3020.1 Bearing -- intermediate Note1 Note1

3020.2 Bearing -- adapter (bottom) 1 1 3031 Thrust bearing 1 1 3110 Bearing body -- thrust bearing 1 1 3250 Bearing holder Note1 Note1 3400 Adjusting sleeve 1

4120.1 Gland 1 1 4130 Packing (optional) Note1 Note1 Note1 4134 Seal cage -- packed box 1 1 4200 Mechanical seal (optional) 1 1 1

4310.1 Klozure lip seal -- bearing body 1 1 1

4310.2 Klozure lip seal -- upper column 1 1 1

4590.1 Gasket -- casing 1 1 1

4590.2 Gasket -- Impeller 1 1 1

4590.3 Gasket -- discharge pipe to casing flange 1 1 1

4590.4 Gasket -- stuffing box to upper column 1 1 1

4590.5 Gasket -- mechanical seal (optional) 1 1 1

4590.6 Gasket -- column to mounting plate 1 1 1

4590.7 Gasket -- manifold to mounting plate 1 1 6531 Strainer 1

6700.2 Pump key 1 7200 Coupling 1 8000 Motor complete (see note 3) 1

Note 1: Check record card for quantity required. Note 2: Check record card for length required. Note 3: When ordering motor parts, give motor serial number and model number as read from the motor nameplate. Also furnish pump serial number.

6.5 Fastener torques

Figure 6-2: Recommended bolt torques for lubricated or PTFE-coated fasteners

Item Description Group 1 Group 2 Group 3

[6570.2-.3] Column/column/adaptor cap screws and nuts ⅝ in. – 122 Nm (90 ft-lb) ⅝ in. – 122 Nm (90 ft-lb) ¾ in. – 210 Nm (155 ft-lb)

[6570.5] Discharge elbow/casing ½ in. – 61 Nm (45 ft-lb) ½ in. – 61 Nm (45 ft-lb) ⅝ in. – 122 Nm (90 ft-lb)

⅝ in. – 122 Nm (90 ft-lb) ⅝ in. – 122 Nm (90 ft-lb) ¾ in. – 210 Nm (155 ft-lb) [6570.7] Manifold/mounting plate cap screws ½ in. – 61 Nm (45 ft-lb) ½ in. – 61 Nm (45 ft-lb) ½ in. – 61 Nm (45 ft-lb) [6580.9] Bearing Body/column cap screws ⅜ in. – 24 Nm (18 ft-lb) ½ in. – 50 Nm (37 ft-lb) ½ in. – 50 Nm (37 ft-lb)

[6570.16] Cap screw cover/adapter (token bolts) ⅜ in. – 27 Nm (20 ft-lb) ⅜ in. – 27 Nm (20 ft-lb) ⅜ in. – 27 Nm (20 ft-lb)

½ in. – 54 Nm (40 ft-lb) [6572.2] Gland packed box studs and nuts ⅜ in. – As required ½ in. – As required ½ in. – As required [6572.3] Gland seal chamber studs and nuts ⅜ in. – 19 Nm (14 ft-lb) ½ in. – 41 Nm (30 ft-lb) ½ in. – 41 Nm (30 ft-lb) [6579.*] Socket Head Cap screws – All locations ½ in. – 54 Nm (40 ft-lb) ½ in. – 54 Nm (40 ft-lb) ½ in. – 54 Nm (40 ft-lb)

Notes:

1. For non-lubricated/coated threads, add 25% to the values given above.

2. Gasket joint torque values are for unfilled PTFE gaskets. Other gasket materials may require additional torque to seal. Exceeding metal joint torque values is not recommended.

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6.6 Setting impeller clearance and impeller replacement

A new impeller gasket [4590.2] must be installed whenever the impeller has been removed from the shaft. Impeller balancing instruction may be found in section 6.8.

Do not adjust the impeller clearance with the seal set. Doing so may result in seal leakage and/or damage.

The impeller could have sharp edges, which could cause an injury. It is very important to wear heavy gloves when handling the impeller.

It is recommended that two people install a Group 3 impeller. The weight of a Group 3 impeller greatly increases the chance of thread damage and subsequent lock-up concerns.

Do not attempt to tighten or loosen the impeller on the shaft by hitting the impeller with a hammer or any other object or by inserting a pry bar between the impeller vanes. Serious damage to the impeller may result from such actions.

Care should be taken in the handling of high chrome iron impellers.

6.6.1 Impeller installation The impeller is threaded to the shaft in a clockwise direction (right hand threads). Apply a coat of grease or anti-seize to the threads to allow for ease of disassembly in the future. Install a new impeller gasket [4590.2].

Using a strap wrench to hold the drive coupling, screw impeller [2200] onto the end of the pump shaft [2100] clockwise until snugly fit. A second strap wrench may be utilized to fully tighten the impeller and compress the impeller gasket [4590.2]. The gasket must be fully compressed to ensure an accurate and stable impeller setting.

If available, an impeller wrench may be utilized to tighten the impeller. Using the shaft key [6700.2], mount the impeller wrench to the end of the shaft. The impeller wrench is placed on the shaft at the coupling end with a key. With the impeller wrench in place, grasp the impeller in both hands (wear heavy gloves] and, with the impeller wrench handle to the

left (viewed from the impeller end of the shaft) spin the impeller forcefully in a clockwise direction to impact the impeller wrench handle on the work surface to the right.

6.6.2 Impeller Removal

Remove the impeller [2200] by unscrewing it counterclockwise (looking in at the vanes).

Do not apply heat to the impeller. If liquid is

entrapped in the hub, an explosion could occur.

While holding the drive coupling with a strap wrench, unscrew the impeller. Do not attempt to use a crowbar as a lever to unscrew the impeller as damage to the vanes may result. Use a strap wrench or a piece of wood as a mallet. Discard the impeller gasket [4590.2]

If available, an impeller wrench may be utilized to loosen the impeller. Using the shaft key [6700.2], mount the impeller wrench to the end of the shaft. With the wrench handle pointing to the left when viewed from the impeller end, grasp the impeller [2200] firmly with both hands (wear heavy gloves). By turning the impeller in the clockwise direction move the wrench handle to the 11 o’clock position and then spin the impeller quickly in a counterclockwise direction so that the wrench makes a sudden impact with a hard surface on the bench. After several sharp raps, the impeller should be free. Unscrew the impeller and remove from the shaft. Discard the impeller gasket [4590.2].

6.6.3 Impeller Setting

Several types of impellers are available for the ESP3 product. Reverse vane and Recessed impellers are set off the rear cover. Open impellers and Lo-Flo impellers are set off the casing. Impeller setting is performed by adjusting the impeller to the correct surface as described above and then adjusting it to the correct gap. For services above 82 °C (180 °F) add another two combinations of shaft keyway/sleeve slots to the values listed.

6.6.3.1 Reverse vane and Recessed impeller setting

a) Rotate the shaft [2100] so that the impeller

adjustment key [6700.3] is toward you.

b) Remove the retaining ring [2530.2] and key

[6700.3] from the adjusting sleeve [3400].

c) Holding the shaft [2100] steady, turn the

adjusting sleeve [3400] clockwise until the impeller [2200] is resting against the running face of the cover [1220].

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d) Back the impeller [2200] off the cover [1220] by

rotating the adjusting sleeve [3400] counterclockwise so that the next slot lines up with one of the shaft keyways:

e) For GP1 and 2 Pumps, continue to rotate the

sleeve [3400] in the same direction for an additional four or five combinations of shaft keyway/sleeve slots (22.5 degrees each - the keyway that lines up will alternate as the sleeve [3400] is turned). For GP3 Pumps continue to rotate the sleeve [3400] in the same direction for another five or six combinations of shaft keyway/sleeve slots (22.5 degrees each - the keyway that lines up will alternate as the sleeve [3400] is turned)

f) Install the impeller adjustment key [6700.3) and

retaining ring [2530.2] back into position.

g) Check for freedom of shaft [2100] rotation by

turning by hand.

As the reverse vane and Recessed Impellers are set from the read cover, these settings can be made in the shop. If setting is being performed in the shop, less casing, it is advisable to leave out the impeller gasket [4590.2] during impeller setting. This will ensure that the impeller is fully seated and will not tighten further in operation. The impeller gasket must be installed before the casing is installed.

6.6.3.2 Open and Lo-Flo impeller setting

a) Rotate the shaft [2100] so that the impeller

adjustment key [6700.3] is toward you.

b) Remove the retaining ring [2530.2] and key

[6700.3] from the adjusting sleeve [3400].

c) Holding the shaft [2100] steady, turn the

adjusting sleeve [3400] counterclockwise until the impeller [2200] is resting against the running face of the casing [1100].

d) Back the impeller [2200] off the casing [1100] by

rotating the adjusting sleeve [3400] clockwise so that the next slot lines up with one of the shaft keyways:

e) For GP1 and 2 Pumps, continue to rotate the

f) Install the impeller adjustment key [6700.3] and

retaining ring [2530.2] back into position.

g) Check for freedom of shaft [2100] rotation by

turning by hand.

6.7 Disassembly

Use extreme care in removing and dismantling pump. Refer to pump assembly drawings for part nomenclature (see Section 8).

Lock out power to driver to prevent personal

injury.

If Flowserve ESP3 pumps contain dangerous chemicals, it is important to follow plant safety guidelines to avoid personal injury or death.

6.7.1 Removing pump from pit

a) Close control valve in discharge line. b) Lock out power supply to driver. c) Disconnect all electrical connections. d) Close all valves on auxiliary equipment and

piping then disconnect all auxiliary piping. e) Disconnect discharge piping from pump. f) Remove coupling guard [7450.1-.2] and coupling

halves [7200]. g) Disconnect driver [8000] and remove. h) Unbolt pump mounting plate [6130] and lift pump

(see Sections 2.3 and 4.4) from pit. Let the

pump drain thoroughly before removing pump

completely. Remove casing drain [6515.1], if

supplied. i) Remove liquid level controls (if any). j) Lift the pump (see Sections 2.3 and 4.4) out of

the pit and lay pump horizontally on supports.

For units that are welded, the welded sections should not be disassembled unless the parts need to be replaced.

6.7.2 Pump disassembly

a) Pump discharge pipe removal

• Discharge pipes four inches and less:

Unscrew the flange [1245.2], locknut [3400], and loosen the lower locknut. Then the upper discharge pipe [1360] can be unscrewed. Discharge pipes greater than four inches: Unscrew the flange [1245.2]. These pumps are furnished with the discharge pipe bolted to the mounting plate [6130] by a flange [1245.3] and four screws [6570.11]. Remove the screws holding the flange to the mounting plate [6130].

• The discharge pipe [1360] can then be removed

by unbolting the elbow [1371] from the discharge of the casing [1100) and pulling the discharge pipe out from the underside of the mounting plate [6130].

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b) Remove bearing lubrication lines [3840.1]. c) Unbolt and remove the pump casing [1100].

The cove plate [1220] may only be held in place by the casing and could fall when the casing is removed. If applicable, remove the two cap screws [6570.16] which attach the rear cover [1220] to the adapter. Carefully remove this part. The strainer [6531] does not need to be removed from the casing unless it is to be cleaned or replaced.

d) Remove the impeller [2200] by unscrewing it

counterclockwise. See section 6.6.2 for instructions.

Do not apply heat to the impeller. If liquid is

entrapped in the hub, an explosion could occur.

e) Remove the shaft sleeve [2400] f) Remove the support head [3160].

Pumps without Vapor Proof or Pressurized Construction For groups 1 and 2 the support head will be disconnected from the mounting plate [6130]. For group 3 the support head will be disconnected from the upper column [1341.1].

For Group 3 pumps, any columns still attached to the pump at this time must be firmly supported. The upper column will disconnect from the mounting plate at the same time that the support head is disconnected. Pumps with Vapor Proof or Pressurized Construction: remove the support head [3160] from the bearing bracket [4310.2]

g) Remove coupling hub. h) Pumps with Vapor Proof or Pressurized

Construction: If a cartridge type mechanical seal [4200] is used, the spacing clips or tabs should be installed prior to loosening the setscrews which attaches the seal to the shaft. This will ensure that the proper seal compression is maintained. It will also help prevent damage to the seal in the following steps.

i) Unbolt and remove the bearing body [3110] j) Remove the retaining ring [2530.2] and key

[6700.3] from the adjusting sleeve [3400].

k) Holding the shaft [2100] steady, turn the

adjusting sleeve [3400] counterclockwise to remove the assembly from the shaft

l) Remove the bearing bracket [4310.2] for pump

with Vapor Proof or Pressurized Construction only. For groups 1 and 2 the bearing bracket will be

disconnected from the mounting plate [6130] For group 3 the bearing bracket will be disconnected from the upper column [1341.1].

For Group 3 pumps, any columns still attached to the pump at this time must be firmly supported. The upper column will disconnect from the mounting plate at the same time that the bearing bracket is disconnected.

Before the next procedure, be sure to cover the shaft threads with a Teflon tape for protection when sliding parts off the shaft to prevent the shaft threads from being damaged or causing damage to other parts.

m) Pumps with Vapor Proof or Pressurized

Construction only. Unbolt the gland [4120.1 or 4120.3] and carefully slide it off the end of the shaft. If the pump contains a seal, VERY CAREFULLY, slide the seal off of the shaft. Remove all seal components and discard all O-rings and gaskets. If the pump contains packing remove the packing at this time.

n) Now the stuffing box [4110] can be unbolted and

removed gently from the shaft.

o) A shaft-nose cone (See Figure 6-3) is

recommended, but not required, for the next step. If a shaft nose cone is to be used, attach the cone in place of the impeller [2200]. Remove the shaft [2100] from the remainder of the pump.

Figure 6-3 Shaft Nose Cones

Description Dwg # PCN

GP1 Shaft BY60723A 75658104 GP2 Shaft BY60724A 75658112

GP3-13" (2 piece) BY60901A 75658120

GP3 BY60725A 75658138

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Always remove the shaft by pulling it out through the mounting plate end as shaft threads may cause damage to the line shaft bearings if pulled through the casing end.

p) Unbolt and remove the adapter [1340.1]. q) Unbolt and remove the intermediate columns

[1341.2] and the bearing holders [3250] until the upper column is reached [1341.1].

r) The shaft bearings should not be removed from

their housings unless they are to be replaced. Figure 6.6 shows a listing of allowable bearing tolerances. If these tolerances are exceeded, either the bearings [3020.1-.2], shaft [2100], or bearing holder [3250] should be replaced.

s) Intermediate shaft bearings [3020.1] can be

pressed or driven out of their bearing holder [3250] when replacing.

t) The adapter bearing [3020.2] may be removed

by pressing or driving the bearing sleeve from the upper flange (column side) out through the lower end (casing side) of the adapter [1340.1].

u) Removal of bearings [3031] from adjusting

sleeve [3400]. Remove snap ring [2530.2]. An arbor or hydraulic press may be used to remove the bearings from the adjusting sleeve. It is extremely important to apply even pressure to the inner bearing race only. Never apply pressure to the outer race as this exerts excess load on the balls and causes damage.

Applying pressure to the outer

race could permanently damage the bearings.

x) If lip seals [4310.1] and [4310.2] (see figure 6-4)

are used, they should be removed and discarded.

Figure 6-4

6.8 Examination of parts

6.8.1 Cleaning/inspection

All parts should now be thoroughly cleaned and inspected. New bearings, O-rings, gaskets, and lip seals must be used. Any parts that show wear or corrosion should be replaced with new genuine Flowserve parts.

It is important that only non-flammable, non-contaminated cleaning fluids are used. These fluids must comply with plant safety and environmental guidelines.

a) Inspect impeller [2200] for excessive wear and

etching due to corrosion. Large nicks and deep pits will unbalance the impeller, cause vibration, and wear in other parts of the pump. Be sure the O-ring [4590.2] sealing surface and impeller

threads are clean. b) Check pump shaft [2100] for straightness. c) Inspect the surface of the shaft in the bearing

[3020.1-.2] areas to make sure it is smooth. It

must be free of grooves, scratches, corrosion or

wear. d) Check ends of shaft for burrs. Make sure that

shaft threads are clean. e) Inspect the casing [1100] thoroughly, removing

all burrs and foreign matter. Check hydraulic

passages for cleanliness. f) Check all other parts for burrs, wear, damage or

corrosion. g) Use a dial indicator to check the straightness of

the shaft extension of the driver and check

indicator readings against the values given in

Figure 6-6. Should any of these limits be

exceeded, check with the driver manufacturer

for recommended repair or replacement parts.

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Figure 6-5 Motor tolerances

A B C

T.I.R. Dimensions -- mm (in.)

Frame Size

143-256TCV 0.10 (0.004) 0.10 (0.004) 0.05 (0.002) 284-286TSCV 0.10 (0.004) 0.10 (0.004) 0.08 (0.003) 324-445TSCV 0.18 (0.007) 0.18 (0.007) 0.08 (0.003)

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h) Inspect inside of bearings [3020.1-.2] in the

adapter [1340.1] and intermediate bearing holder(s) [3250]. Check for cracks, uneven or excessive wear, scoring or heat discoloration, and corrosion. Bearings should be replaced as described in Section 6.7.2.

6.8.2 Critical measurements and tolerances

To maximize reliability of pumps, it is important that certain parameters and dimensions are measured and maintained within specified tolerances. It is important that all parts be checked. Any parts that do not conform to the specifications should be replaced with new Flowserve parts.

6.8.3 Parameters that should be checked by users

Flowserve recommends that the user check the measurements and tolerances in Figure 6-6 whenever pump maintenance is performed. Each of these measurements is described in more detail on the following pages.

6.8.3.1 Shaft

Replace if grooved, pitted or worn, especially where the shaft rides in the sleeve bearings.

6.8.3.2 Bearings

It is recommended that rolling element bearings not be used after removal from the shaft.

6.8.3.3 Impeller balancing

To minimize shaft whip it is imperative that the impeller is balanced. All impellers manufactured by Flowserve are balanced after they are trimmed. If for any reason, a customer trims an impeller, it must be re-balanced.

The maximum values of acceptable unbalance are:

• Up to 1800 rpm: 40 g·mm/kg (0.021 oz-in/lb)

• Above1800 rpm: 20 g·mm/kg (0.011 oz-in/lb)

Flowserve performs a single plane spin balance on most impellers. The following impellers are exceptions: 10X8-14, 10X8-16 and 10x8-16H. On these Flowserve performs a two plane dynamic balance, as required by the ASME B73.1M standard. All balancing, whether single or two plane, is performed to the ISO 1940 Grade 6.3 tolerance criteria.

6.8.3.4 Vibration analysis

Vibration analysis is a type of condition monitoring where a pump’s vibration “signature” is monitored on a regular, periodic basis. The primary goal of vibration analysis is extension on MTBPM. By using this tool Flowserve can often determine not only the existence of a problem before it becomes serious, but also the root cause and possible solution.

Modern vibration analysis equipment not only detects if a vibration problem exists, but can also suggest the cause of the problem. On a centrifugal pump, these causes can include the following: unbalance, misalignment, defective bearings, resonance, hydraulic forces, cavitation and recirculation. Once identified, the problem can be corrected, leading to increased MTBPM for the pump. Flowserve strongly urges customers to work with an equipment supplier or consultant to establish an ongoing vibration analysis program.

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Figure 6-6 Line shaft bearing and bearing holder wear limits

Ref. Number Description

2100

3020.1/3020.2

3250/1340.1

Group 1 Shaft Group 2 Shaft Group 3 Shaft Group 1 Line Shaft Bearings

Group 2 Line Shaft Bearings

Group 3 Line Shaft Bearings

Group 1 Bearing Holder/Adapter Group 2 Bearing Holder/Adapter Group 3 Bearing Holder/Adapter

Carbon ARHT Bronze Rubber Teflon Iron

Max. Inside Diameter

28.994 mm (1.1415 in.)

29.096 mm (1.1455 in.)

28.766 mm (1.1325 in.)

28.956 mm (1.1400 in.)

28.766 mm (1.1325 in.)

38.583 mm (1.5190 in.)

38.545 mm (1.5175 in.)

38.329 mm (1.5090 in.)

38.481 mm (1.5150 in.)

38.329 mm (1.5090 in.)

54.458 mm (2.1450 in.)

54.445 mm (2.1455 in.)

54.204 mm (2.1350 in.)

54.242 mm (2.1365 in.)

54.356 mm (2.1410 in.)

54.204 mm (2.1350 in.)

41.288 mm (1.6255 in.)

50.787 mm (1.9995 in.)

73.114 mm (2.8785 in.)

Min. Outside Diameter*

28.42 mm (1.119 in.)

37.95 mm (1.494 in.)

53.82 mm (2.119 in.)

*Shaft must not have grooves, nicks, scratches or other discontinuities at the bearing journal locations.

Figure 6-7 Additional tolerances

Ref. Number Description

3400

3110

Adjusting Sleeve O.D. (under ball bearing)

Bearing Body I.D. (over ball bearing)

Group 1 40.013 mm (1.5753 in.) 40.002 mm (1.5749 in.) Group 2 Group 3

Group 1 Group 2 Group 3

Max. Diameter

50.013 mm (1.9690 in.) 50.002 mm (1.9686 in.)

65.016 mm (2.5597 in.) 65.004 mm (2.5592 in.)

90.04 mm (3.545 in.) 90.02 mm (3.544 in.)

110.03 mm (4.332 in.) 110.01 mm (4.331 in.)

140.03 mm (5.513 in.) 140.00 mm (5.512 in.)

Min. Diameter

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6.9 Assembly of pump and seal

It is important that all pipe threads be sealed properly. PTFE tape provides a very reliable seal over a wide range of fluids, but it has a serious shortcoming if not installed properly. If, during application to the threads, the tape is wrapped over the end of the male thread, strings of the tape will be formed when threaded into the female fitting. These strings can then tear away and lodge in the piping system. If this occurs in the seal flush system, small orifices can become blocked effectively shutting off flow. For this reason, Flowserve does not recommend the use of PTFE tape as a thread sealant.

Flowserve has investigated and tested alternate sealants and has identified two that provide an effective seal, have the same chemical resistance as the tape, and will not plug flush systems. These are La-co Slic-Tite and Bakerseal. Both products contain finely ground PTFE particles in an oil-based carrier. They are supplied in a paste form which is brushed onto the male pipe threads. Flowserve recommends using one of these paste sealants.

Full thread length engagement is required for all fasteners.

SHAFT

Shaft Diameter A

28.58 mm (1.125 in.) 3.2 mm (.125 in.)

38.10 mm (1.500 in.) 3.2 mm (.125 in.)

53.98 mm (2.125 in.) 3.2 mm (.125 in.)

Holder

Bearing

Refer to figure 6-2 for recommended bolt

torques.

6.9.1 Replacing shaft sleeve bearings

a) After removing the old intermediate bearings

[3020.1] (see section 6.7.2) clean and deburr bearing holder bore and lubrication port. Apply a light coating of grease or oil to bearing holder bore and out-side diameter of new bearing. Carefully press new bearing into holder to "A" dimension in Figure 6-8.

b) After removing the adapter bearing [3020.2] (see

section 6.7.2) clean and deburr adapter bore and lubrication port. Apply a light coating of grease or oil to bearing holder bore and outside diameters of new bearings. Carefully press the new bearing into the adapter flush with the counter bore as shown in Figure 6-9.

c) Be sure that all bearings [3020.1-.2] are now

within their bearing holders [3250, 1340.1].

Figure 6-8 Intermediate bearing

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Figure 6-9 Adapter bearing

6.9.2 Assembling mounting plate, column(s), adapter and shaft

If a shaft nose cone is available, the mounting plate, column(s), intermediate bearing(s) and adapter may be assembled prior to shaft insertion. If a nose cone is not available, the pump must be built in section over the shaft. Use of a shaft nose cone is recommended.

a) Standard and vapor tight construction:

connect the upper column [1341.1] to the mounting plate [6130]. For Group 3, the upper column and support head [3160] must be bolted to the mounting plate at the same time.

In this configuration, the upper column

contains a lip seal [4310.2] which is installed with the energizing spring down. Although installation is more difficult, it is beneficial to install the lip seal after shaft installation to prevent damage. Wrap the shaft thread with Teflon tape to protect lip seal from damage.

Vapor proof or pressurized construction:

replace the upper column gasket [4590.5] and reconnect the upper column [1341.1] to the mounting plate [6130]. For Group 3, the bearing bracket [4310.2] must be bolted to the mounting plate at the same time.

Assembly with nose cone b) If intermediate bearings are used, install the

bearing holder [3250] and intermediate column [1341.2] and bolt them together. Repeat for each section.

c) Bolt the adapter [1340.1] back onto the last

column in the pump.

d) Screw the shaft bullet onto the end of the shaft

[2100] at the impeller end.

Always insert the shaft from the mounting plate side of the pump. Never insert it from the adapter side because shaft threads may cause damage to the internal bearings. e) The pump shaft [2100] should now be inserted

into the pump from the mounting plate side.

Standard and vapor tight construction require a lip seal [4310.2] in the upper column. If the lip seal is installed prior to the shaft, than ensure the lip seal and shaft are lubricated to prevent damage to the lip seal. The lip seal may be installed after the shaft is slid into place, but installation is more difficult (see section a) for details). Fill the cavity between the lips ½ to ⅔full

Assembly without nose cone

It is important that the shaft and columns are well supported after the shaft is partially inserted as bending in the shaft may occur. b) Insert the shaft from the motor side of the pump

through the starter column [1341.1] until the shaft threads [for the thrust bearing - 3031] are about 3 inches from the starter column Standard and vapor tight construction require a lip seal [4310.2] in the upper column. If the lip seal is installed prior to the shaft, than ensure the lip seal and shaft are lubricated to prevent damage to the lip seal. The lip seal may be installed at the end of this sequence, but installation is more difficult (see section a) for details).

c) If intermediate bearing(s) are used, slide the

bearing holder [3250] onto the end of the shaft [2100], followed by the column [1341.2] and bolt together. Repeat for each section.

d) Slide the adapter [1340.1] onto the shaft [2100]

and bolt to the column [1341.1] or [1341.2].

6.9.3 Cover, Impeller and Casing Installation

a) Install the cover [1220] to the adapter [1340.1].

If applicable, hold the cover in place with cap screws [6570.16].

b) Install the impeller. Section 6.6 covers all

aspects of impeller installation. Install a new gasket [4590.2], sleeve O-ring [4590.1] and lubricate threads.

c) Place a new gasket [4590.1] on the gasket face

of the cover [1220] and bolt the casing [1100] to the adapter [1340.1]

6.9.4 Ball bearing/Adjusting Sleeve Assembly

Mounting of bearings must be done in a clean environment. Thrust bearing life can be drastically reduced if even very small foreign particles work their way into the bearings. Wear clean gloves.

Bearings should be removed from their protective packaging only immediately before assembly to limit exposure to possible contamination. After removing

Page 47

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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the packaging they should only come in contact with clean hands, fixtures, tools and work surfaces.

Pump Group Size Ball Bearing Size

GP1 – 1E GP2 – 2E GP3 – 3E

7308 7310 7313

Bearings have a slight interference fit which requires that they be pressed on the adjuster with an arbor or hydraulic press. Even force should be applied to only the inner race. Never press on the outer race, as the force will damage the balls and races.

An alternate method of installing bearings is to heat the bearings to 93 °C (200 °F) by means of an oven or induction heater. With this approach the bearing must be quickly positioned on the adjuster.

Never heat the bearings above 110 °C (230 °F). To do so will likely cause the bearing fits to permanently change, leading to early failure.

Duplex angular contact bearings must be mounted face-to-face with the wider thrust sides of the outer races away from each other as shown in figure 6-10. Only bearings designed for universal mounting should be used. The SKF designation is “BEGAM”. NTN’s designation is “BL1G”.

Figure 6-10

6.9.5 Seal and packing installation (if equipped)

Cover the shaft threads with a Teflon tape to prevent them from causing internal damage to other components.

a) Attach the stuffing box [4110] to the upper

column [1341.1]. NOTE: Some cartridge (canister) seals are designed to bolt directly to the upper column and will not have a separate stuffing box.

b) Seal component installation

Component Seal that require setting: Most component seals required setting. The impeller must be set and the shaft marked at box face before seal assembly can take place. The following steps will build the pump to the point the impeller can be set and the shaft marked. The pump must then be disassembled to the point that the seal can be installed and set according to the instruction included with the seal.

Figure 6-11 Typical Inside Component Seal

a) Press the bearings [3031) onto the adjusting

sleeve [3400) as shown in Figure 6-10. If the bearings have been heated for installation, the bearing should be pressed against the shoulder after the bearing has cooled below 38 °C (100

°F). b) Install snap ring [2530.2]. c) Pack the bearing with grease. See Figure 5-5.

Page 48

Figure 6-12 Typical Outside Component Seal

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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Component Seals that do not require setting:

Most double component seals do not required

any settings. The seal may be installed at this

point according to the instructions provided with

the seal. Care must be taken that the seal rotor

is lubricated properly so that it will be able to

move on the shaft as the impeller is set in the

following steps.

Figure 6-13 Typical Double Component Seal

Cartridge and Gas Canister seal:

CAREFULLY slip the seal [4200] onto the shaft

[2100] and slide it down until it sets into the

stuffing box [4110] or upper column [1341.1] on

with Gas Canister type seals. DO NOT SET

THE SEAL AT THIS TIME. Leave the gland

nuts slightly loose.

Figure 6-14 Typical Cartridge Seal

Packing:

Install one ring at a time, pushing it well into

place. Two rings of packing must be installed,

the seal cage, then succeeding rings of packing

until the box is filled.

NOTE: The joints of succeeding rings must be

staggered. The taped hole in the stuffing box for

packing lubrication must line up with the seal

cage when the packing is compressed.

After the last ring of packing is in place, draw up

the nuts [6580.8] on the gland [4120.1] evenly

finger tight. Save additional packing rings as they may become necessary as the packing is tightened during operation.

Figure 6-15

Packing Information

Group 1 Group 2 Group 3 Packing size, square

Packing arrangement Seal Cage width

Max.

Shaft Diameter

Min,

7.9 mm

(0.31 in.)

2-C-3 2-C-3 2-C-3

12.7 mm (0.50 in.)

28.58 mm

(1.125 in.)

28.52 mm (1.123 in.)

c) GP1 and 2 Pumps:

The lower lip seal [4310.2] should be installed with the spring down into the bearing bracket [3130]. Fill the cavity between the lips ½ to ⅔ full with bearing grease. Install the bearing bracket [3130] to the mounting plate [6130] GP3 Pumps: The bearing bracket [3130] has already been installed. The lower lip seal [4310.2] should be installed with the spring down into the bearing adapter plate [1340.4]. Fill the cavity between the lips ½ to ⅔ full with bearing grease. Install the bearing adapter plate [1340.4] onto the top of the bearing bracket [3130]. Temporarily hold the adapter bracket in place with cap screws.

d) Install bearing/adjusting sleeve assembly.

Screw the adjusting sleeve [3400] to the shaft

e) Install O-ring [4590.2] and the bearing body

[3110]. Secure with cap screws [6570.9]. The bearing body contains lip seal [4310.1]. The seal is installed with the spring down. Lubricate the lip seal with grease prior to placing over the shaft. Fill the cavity between the lips ½

to ⅔full. f) Set the impeller as described in section 6.6.3 g) Set the seal.

Cartridge and Gas Canister seal:

Follow the instructions provided with the seal.

Tighten the gland nuts [6580.8]. Tighten the

seal sets screws to the shaft. Remove the seal

setting clips.

Packing:

Ensure the gland nuts [6580.8] are evenly finger

tight and then tighten and additional ¼ turn.

Final tightness is set via leakage. A slight

amount of leakage through the gland [4120.1] is

necessary for proper lubrication. Packing

glands must never be tightened to the point

7.9 mm (0.31 in.)

19.0 mm (0.75 in.)

38.10 mm (1.500 in.)

38.05 mm

(1.498 in.)

9.5 mm

(0.38 in.)

12.7 mm (0.50 in.)

47.63 mm (1.875 in.)

47.57 mm (1.873 in.)

Page 49

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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where leakage from the packing is stopped.

Component seals that do not required setting:

Tighten the gland nuts [6580.8]

h) Components seals that required setting:

The following steps are only necessary for these types of seals.

• Put bluing on the shaft and mark the shaft at the face of the gland [4120.3]. This mark is used as a reference for setting the seal.

• Remove the bearing body installed in step e).

• Remove the adjusting sleeve installed [3400]

in step d).

• Remove the bearing bracket [3130] or adapter bracket installed in step c).

• Install and set the seal according the instruction provided with the seal. Inside component seal may prove difficult to set. If necessary, remove the casing and impeller so that the shaft may be moved to allow access for setting the seal.

• Repeat steps c), d) and e).

Seals must never be run without

lubrication. Abrasive lubrication will greatly reduce seal life.

A variety of seal piping plans designed to suit certain pumping conditions and liquids are available.

6.9.6 Installation of ball bearings and housing

The following steps have previously been performed for pumps with seals. a) Install bearing/adjusting sleeve assembly.

Screw the adjusting sleeve [3400] to the shaft

b) Install O-ring [4610.2] and the bearing body

[3110]. Secure with cap screws [6570.9]. The bearing body contains lip seal [4310.1]. The lip seal is installed with the spring down. Lubricate the lip seal with grease prior to placing over the shaft. Fill the cavity between the lips ½ to ⅔full.

c) Set the impeller as described in section 6.6.3

6.9.7 Installation of motor support head GP1 and 2 Pumps:

For pumps without seals, attach the support head [3160] to the upper column [1341.1] with cap screws [6579.2]. For pumps with seals, attach the support head [3160] to the bearing bracket [4310.2] with cap screws [6579.4] GP3 Pumps: For pumps without seals, the support head has already been installed.

For pumps with seals, remove the cap screws temporarily holding the bearing adapter plate [1340.4] in place. Attach the support head to the adapter bracket with cap screws.

6.9.8 Discharge piping

a) If the strainer [6531] had been removed for

cleaning or replacement purposes, reattach

strainer to suction flange of the casing. b) Reconnect all bearing lubrication lines [3840.1]. c) For Groups 1, 2, and 6x4-13: At this point the

lower locknut [3400] should be screwed all the

way down the threads on the upper end of the

discharge pipe [1360]. The discharge elbow

[1371] should be screwed onto the lower end of

the discharge pipe (if not already). Check to see

if the companion flange [1245.1] is still

connected to the discharge elbow. Next, the

discharge pipe should be slid up through the

mounting plate [6130] until the companion flange

lines up with the discharge flange of the casing

[1100].

To ensure a proper seal at the casing discharge flange, it is important that the companion flange is connected to the casing before the upper locknuts are tightened to against the mounting plate.

d) Replace the gasket [4590.2] between the

companion flange and the discharge flange of the casing and bolt back together.

e) The upper locknut [6580.8] can now be screwed

onto the threads at the upper end of the discharge pipe and both locknuts can be tightened against the mounting plate.

f) For Group 3 (excluding 6x4x13): The

discharge pipe is attached the same way to the casing discharge flange (see step “f” above). The only difference in the assembly is that the Group 3 pipes have a flange [1245.3] welded to the discharge pipe [1360] that bolts to the underside of the mounting plate [6130].

6.9.9 Final Assembly

• Ensure ball bearing, line shaft bearings, and seal

lubrication lines are installed

• Grease the thrust bearing [3031] with initial lube

quantity found in figure 5-5.

• Follow the installation instruction in section 4.

• Follow the instruction found in section 5.

• Ensure all guards are in place.

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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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Insufficient NPSH. (Noise may not be

7 FAULTS; CAUSES AND REMEDIES

The following is a guide to troubleshooting problems for the Flowserve ESP pumps. Common problems are analyzed and solutions offered. Obviously, it is impossible to cover every possible scenario. If a problem exists which is not covered by one of the examples, than refer to one of the books listed in section 10 Additional sources of information or contact a Flowserve sales engineer or distributor/representative for assistance.

FAULT SYMPTOM

Pump not reaching design flow rate

Pump not reaching design head (TDH)

⇓⇓⇓⇓

No discharge or flow with pump running

⇓⇓⇓⇓

 

  

 

  

 

  

 

    

 

Pump operates for short period, then loses prime

⇓⇓⇓⇓

Excessive noise from wet end

⇓⇓⇓⇓

Excessive noise from thrust bearing end

⇓⇓⇓⇓

Pump uses too much power

⇓⇓⇓⇓

PROBABLE CAUSES POSSIBLE REMEDIES

⇓⇓⇓⇓

 



 



present.)

System head greater than anticipated.

Entrained air. Air leak from atmosphere on suction side.

Entrained gas from process. Process generated gases may require larger pumps. Speed too low. Check motor speed against design speed.

Direction of rotation wrong.

Impeller too small. Impeller clearance too large. Reset impeller clearance.

Plugged impeller, strainer or casing which may be due to a product or large solids.

Wet end parts (casing or impeller) worn, corroded or missing.

Liquid level in sump too low. Impeller rubbing.

Damaged pump shaft, impeller. Replace damaged parts. Liquid vortexing in sump.

Bearing contamination appearing on the raceways as scoring, pitting, scratching or rusting caused by adverse environment and entrance of abrasive contaminants from atmosphere.

Speed too high.

Recalculate NPSH available. It must be greater than the NPSH required by pump at desired flow. Increase low liquid level in the sump, lengthen pump or lower fluid temperature to increase the NPSHa.

Reduce system head by increasing pipe size and/or reducing number of fittings. Increase impeller diameter. (Note: Increasing impeller diameter may require use of a larger motor.)

1. Check for air entrainment sources in the sump.

2. If vortex formation is observed in suction tank, install a vortex breaker.

3. Check for minimum submergence.

After confirming wrong rotation, reverse any two of three leads on a three phase motor. The pump should be disassembled and inspected before it is restarted.

Replace with proper diameter impeller. (NOTE: Increasing impeller diameter may require use of a larger motor.)

1. Reduce length of fiber when possible.

2. Reduce solids in the process fluid when possible.

3. Consider larger pump.

4. Clean strainer. Replace part or parts. If pump and bearing system has run dry for a long period,

disassemble and inspect the pump before operation.

1. Check and reset impeller clearance.

2. Check outboard bearing assembly for axial endplay.

2. Rapid temperature changes; increase impeller clearance.

Add sump vortex breakers to avoid adverse fluid rotation as it approaches the impeller. Consult ANSI/HI 2.3.5

1. Work with clean tools in clean surroundings.

2. Remove all outside dirt from housing before exposing bearings.

3. Use clean solvent and flushing oil.

4. Protect disassembled bearing from dirt and moisture.

5. Clean inside of bearing body before replacing bearing.

6. Check lip seals and replace as required.

7. Check all plugs and tapped openings for tightness. Adjust VFD or install proper speed motor.

Page 51

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Pump not reaching design flow rate

again by either axial or circumferential

Pump not reaching design head (TDH)

⇓⇓⇓⇓

No discharge or flow with pump running

⇓⇓⇓⇓

Pump operates for short period, then loses prime

⇓⇓⇓⇓

Excessive noise from wet end

⇓⇓⇓⇓

Excessive noise from thrust bearing end

⇓⇓⇓⇓

Pump uses too much power

⇓⇓⇓⇓



ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

PROBABLE CAUSES POSSIBLE REMEDIES

Too much flow. Brinelling of bearing identified by

indentation on the ball races, usually caused by incorrectly applied forces in assembling the bearing or by shock loading such as hitting the bearing or drive shaft with a hammer.

False brinelling of bearing identified indentations usually caused by

vibration of the balls between the races in a stationary bearing.

Thrust overload on bearing identified by flaking ball path on one side of the outer race or in the case of maximum capacity bearings, may appear as a spalling of the races in the vicinity of the loading slot. These thrust failures are caused by improper mounting of the bearing or excessive thrust loads.

Misalignment identified by fracture of ball retainer or a wide ball path on the inner race and a narrower cocked ball path on the outer race. Misalignment is caused by poor mounting practices or defective drive shaft. For example, bearing not square with the centerline or possibly a bent shaft due to improper handling.

Bearing damaged by electric arcing identified as electro- etching of both inner and outer ring as a pitting or cratering. Electrical arcing is caused by a static electrical charge emanating from belt drives, electrical leakage or short-circuiting.

Bearing damage due to improper lubrication, identified by one or more of the following:

1. Abnormal bearing temperature rise.

2. A stiff cracked grease appearance.

3. A brown or bluish discoloration of the bearing races.

Liquid has higher viscosity or specific gravity than thought.

Binding in the pump or driver. 1. Clean column mating surfaces.

System resistance to flow is too low. Close discharge valve more. Reduce impeller diameter.

When mounting the bearing on the drive shaft use a proper size ring and apply the pressure against the inner ring only. Be sure when mounting a bearing to apply the mounting pressure slowly and evenly.

1. Correct the source of vibration.

2. In units that may be out of service for extended periods, the drive shaft should be turned over periodically to relubricate all bearing surfaces at intervals of one to three months.

Follow correct mounting procedures for bearings.

Handle parts carefully and follow recommended mounting procedures. Check all parts for proper fit and alignment.

1. Where current shunting through the bearing cannot be corrected, a shunt in the form of a slip ring assembly should be incorporated.

2. Check all wiring, insulation and rotor windings to be sure that they are sound and all connections are properly made.

3. Where pumps are belt driven, consider the elimination of static charges by proper grounding or consider belt material that is less generative.

1. Be sure the lubricant is clean.

2. Be sure proper amount of lubricant is used. In the case of greased lubricated bearings, be sure that there is space adjacent to the bearing into which it can rid itself of excessive lubricant, otherwise the bearing may overheat and fail prematurely.

3. Be sure the proper grade of lubricant is used.

Analyze fluid being pumped and adjust it or pump driver.

2. Pump shaft bent and binding in sleeve bearings.

Page 52

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8 PARTS LIST AND DRAWINGS

PARTS LIST

Figure 8-1: Group 1&2 sectional

6700.1

6570.1

6700.2

6700.3

3853.1

6850.1

3853.2

6570.7

1245.2

3869

6580.8

1360

INTERMEDIATE BEARING ASSEMBLY(S) FURNISHED AS REQUIRED BY PUMP LENGTH

3840.4

6570.14

1232.2

1232.1

6580.9

3830

3840.1

3840.3

6850.3

3840.2

6515.2

6310.5

6310.4

1371

6570.4

1245.1

6580.4

4590.3

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

DESCRIPTIONEUROPUMP_REF_NO

8000

1340.3

3160

7200

2530.1

3400

4310.1

6570.9

3031

3110

2530.2

6579.2

6579.1

6820

6130

4610.2

4310.2

1341.1

6570.2

3250

3853.3

3020.1

6580.2

1341.2

2100

6570.3

1340.1

6580.3

3020.2

6572.1

4610.1

6580.1

6570.16

4590.1

1220

2500

2200 1100

6515.1

2400

4590.2

6580.5

1340.2

6541.2

6570.5

6531

6541.1

6570.6

3840.2

3853.1

6570.14

8000

CASING1100 COVER1220 CLAMP - LUBE PIPING1232.1 COVER PLATE - CLAMP1232.2 FLANGE - COMPANION1245.1

FLANGE - DISCHARGE1245.2 ADAPTOR1340.1 ADAPTOR - STRAINER1340.2 ADAPTOR - MOTOR1340.3

COLUMN - UPPER1341.1

COLUMN - INTERMEDIATE1341.2

PIPE - DISCHARGE1360

ELBOW - DISCHARGE1371

SHAFT2100

IMPELLER2200

SLEEVE240 0

THROTTLE BUSHING2500

SNAP RING2530.1

RETAINING RING2530.2

BEARING - INTERMEDIATE3020.1

BEARING - BOTTOM3020.2

BEARING - THRUST3031

BEARING BODY3110

SUPPORT HEAD3160

HOLDER - BEARING3250

SLEEVE - ADJUSTING3400

BRACKET - LUBE PIPING3830

HOSE KIT - LUBE PIPING3840.1

PIPE NIPPLE - LUBE LINE

ELBOW - LUBE PIPING3840.3

ELBOW - LUBE PIPING3840.4

NIPPLE - PIPE

FITTING GREASE ( THRUST BRG )3853.2

FITTING GREASE (BRG. HOUSING + ADAPTOR)3853.3

MANIFOLD - LUBE PIPING3869

LIP SEAL - UPPER4310.1

LIP SEAL - LOWER431 0.2

GASKET - CASING4590.1

GASKET - IMPELLER4590.2

GASKET - DISCHARGE PIPE4590.3

O-RING - SLEEVE4610.1

O-RING - BEARING BODY4610.2

MOUNTING PLATE6130

NIPPLE - COMPANION6310.4

NIPPLE - DISCHARGE6310.5

PLUG - CASING DRAIN651 5.1

PLUG - CASING DISCHARGE6515.2

STRAINER6531

WASHER - STRAINER TO ADAPTOR6541.1

WASHER - ADAPTER TO CASING6541.2

CAP SCREW - SUPP HD TO MTR6570.1

CAP SCREW - CLAMP

CAP SCREW - TOKEN BOLTS6570.16

CAP SCREW - COUPL.GUARD ( NOT SHOWN )6570.17

CAP SCREW - INTER. BRG6570.2

CAP SCREW - COL. TO ADAPTOR6570.3

CAP SCREW - DISCHARGE6570.4

CAP SCREW - STNR. ADAPT. TO CASING6570.5

CAP SCREW - STNR. TO ADAPTOR6570.6

CAP SCREW - MANIFOLD. TO MTG PLT6570.7

CAP SCREW - BRG BODY TO COL.6570.9

STUD - CASING6572.1

CAP SCREW - COL. TO MTG. PLT.6579.1

CAP SCREW - SUPP HD TO MTG. PLT.6579.2

NUT - HEX CASING STUD6580.1

NUT - COUPLING GUARD ( NOT SHOWN )6580.12

NUT - HEX INTER. BRG6580.2

NUT - COL. TO ADAPT.6580.3

NUT - HEX CASING DISCHARGE6580.4

NUT - HEX ADAPT. TO CASING6580.5

LOCKNUT - PIPE6580.8

NUT - HEX CLAMP6580.9

KEY - DRIVER SHAFT6700.1

KEY - PUMP SHAFT6700.2

GIB KEY6700.3

LIFTING EYE6820

COUPLING - GREASE6850.1

COUPLING - REDUCING6850.3

COUPLING - FLEXIBLE7200

COUPLING GUARD ( NOT SHOWN )7450.1 & 7450.2

DRIVER

Page 53

0696AGR2ESP3A001

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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Figure 8-2: Group 3 sectional

Ref. No. Old P/N DESCRIPTION

1340.1 0014 ADAPTOR

1232.1 0440 CLAMP -- LUBE PIPING 7200 0561 COUPLING -- FLEXIBLE

1232.2 1220 COVER PLATE -- CLAMP 8000 0743 DRIVER 1371 0767 ELBOW -- DISCHARGE

6700.1 11A9A KEY -- DIRVER SHAFT

6700.2 11A9B KEY -- PUMP SHAFT

6541.1 12A5 WASHER -- STRAINER

1245.3 12A8 FLANGE -- DISCHARGE PIPE

4590.2 4590.2 O-RING -- IMPELLER 3031 3031 BEAIRNG -- THRUST

6515.1 30A7A PLUG -- CASING DRAIN

6515.2 30A7B PLUG -- CAISNG DISCHARGE

4590.2 32A11 GASKET -- CASING DISCHARGE

6570.1 35A2A CAP SCREW -- SUPP HD TO MTR

6570.2 35A2B CAP SCREW -- INTER. BRG

6570.3 35A2C CAP SCREW -- COL. TO ADAPTOR

6570.4 35A2D CAP SCREW -- DISCHARGE

6570.6 35A2F CAP SCREW -- STNR. TO ADAPTOR

6570.7 35A2G CAP SCREW -- MFLD. TO MTG PLT

6570.9 35A2J CAP SCREW -- BRG BODY TO COL.

6570.11 35A2H CAP SCREW -- FLG. TO MTG PLT

6570.14 35A2P CAP SCREW -- CLAMP

6580.1 38A4A NUT -- HEX CASING STUD

6580.2 38A4B NUT -- HEX INTER. BRG

6580.3 38A4C NUT -- HEX ADAPTOR

6580.4 38A4D NUT -- HEX CASING DISCHARGE

6580.5 38A4E NUT -- HEX STRAINER

6580.6 38A4J NUT -- HEX CLAMP

1245.2 39A8 FLANGE -- DISCHARGE

6572.1 62A3 STUD -- CASING

3840.3 65A7 ELBOW -- LUBE PIPING

3840.4 106A ELBOW -- LUBE PIPING

6570.12 119A2B CAP SCREW -- SUPP HD - MTG PLT

2530.1 2530.1 SNAP RING

3853.1 18A7B NIPPLE -- PIPE

2530.2 181A13 RETAINING RING

3853.2 78A7 COUPING -- PIPE

3853.3 3853.2 FITTING GREASE (THRUST BRG) 3160 1063 SUPPORT HEAD

3840.1 1104 HOSE KIT -- LUBE PIPING 3250 1109 HOLDER -- BEARING 2200 1129 IMPELLER 3869 3869 MANIFOLD -- LUBE PIPING 3830 1296 BRACKET -- LUBE PIPING 1360 1423A PIPE -- DISCHARGE

3840.2 1423B PIPE NIPPLE -- LUBE LINE

1340.2 1467 ADAPTOR -- STRAINER 2500 1663 SEALING RING -- ADAPTOR 3400 3400 SLEEVE -- ADJUSTING 6130 6130 MOUNTING PLATE 1100 2469 CASING

1341.1 2507A COLUMN -- UPPER

1341.2 2507B COLUMN -- INTERMEDIATE

4590.1 2584A GASKET -- CASING

6700.3 2647 GIB KEY

4310.1 4310.1 LIP SEAL -- UPPER

4310.2 4310.2 LIP SEAL -- LOWER 2100 2807 SHAFT 6531 2845 STRAINER

6541.3 2888 IMPELLER WASHER

3020.1 2945A BEARING -- INTERMEDIATE

3020.2 2945B BEARING -- BOTTOM 3110 3110 BEARING BODY

1220 - COVER (NOT SHOWN) 2400 - SLEEVE (NOT SHOWN) 2500 - THROTTLE BUSH. (NOT SHOWN)

4610.1 - O-RING SLEEVE (NOT SHOWN)

4610.2 - O-RING BRG. BODY (NOT SHOWN)

6570.16 - CAP SCREW – TOKEN BOLT (NOT S)

6570.17 - CAP SCREW – CPL GUARD (NOT SH)

6580.12 - NUT – CPL GUARD (NOT SHOWN) 6820 - LIFTING EYE (NOT SHOWN)

7450.1-.2 - COULING GUARD (NOT SHOWN)

Page 54

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Figure 8-3: Group 1&2 tail pipe assembly

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

6515.1

6580.14

4590.9

6570.11

1428

6580.5

1340.2

6541.2

6570.5

6531

6541.1

6570.6

PARTS LIST

DESCRIPTIONEUROPUMP_REF_NO ADAPTOR1340.1 ADAPTOR - STRAINER1340.2 TAILPIPE GASKET - TAILPIPE4590.9 PLUG - CASING DRAIN6515.1 STRAINER6531 WASHER - STRAINER TO ADAPTOR6541.1 WASHER - ADAPTER TO CASING6541.2 CAP SCREW - STNR. ADAPT. TO CASING6570.5 CAP SCREW - STNR. TO ADAPTOR6570.6 CAP SCREW - TAILPIPE TO CASING6570.11 NUT - HEX ADAPT. TO CASING6580.5 NUT - HEX TAILPIPE TO CASING6580.14

Page 55

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

of 64

Figure 8-4: Group 3 tail pipe assembly

0696AGR2ESP3T001

Page 56

Ref. No. Old P/N DESCRIPTION

6541.1 12A5 WASHER -- STRAINER

6515.1 30A7A PLUG -- CASING DRAIN

4590.6 32A11A GASKET -- CASING SUCTION

6570.6 35A2F CAP SCREW -- STNR. TO ADAPTOR

6570.10 35A2K CAP SCREW -- CASING TO TAILPIPE

6580.5 38A4E NUT -- HEX STRAINER

6580.7 38A4F NUT -- HEX CASING TO TAILPIPE

1341.3 1428 TAIL PIPE ASSEMBLY

1340.2 1467 ADAPTOR -- STRAINER 1100 2469 CASING 6531 2845 STRAINER

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Figure 8-5: Vapor-tight construction

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

1245.2

6570.7

4590.7

3869

6130

4590.6

3110

7450.1 & 7450.2

6700.1

6570.1

1340.3

7200

6700.2

6700.3

3400

3853.1

6850.1

3853.2

PARTS LIST

BEARING BODY3 110 SUPPORT HEAD3160 SLEEVE - ADJUSTING3400 NIPPLE - PIPE3853.1 FITTING GREASE ( THRUST BRG )3853.2 MANIFOLD - LUBE PIPING3869 LIP SEAL - UPPER4310.1 LIP SEAL - LOWER4310.2 GASKET - UPPER COL.TO MTG. PL.4590.6 GASKET - MANIFOLD TO MTG.PL.4590.7 O-RING - BEARING BODY4610.2 MOUNTING PLATE6130 CAP SCREW - SUPP HD TO MTR6570.1 CAP SCREW - COUPL.GUARD ( NOT SHOWN )6570.17 CAP SCREW - MANIFOLD. TO MTG PLT6570.7 CAP SCREW - BRG BODY TO COL.6570.9 CAP SCREW - COL. TO MTG. PLT.6579.1 CAP SCREW - SUPP HD TO MTG. PLT.6579.2 NUT - COUPLING GUARD ( NOT SHOWN )6580.12 KEY - DRIVER SHAFT67 00.1 KEY - PUMP SHAFT6 700.2 GIB KEY6700.3 LIFTING EYE6820 COUPLING - GREASE6850.1 COUPLING - FLEXIBLE7200 COUPLING GUARD ( NOT SHOWN ) DRIVER8000

DESCRIPTIONEUROPUMP_REF_NO

FLANGE - DISCHARGE1245.2 ADAPTOR - MOTOR1340.3 COLUMN - UPPER1341.1 SNAP RING2 530.1 RETAINING RING2530.2 BEARING - THRUST3031

PARTS LIST

8000

3160

2530.1

4310.1

6570.9

2530.2

3031

4310.2

6579.2

6579.1

6820

4610.2

1341.1

DESCRIPTIONEUROPUMP_REF_NO

Page 57

0696AGR2ESP3B001

of 64

Figure 8-6: Vapor-proof construction

8000

1340.3

6570.1

6700.2

6700.3

3400

3160

3853.1

6850.1

3853.2

4610.2

6580.8

1245.2

6570.7

3869

4590.7

6572.2

3130

4590.4

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

8000

7200

2530.1

4310.1

6570.9

2530.2

3031

3110

4310.2

6579.4

4120.1

4130

4134

4110

6570.11

6579.2

6579.1

6820

6130

4590.6

1341.1

4310.1

6570.17

6570.18

6580.8

PARTS LIST

LIP SEAL - UPPER LIP SEAL - LOWER4310.2 GASKET - STUFF BOX TO UPPER COL4590.4 GASKET - UPPER C OL.TO MTG. PL.4590.6 GASKET - MANIFO LD TO MTG.PL.4590.7 O-RING - BEARING BODY4610.2 MOUNTING PLATE6130 CAP SCREW - SUP P HD TO MTR6570.1 CAPSCREW - STUFF BOX TO COL6570.11 CAP SCREW - COU PL.GUARD ( NOT SHOWN ) CAP SCREW - SEA L GUARD ( NOT SHOWN ) CAP SCREW - MAN IFOLD. TO MTG PLT6570.7 CAP SCREW - BRG BODY TO COL.6570.9 STUD - GLAND6572.2 CAP SCREW - COL . TO MTG. PLT.6579.1 CAP SCREW - SUP P HD TO MTG. PLT.6579.2 CAPSCREW - SUPP H D TO BRG BKT6579.4 NUT - COUPLING G UARD ( NOT SHOWN )6580.12 NUT - SEAL GUAR D ( NOT SHOWN )6580.13 NUT - HEX KEY - DRIVER SHAFT6 700.1 KEY - PUMP SHAFT6700.2 GIB KEY6700.3 LIFTING EYE6820 COUPLING - GREASE6850.1 COUPLING - FLEXIBLE7200 COUPLING GUAR D ( NOT SHOWN )7450 .1 & 7450.2 SEAL GUARD ( NOT SHOWN )7450.3 DRIVER8000

DESCRIPTIONEUR OPUMP_REF_NO DESCRIPTION

EUROPUMP_REF_NO

1245.2

PARTS LIST

FLANGE - DISCHARGE

ADAPTOR - MOTOR1340.3

COLUMN - UPPER134 1.1 SNAP RING2530.1 RETAINING RING2530.2 BEARING - THRUST3031 BEARING BODY3110 BRG BRACKET3130 SUPPORT HEAD3160 SLEEVE - ADJUSTING3400 NIPPLE - PIPE3853.1 FITTING GREASE ( THRUST BRG )3853.2 MANIFOLD - LUBE PIPING3869 STUFFING BOX4110 GLAND4120.1 PACKING4130 SEAL CAGE4134

0696AGR2ESP3C001

Page 58

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

of 64

Figure 8-7: Pressurized design

6700.1

6570.1

7200

6700.2

6700.3

3853.1

6850.1

3110

3853.2

4610.2

6580.8

4120.3

6572.2

6570.11

1245.2

6570.7

3869

4590.7

8000

1340.3

3160

2530.1

3400

4310.1

6570.9

3031

2530.2

4310.2

6579.4

4590.5

4200

4110

3130

6579.2

6579.1

6820

6110

1341.1

4590.6

4590.4

PARTS LIST

MOUNTING PLATE6110 CAP SCREW - SUPP HD TO MTR6570.1 CAPSCREW - STUFF BOX TO COL6570.11

6570.18

6580.12

6580.13

6580.8

7450.3 8000

CAP SCREW - COUPL.GUARD ( NOT SHOWN )6570.17 CAP SCREW - SEAL GUARD ( NOT SHOWN ) CAP SCREW - MANIFOLD. TO MTG PLT6570.7 CAP SCREW - BRG BODY TO COL.6570.9 STUD - GLAND6 572.2 CAP SCREW - COL. TO MTG. PLT.6 579.1 CAP SCREW - SUPP HD TO MTG. PLT.6579.2 CAPSCREW - SUPP HD TO BRG BKT6579.4 NUT - COUPLING GUARD ( NOT SHOWN ) NUT - SEAL GUARD ( NOT SHOWN ) NUT - HEX KEY - DRIVER SHAFT6700.1 KEY - PUMP SHAFT6700.2 GIB KEY6700.3 LIFTING EYE6820 COUPLING - GREASE6850.1 COUPLING - FLEXIBLE7200 COUPLING GUARD ( NOT SHOWN )7450.1 & 7450.2 SEAL GUARD ( NOT SHOWN ) DRIVER

DESCRIPTIONEUROPUMP_REF_NO

3400

3853.2

PARTS LIST

FLANGE - DISCHARGE1245.2 ADAPTOR - MOTOR1340.3 COLUMN - UPPER1 341.1 SNAP RING2530.1 RETAINING RING2530.2 BEARING - THRUST3031 BEARING BODY3110 BRG BRACKET3130 SUPPORT HEAD3160 SLEEVE - ADJUSTING NIPPLE - PIPE3853.1 FITTING GREASE ( THRUST BRG ) MANIFOLD - LUBE PIPING3869 STUFFING BOX4110 FLUSH GLAND4120.3 MECHANICAL SEAL4200 LIP SEAL - UPPER4310.1 LIP SEAL - LOWER4310.2 GASKET - STUFF BOX TO UPPER COL4590.4 GASKET - MECH. SEAL GUARD4590.5 GASKET - UPPER COL.TO MTG. PL.4590.6 GASKET - MANIFOLD TO MTG.PL.4590.7 O-RING - BEARING BODY4610.2

DESCRIPTIONEUROPUMP_REF_NO

0696AGR2ESP3D001

Page 59

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Figure 8-8: Product lubrication

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

Page 60

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

of 64

Figure 8-9: Product lubrication separators

Page 61

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

of 64

8.1 General arrangement drawing

The typical general arrangement drawing and any specific drawings required by the contract will be sent to the Purchaser separately unless the contract specifically calls for these to be included into the User Instructions. If required, copies of other drawings sent separately to the Purchaser should be obtained from the Purchaser and retained with these User Instructions.

9 CERTIFICATION

Certificates, determined from the contract requirements are provided with these instructions where applicable. Examples are certificates for CE marking and ATEX marking etc. If required, copies of other certificates sent separately to the Purchaser should be obtained from Purchaser for retention with these User Instructions.

10 OTHER RELEVANT DOCUMENTATION AND MANUALS

10.1 Supplementary User Instructions

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

10.2 Change notes

If any changes, agreed with Flowserve Pump Division, are made to the product after it is supplied, a record of the details should be maintained with

these User Instructions.

10.3 Additional sources of information

The following are excellent sources for additional information on Flowserve Mark 3 pumps, and centrifugal pumps in general.

Pump Engineering Manual R.E. Syska, J.R. Birk, Flowserve Corporation, Dayton, Ohio, 1980.

Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process, ASME B73.1M The American Society of Mechanical Engineers, New York, NY.

Specification for Vertical In-Line Centrifugal Pumps for Chemical Process, ASME B73.2M The American Society of Mechanical Engineers, New York, NY.

American National Standard for Centrifugal Pumps for Nomenclature, Definitions, Design and Application (ANSI/HI 1.1-1.3) Hydraulic Institute, 9 Sylvan Way, Parsippany, New Jersey 07054-3802.

American National Standard for Vertical Pumps for Nomenclature, Definitions, Design and Application (ANSI/HI 2.1-2.3) Hydraulic Institute, 9 Sylvan Way, Parsippany, New Jersey 07054-3802.

American National Standard for Centrifugal Pumps for Installation, Operation, and Maintenance (ANSI/HI 1.4) Hydraulic Institute, 9 Sylvan Way, Parsippany, New Jersey 07054-3802.

Durco ESP3 Sales Bulletin (PS-10-24d) Durco ESP3 Maintenance Checklist (FPD-1430) Durco ESP3 PRM (FPD-1433) RESP73H Application of ASME B73.1M-1991,

Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process, Process Industries Practices

Construction Industry Institute, The University of Texas at Austin, 3208 Red River Street, Suite 300, Austin, Texas 78705.

Pump Handbook 3nd edition, Igor J. Karassik et al, McGraw-Hill, Inc., New York, NY, 2000.

Centrifugal Pump Sourcebook 2nd edition, John W. Dufour and William E. Nelson, McGraw-Hill Professional, Inc., New York, NY, 1992.

Pumping Manual, 9th edition T.C. Dickenson, Elsevier Advanced Technology, Kidlington, United Kingdom, 1995.

Page 62

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NOTES:

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

Page 63

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

Your Flowserve factory contacts:

Flowserve Pump Division 3900 Cook Boulevard Chesapeake, VA 23323-1626 USA

Telephone +1 757 485 8000 Fax +1 757 485 8149

Flowserve Pumps Limited PO Box 17, Newark, Notts NG 24 3BU United Kingdom

Telephone (24 hours) +44 (0)1636 494 600 Sales & Admin Fax +44 (0)1636 705 991 Repair & Service Fax +44 (0)1636 494 833 E-mail inewark@flowserve.com

Your local Flowserve representative:

To find your local Flowserve representative please use the Sales Support Locator System found at www.flowserve.com

FLOWSERVE REGIONAL SALES OFFICES:

USA and Canada

Flowserve Corporation 5215 North O’Connor Blvd., Suite 2300 Irving, Texas 75039-5421 USA Telephone +1 972 443 6500 Fax +1 972 443 6800

Europe, Middle East, Africa

Flowserve FSG – Italy Worthing S.r.l. Via Rossini 90/92 20033 Desio (Milan), Italy Telephone +39 0362 6121 Fax +39 0362 628 882

Latin America and Caribbean

Flowserve Corporation 6840 Wynnwood Lane Houston, Texas 77008 USA Telephone +1 713 803 4434 Fax +1 713 803 4497

Asia Pacific

Flowserve Pte. Ltd 10 Tuas Loop Singapore 637345 Telephone +65 6771 0600 Telefax +65 6862 2329

Flowserve ESP3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual