Flowserve ESP3 User Manual

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

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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

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

1.5 Duty conditions

This product has been selected to meet the
specifications of your 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

Page 6

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.

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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.

Page 12

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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

Page 14

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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

Teflon

Viton

ARHT

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

Water and compatible

liquids including alkaline

General abrasive liquids

compatible with rubber

compatible with carbon

compatible with carbon

compatible with carbon

Dirty acids, hot water

compatible with PEEK

chemicals compatible

fuels

liquids

caustics

Clean acids not

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

SS only
SS only

SS only
SS only

SS only
SS only

Page 15

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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_________ __________

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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

Page 18

of 64

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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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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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