Flowserve ESP3 User Manual

USER INSTRUCTIONS

ESP3 Vertical Immersion Sump Pump	Installation
	Operation
Mark 3 Standard, Lo-Flo and Recessed Impeller Hydraulics	Maintenance
PCN=26999943 – 08-11 (E)
Original Instructions

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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
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

		Page
6 MAINTENANCE ...................................................		37
6.1	Maintenance schedule...................................	37
6.2	Spare parts.....................................................	38
6.3	Recommended spares and consumable items
	.......................................................................	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
7 FAULTS; CAUSES AND REMEDIES ..................		51
8 PARTS LIST AND DRAWINGS ...........................		53
8.1	General arrangement drawing.......................	62
9 CERTIFICATION..................................................		62
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ...........................................................		62
10.1 Supplementary User Instructions ................		62
10.2 Change notes ..............................................		62
10.3 Additional sources of information ................		62

Page 2 of 64

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.

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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

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

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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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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.

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

This sign is not a safety symbol but indicates an important instruction in the assembly process.

1.6.2 Personnel qualification and training

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

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

1.6.3 Safety action

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

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

DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP

The appropriate safety precautions should be taken where the pumped liquids are hazardous.

FLUOROELASTOMERS (When fitted.) When a pump has experienced temperatures over 250 ºC (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this condition these are extremely dangerous and skin contact must be avoided.

HANDLING COMPONENTS

Many precision parts have sharp corners and the wearing of appropriate safety gloves and equipment is required when handling these components. To lift heavy pieces above 25 kg (55 lb) use a crane appropriate for the mass and in accordance with current local regulations.

NEVER OPERATE THE PUMP WITHOUT THE COUPLING GUARD AND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED

GUARDS MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL

THERMAL SHOCK

Rapid changes in the temperature of the liquid within the pump can cause thermal shock, which can result in damage or breakage of components and should be avoided.

NEVER APPLY HEAT TO REMOVE 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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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

1.6.4.2 Marking

Maximum permitted liquid temperature for pumps

An example of ATEX equipment marking is shown

Temperature

Maximum

Temperature limit of liquid

below. The actual classification of the pump will be

surface

handled (* depending on

class to

temperature

material and construction

engraved on the nameplate.

EN 13463-1

permitted

variant – check which is lower)

T6

85 °C (185 °F)

Consult Flowserve

II 2 GD c IIC 135ºC (T4)

T5

100 °C (212 °F)

Consult Flowserve

T4

135 °C (275 °F)

115 °C (239 °F) *

Equipment Group

T3

200 °C (392 °F)

180 °C (356 °F) *

T2

300 °C (572 °F)

275 °C (527 °F) *

I = Mining

T1

450 °C (842 °F)

400 °C (752 °F) *

* The table only takes the ATEX temperature class into consideration.

II = Non-mining

Pump design or material, as well as component design or material,

Category

may further limit the maximum working temperature of the liquid.

2 or M2 = High level protection

The temperature rise at the seals and bearings and due

3 = normal level of protection

to the minimum permitted flow rate is taken into account

Gas and/or dust

in the temperatures stated.

G = Gas

The responsibility for compliance with the specified

D = Dust

c = Constructional safety

maximum liquid temperature is with the plant

operator.

(in accordance with En13463-5)

Gas Group

Temperature classification “Tx” is used when the

liquid temperature varies and the pump could be

IIA – Propane (Typical)

installed in different hazardous atmospheres. In this

IIB – Ethylene (Typical)

case the user is responsible for ensuring that the

IIC – Hydrogen (Typical)

pump surface temperature does not exceed that

Maximum surface temperature (Temperature

Class)

permitted in the particular hazardous atmosphere.

(see section 1.6.4.3)

Do not attempt to check the direction of rotation with the

1.6.4.3 Avoiding excessive surface temperatures

coupling element/pins fitted due to the risk of severe

ENSURE THE EQUIPMENT TEMPERATURE

contact between rotating and stationary components.

CLASS IS SUITABLE FOR THE HAZARD ZONE

Where there is any risk of the pump being run against a

Pump liquid temperature

closed valve generating high liquid, casing and

discharge pipe external surface temperatures, fit an

Pumps have a temperature class as stated in the ATEX

external surface temperature protection device.

Ex rating on the nameplate. These are based on a

maximum ambient temperature of 40 ºC (104 ºF); refe r

Avoid mechanical, hydraulic or electrical overload by

to Flowserve for higher ambient temperatures.

using motor overload trips, temperature monitor or a

The surface temperature on the pump is influenced by

power monitor and perform routine vibration monitoring.

the temperature of the liquid handled. The maximum

In dirty or dusty environments, make regular checks

permissible liquid temperature depends on the

and remove dirt from areas around close clearances,

temperature class and must not exceed the values in the

bearing housings and motors.

table applicable below.

1.6.4.4

Preventing the buildup of explosive

mixtures

ENSURE PUMP IS PROPERLY FILLED AND

VENTED AND DOES NOT RUN DRY

Ensure that the pump and relevant suction and discharge piping is totally filled with 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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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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

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

J218JZ250

ENSURE ALL EXTERNAL CONNECTIONS TO THE PUMP / SHAFT SEALING AND DRIVER ARE CONNECTED AND OPERATIONAL

FULLY PRIME UNIT AND SYSTEM.

DO NOT RUN UNIT DRY

FAILURE TO FOLLOW THESE PROCEEDURES MAY RESULT IN PERSONAL INJURY

AND/ OR EQUIPMENT DAMAGE

J218JZ250

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

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

CDC: 603 604 610 612 621 623 624

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 motor” noise is that typically expected from standard

and high efficiency motors when on load directly driving the pump. Note that a motor driven by an inverter may show an increased noise at some speeds.

If a pump unit only has been purchased for fitting with your own driver then the “pump only” noise levels in the table should be combined with the level for the driver obtained from the supplier. Consult Flowserve or a noise specialist if assistance is required in combining the values.

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

The values are in sound pressure level LpA at 1 m (3.3 ft) from the machine, for “free field conditions over a reflecting plane”. 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 size			Typical sound pressure level LpA at 1 m reference 20 µPa, dBA
	and speed		3 550 r/min		2 900 r/min		1 750 r/min		1 450 r/min
	kW (hp)
			Pump	Pump and	Pump	Pump and	Pump	Pump and	Pump	Pump and
			only	motor	only	motor	only	motor	only	motor
	<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)	1	1	1	1	85	87	83	85
	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.

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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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

Serial No.

Equipment No.

Purchase Order

Model

Size 2E6X4 SP-13A/12.5 RV

MDP

Material

Date DD/MMM/YY

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

Page 10 of 64

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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.

Page 11 of 64

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

Figure 3-2: Minimum continuous flow

		MCF % of BEP
Pump size
	3500/2900	1750/1450	1180/960
	r/min	r/min	r/min
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%

Figure 3-3: Alloy cross-reference chart

	Flowserve	Generic	Durco Legacy	ASTM	Material
	Material Code		Codes	Specifications	Group No.
		Designation
	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	Monel®400	DMM	A494, Gr. M35-1	3.4
	K3005	Inconel®600	DINC	A494, Gr. CY40	3.5
	K4007	Hastelloy®B	DC2	A494, Gr. N7M	3.7
	K4008	Hastelloy®C	DC3	A494, Gr. CW6M	3.8
	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.

Page 12 of 64

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

Figure 3-4 Class 150 Flanges

										Material Group No.
Temp	1.0	1.1		2.1		2.2		2.8		3.17	3.2		3.4		3.5	3.7		3.8		Ti		Cr
˚C												bar
-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
										Material Group No.
Temp	1.0	1.1		2.1		2.2		2.8		3.17		3.2		3.4	3.5	3.7		3.8		Ti		Cr
˚F												psi
-100				275		275		285		230		140		230	220	290		290		290
-20	250	285		275		275		285		230		140		230	220	290		290		290
0	250	285		275		275		285		230		140		230	220	290		290		290		183
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

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

							Material Group No.
Temp	1.0	1.1	2.1	2.2	2.8		3.17			3.2		3.4		3.5		3.7		3.8	Ti
˚C								bar
-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
							Material Group No.
Temp	1.0	1.1	2.1	2.2	2.8		3.17		3.2			3.4		3.5		3.7		3.8	Ti
˚F								psi
-100			450	450	450		350		252			350		400		450		450	450
-20	450	450	450	450	450		350		252			350		400		450		450	450
0	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
700		325	266	269								277		313		342		342	144

Page 13 of 64

						ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11
3.4.5 Minimum suction pipe submergence
The minimum submergence is shown in Figure 3-6.
Figure 3-6
Minimum submergence (meters)
Suct.								Flow (m3/hr.)
Size	6.8	11.4	20.5	45.5	79.5	136		273	341		500		568		727	1023	1250
1.5	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)
Suct.							Flow (USgpm)
Size	30	50	90	200	350	600		1200	1500		2200		2500		3200	4500	5500
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

Page 14 of 64

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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.

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

∙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).

Figure 3-7: ESP3 Bearing selection

	Bearing Material	Max Temp	Liquid Pumped	Lubricant	Shaft Material
			Most clean acids,
		177˚C	general chemicals,	External flush	Steel or SS
	Carbon		water, cleaning fluids,	Product Lube	Steel or SS
		350˚F
			gasoline, kerosene, jet
			fuels
		82˚C	Water and compatible	External flush	Steel only
	Bronze			Product Lube	Steel only
		180˚F	liquids
				Grease Lube	Steel only
		82˚C	Water and compatible	External flush	Steel
	Cast Iron		liquids including alkaline	Product Lube	Steel
		180˚F
			caustics	Grease Lube	Steel
		71˚C	General abrasive liquids	External flush	SS only
	Rubber			Product Lube	SS only
		160˚F	compatible with rubber
		177˚C	Clean acids not	External flush	SS only
	Teflon	350˚F		Product Lube	SS only
			compatible with carbon
		Liquid Lube
		82˚C	Clean acids not
	Teflon	180˚F		Grease	SS only
			compatible with carbon
		Grease Lube
		149˚C	Dirty acids not	External flush	SS only
	Viton		compatible with carbon	Product Lube	SS only
		300˚F
			or rubber
		121˚C	Dirty acids, hot water	External flush	SS only
	ARHT	250˚F	and chemicals	Product Lube	SS only
		Liquid Lube	compatible with PEEK
		82˚C	Dirty acids and
	ARHT	180˚F	chemicals compatible	Grease	SS only
		Grease Lube	with PEEK

Page 15 of 64

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

Figure 3-8: Engineering information

	Pump Group Size	GP1 – 1E	GP2 – 2E	GP3 – 3E
	Ball Bearing Size	7308	7310	7313
	1st Critical Speed @ 3550 span	6000	5555	n.a.
	1st Critical Speed @ 1750 span	2344	2469	2833
	1st Critical Speed @ 1180 span	2344	2469	2833
	Std. Bearing Span @ 3550 rpm	760 mm (30 in.)	915 mm (36 in.)	n.a.
	Std, Bearing Span @ 1750 rpm	1220 mm (48 in.)	1220 mm (48 in.)	1520 mm (60 in.)
	Standard Bearing Span @	1220 mm (48 in.)	1220 mm (48 in.)	1520 mm (60 in.)
	1180 rpm
	Shaft Diameter @ Sleeve	28.58 mm (1.125 in.)	38.10 mm (1.500 in.)	53.98 mm (2.125 in.)
	Bearing
	Shaft Diameter @ Stuffing Box	28.58 mm (1.125 in.)	38.10 mm (1.500 in.)	47.63 mm (1.875 in.)
	Shaft Diameter @ Coupling	25.4 mm (1.000 in.)	34.93 mm (1.375 in.)	41.28 mm (1.625 in.)
	Keyway Size mm (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)
	Nominal Impeller Clearance	.46 mm (0.018 in.)	.46 mm (0.018 in.)	.64 mm (0.025 in.)
	Corrosion Allowance	3.2 mm (0.125 in.)	3.2 mm (0.125 in.)	3.2 mm (0.125 in.)
	Minimum Pit Depth	.61 m (2.0 ft)	.61 m (2.0 ft)	.91 m (3.0 ft)
	Maximum Pit Depth	6.10m (20.0 ft)	6.10 m (20.0 ft)	6.10 m (20.0 ft)

Page 16 of 64

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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.

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.

1 _________		__________
2	_________	__________
3	_________	__________
4	_________	__________
5	_________	__________
6	_________	__________
7	_________	__________
8	_________	__________
9	_________	__________
10 _________		__________
11 _________		__________
12 _________		__________
13 _________		__________
14 _________		__________
15 _________		__________
16 _________		__________
17 _________		__________
18 _________		__________
19 _________		__________

Page 17 of 64

ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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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ESP3 USER INSTRUCTIONS ENGLISH 26999943 08-11

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

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

4.7.3 Discharge piping

Figure 4-1

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.

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.

GATE

VALVE

CHECK

VALVE

CONCENTRIC INCREASER

PUMP. DISCHARGE

MOUNTING, PLATE

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