Flowserve FM Centrifugal Pump PCN=71576526, 71576526 User Instructions

USER INSTRUCTIONS

FM centrifugal pump

Multi-stage, centrifugal close-coupled pump with an axial
suction and a vertical axis discharge

PCN=71576526 – 03/07 (E)

Installation

Operation

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 2of 32 flowserve.com

CONTENTS

Page

1 INTRODUCTION AND SAFETY ......................... 4

1.1 General.......................................................4

1.2 CE marking and approvals........................... 4

1.3 Disclaimer.................................................... 4

1.4 Copyright..................................................... 4

1.5 Duty conditions............................................ 4

1.6 Safety.......................................................... 5

1.7 Nameplate and safety labels........................ 8

1.8 Specific machine performance..................... 8

1.9 Noise level................................................... 9

2 TRANSPORT AND STORAGE......................... 10

2.1 Consignment receipt and unpacking .......... 10

2.2 Handling.................................................... 10

2.3 Lifting......................................................... 11

2.4 Storage...................................................... 11

2.5 Recyclingand endof product life ............... 11

3 PUMP DESCRIPTION ...................................... 11

3.1 Descriptionand restrictions of use ............. 11

3.2 Nomenclature............................................ 12

3.3 Coveragecharts........................................ 13

4 INSTALLATION................................................. 15

4.1 Location..................................................... 15

4.2 Foundation ................................................ 15

4.3 Piping........................................................ 15

4.4 Electrical connections ................................ 17

4.5 Protection systems.................................... 18

5 COMMISSIONING START-UP, OPERATION AND

SHUTDOWN....................................................... 18

5.1 Direction of rotation.................................... 18

5.2 Guarding.................................................... 18

5.3 Priming and auxiliary supplies.................... 18

5.4 Starting the pump....................................... 19

5.5 Running the pump ..................................... 19

5.6 Stopping and shutdown ............................. 21

5.7 Hydraulic, mechanical andelectrical duty... 22

5.8 Pumps for Food Use or Potable Water....... 22

Page

6 MAINTENANCE................................................ 22

6.1 General..................................................... 22

6.2 Maintenance schedule............................... 23

6.3 Spare parts................................................ 25

6.4 Recommended spares............................... 25

6.5 Disassembly.............................................. 25

7 FAULTS; CAUSES AND REMEDIES................. 27

8 PARTS LIST AND DRAWINGS......................... 28

8.1 Sectional drawing ...................................... 28

8.2 Sectional drawing parts list........................ 29

8.3 General arrangement drawing.................... 29

9 CERTIFICATION.............................................. 29

10 OTHER RELEVANTDOCUMENTATION AND

MANUALS ........................................................... 29

10.1 Supplementary User Instructions manuals29

10.2 Change notes .......................................... 29

10.3 Additional sources of information.............. 29

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 3 of 32 flowserve.com

INDEX

Page

Additional sources (10.3) .....................................29

ATEX marking (1.6.4.2)..........................................7

CE marking andapprovals (1.2).............................4

Certification (9)....................................................29

Change notes (10.2)............................................29

Cleaning prior to operation (5.8.1)........................22

Commissioning, start-up, operation (5).................18

Compliance, ATEX (1.6.4.1)...................................6

Configurations (3.1) .............................................11

Copyright (1.4).......................................................4

Coverage charts (3.3)..........................................13

Direction of rotation (5.1)......................................18

Disassembly (6.5)................................................25

Discharge piping(4.3.3) ......................................16

Disclaimer (1.3)......................................................4

Dismantling (see 6.5, Disassembly) .....................25

Drawings (8.1).....................................................28

Duty conditions (1.5)..............................................4

Electrical connections (4.4)..................................17

Electrical supply (4.4.2)........................................17

End of product life (2.5)........................................11

Faults; causes and remedies (7)..........................27

Final checks (4.3.4)..............................................17

First pump start up (5.4.2) ...................................19

Foundation (4.2)..................................................15

Forces andmoments (see 4.3.1)..........................16

General arrangement drawing (8.3)......................29

Gland packing (6.2.5)...........................................24

Guarding (5.2)......................................................18

Handling (2.2)......................................................10

Hydraulic, mechanical and electrical duty (5.7).....22

Inspection (6.2.2and 6.2.3)..................................24

Installation (4)......................................................15

Internal coating (6.2.6).........................................25

Lifting (2.3)...........................................................11

Location (4.1).......................................................15

Maintenance (6)...................................................22

Maintenance schedule (6.2).................................23

Mechanical seal (6.2.4)........................................24

Nomenclature (3.2) ..............................................12

Nameplate (1.7.1)..................................................8

Operating limits (see3.1) .....................................12

Orderingspare parts (6.3.1).................................25

Parts lists (8.2).....................................................29

Piping (4.3)..........................................................15

Protection systems (4.5)......................................18

Pump masses (2.2.2)...........................................10

Receipt and unpacking (2.1) ................................10

Recommended spares (6.4).................................25

Recycling (2.5).....................................................11

Replacement parts (see 6.3 and 6.4)....................25

Running the pump (5.5) .......................................19

Safety action (1.6.3)...............................................5

Safety labels (1.7.2)...............................................8

Safety markings (1.6.1)..........................................5

Safety, protectionsystems (see 1.6 and4.8)

Page

Sectional drawings (8.1) ......................................28

Sound level (see 1.9, Noise level)..........................9

Sources, additional information (10.3)..................29

Spare parts (6.3)..................................................25

Specific machine performance (1.8).......................8

Standard maintenance (6.2.1) .............................23

Starting the pump (5.4)........................................19

Stop/start frequency (5.5.6)..................................21

Stoppingand shutdown (5.6) ............................... 21

Storage, pump (2.4).............................................11

Storage, spare parts (6.3.2) .................................25

Suction piping (4.3.2)...........................................16

Supplementary manuals or information sources...29

Transport and storage (2) ...................................10

Trouble-shooting (see 7)...................................... 27

Vibration (5.5.5)...................................................21

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 4 of 32 flowserve.com

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 service for any further
information about the product in its installationand
operation or about its support products, repair and
diagnostic services.

These instructionsare intendedto facilitate
familiarization with the product andits permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service andavoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installingthe product. Always coordinate repair
activity with operations personnel, and follow all
plant safety requirements andapplicable safety and
health laws and 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.

1.2 CE marking and approvals

It is a legal requirement that machinery and
equipment put into service withincertain regionsof
the worldshall conformwith the applicable CE
MarkingDirectives coveringMachinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED) andEquipment for Potentially Explosive
Atmospheres (ATEX).

Where applicabletheDirectives andany additional
Approvals cover importantsafety aspectsrelating to
machinery andequipment and the satisfactory
provision oftechnicaldocuments andsafety
instructions. Where applicablethis document
incorporatesinformationrelevanttotheseDirectives
and Approvals.

To confirm the Approvalsapplyingandifthe productis
CE marked,checktheserial number plate markings
andthe Certification. (Seesection 9, Certification.)

1.3 Disclaimer

Information in these UserInstructions is believed
to be reliable.In spiteof all the efforts of Flowserve
Corporation to provide soundandall necessary
information the content of thismanualmayappear
insufficientandis not guaranteed by Flowserveas
to its completenessor accuracy.

Flowserve manufactures productstoexacting
InternationalQualityManagementSystem Standards
as certifiedandaudited by externalQuality Assurance
organizations. Genuine partsand accessories have
beendesigned,tested andincorporated into the
productsto helpensure theircontinuedproduct quality
and performancein use. As Flowservecannot test
parts andaccessoriessourced fromothervendorsthe
incorrect incorporationofsuch partsandaccessories
may adverselyaffect the performanceandsafety
featuresof the products. Thefailureto properlyselect,
installor use authorized Flowserve partsand
accessoriesisconsideredto be misuse. Damage or
failurecausedby misuse is notcovered by the
Flowserve warranty. In addition,any modificationof
Flowserve productsor removal of originalcomponents
may impairthesafety of these products intheir 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 shouldbe kept
with these instructions.

The productmust not be operatedbeyond
the parameters specified for the application. If
there is anydoubt 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,
temperature or duty) it is requested that the user
seeks the written agreement of Flowserve before
start up.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 5 of 32 flowserve.com

1.6 Safety

1.6.1 Summary of safety markings

These UserInstructions containspecific safety
markings where non-observance of aninstruction
wouldcause hazards. Thespecific safety markings
are:

This symbol indicates electricalsafety
instructions where non-compliance will involve a
highrisk 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 substances
and toxicfluid”safety instructions where non­compliance would affect personalsafety andcould
result in loss of life.

This symbol indicates safety
instructions where non-compliance willinvolve some
risk to safe operationand personalsafety andwould
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 cloth is damp. It is usedwhere non­compliance in the hazardous area would cause the
risk of an explosion.

Thissign is not a safetysymbol butindicates

an importantinstructionin 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 andskill, 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
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

GUARDS MUST NOT BE REMOVED WHILE

THE PUMP IS OPERATIONAL

DRAIN THE PUMPAND ISOLATE
PIPEWORK BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.

FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482ºF), 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 havesharp corners and the
wearing of appropriate safety gloves andequipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass andin accordance with
current local regulations.

THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pumpcan cause thermal shock, which can result
in damage or breakage ofcomponents and should
be avoided.

NEVERAPPLY HEATTO REMOVE
IMPELLER
Trapped lubricant or vapor could causean explosion.

HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present adanger to operators and
persons enteringthe immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those enteringthe
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.

If the temperature is greater than 68 °C (175 °F)
or below 5 °C (20 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 6 of 32 flowserve.com

HAZARDOUS LIQUIDS
Whenthepump is handlinghazardous liquidscare
must be takento avoidexposure to the liquid by
appropriatesittingof the pump, limitingpersonnel
access and byoperatortraining.Ifthe liquid is
flammable and/orexplosive, strictsafety procedures
must be applied.

Gland packingmust not be used when pumping
hazardous liquids.

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

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

STARTTHE PUMP WITHOUTLET
VALVE PARTOPENED
(Unless otherwise instructed at a specificpoint in the
User Instructions.)

This is recommended to minimize the risk of
overloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve
further open only on installations wherethis situation
cannot occur. Pumpoutlet valve shall may need to
be adjusted to comply with the duty followingthe
run-up process. (Seesection 5, Commissioning
start-up, operation and shutdown.)

NEVER RUN THE PUMP DRY

INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pumpat zeroflow or below the
recommended minimumflow continuously willcause
damage to theseal.

DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normalor at a
flow rate with no backpressure on the pump may
overload the motor and cause cavitation. Low flow
rates may cause a reduction in pump/bearing life,
overheating of the pump, instability and
cavitation/vibration.

1.6.4 Productsused in potentially explosive
atmospheres

The following instructionsfor pumps andpump
units when installedin potentiallyexplosive
atmospheres must be followed to help ensure
explosionprotection.

The terminology and procedures ensure that the
installed pump is in compliance with the European
Directive 94/9/EC, knownasthe ATEXDirective, which
is mandatory in Europe andmay also be specified in
other countries.Where applicable, bothelectricaland
non-electrical equipment must meet the requirements
94/9/EC.

Evenif theinstallationis ina region where ATEXis not
theapplicable regulation, the generalmeasures
described shall be followedtoensure safeoperation.

The measures are explained under the headings of:

 Avoiding excessive surface temperature
 Preventing build up of explosive mixtures
 Preventing the generation of sparks
 Preventing leakages
 Maintaining the pump to avoid hazard

1.6.4.1 Scope of compliance

Use equipmentonly inthezone for whichitis
appropriate. Alwayscheckthat the driver,drive
couplingassembly, seal and pump equipmentare
suitably ratedand/orcertifiedfor theclassification of
thespecificatmospherein which they areto be
installed.

WhereFlowserve hassupplied only the bareshaft
pump, the Ex rating applies only to the pump. The
partyresponsible for assembling the pump setshall
selectthe coupling, driver andany additional
equipment, with the necessary CE Declaration of
Conformity establishing it issuitablefor the area in
whichit is to be installed.

The output froma variable frequency drive (VFD)can
cause additional heatingaffectsin the motor andso, for
pumps sets with a VFD, the ATEXCertificationforthe
motor muststatethatit is coversthesituationwhere
electricalsupply isfromthe VFD. This particular
requirementstillapplies evenif the VFD is ina safe
area.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 7 of 32 flowserve.com

1.6.4.2 Marking

Anexample of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.

II 2 GD c IIC 135 ºC (T4)

Equipment Group
I = Mining
II = Non-mining

Category
2 or M2 = High level protection
3 = normal levelof protection

Gas and/or Dust
G = Gas; D=Dust

c = Constructionalsafety

(in accordance withEN 13463-5)

Gas Group (Equipment Category 2 only)
IIA –Propane (typical)
IIB –Ethylene (typical)
IIC – Hydrogen(typical)

Maximum surface temperature(TemperatureClass)
(seesection 1.6.4.3)

1.6.4.3 Avoiding excessive surface temperatures

ENSURE THE EQUIPMENT TEMPERATURE

CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the

ATEX Ex rating on the nameplate. These are based
on a maximumambient of 40 °C (104 °F); 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 that follows.

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

Temperature

classto

EN13463-1

Maximum

surface

temperature

permitted

Temperature limit of liquid

handled (* depending on

material and construction

variant- check which is

lower)

T6
T5
T4
T3
T2
T1

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

Consult Flowserve
Consult Flowserve

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

The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.

Temperature classification “Tx” is used when the
liquid temperature varies and the pumpcould 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.

If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a hightemperature resulting from
contact between rotating and stationary
components. Furthermore, confinement of liquid in
the pumpand pipes must be avoided (valve closed).
If the liquid heats up this may cause excessive
pressure andlead to bursting of pump components.

Wherethere is anyrisk of the pump being runagainst
a closed valve generating high liquid and casing
externalsurface temperatures it is recommended that
users fit anexternalsurface temperature protection
device.

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

In dirty or dusty environments, regular checks must
be made and dirt removed fromareas around close
clearances, bearinghousings and motors.

1.6.4.4 Preventing the build up of explosive
mixtures

ENSURE PUMP IS PROPERLY FILLED AND

VENTED AND DOES NOT RUN DRY.
Ensure pump and relevant suction and discharge

pipeline systemis totally filledwith liquid at all times
during the pump 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.

If the operation of thesystem cannot avoid this
condition the fitting of an appropriate dry run
protection device is recommended (eg liquid
detection or power monitor).

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

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 8 of 32 flowserve.com

1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking.
To avoid the potential hazard from random induced
current generating a spark the ground contact on the
baseplate must be used.

Avoid electrostatic charge: do not rub non­metallic surfaces with a dry cloth, ensure cloth is
damp.
Where applicable the coupling must be selected to
comply with 94/9/EC and correct alignment must be
maintained.

Additional requirements for metallic pumps on
non-metallic baseplates

When metallic components are fitted on a non­metallic baseplate they must be individually earthed
(grounded).

1.6.4.6 Preventing leakage

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

Avoidentrapmentof liquid in the pump andassociated
pipingdue toclosingofsuction anddischargevalves,
which couldcause dangerous excessive pressuresto
occurif thereis heatinputto the liquid. Thiscanoccur
if the pump is stationary or running.

Bursting of liquid containing parts due to freezing
must be avoided by draining or protectingthe pump
and ancillary systems.

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

If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.

1.6.4.7 Maintenance to avoid the hazard

CORRECTMAINTENANCE IS REQUIRED
TO AVOID POTENTIAL HAZARDS WHICHGIVE 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, cleaningand painting
materials used must not give rise tosparking or
adversely affect the ambient conditions.

Where there is a risk fromsuch tools or materials;
maintenance must be conducted in a safe area.
It is recommended that a maintenance planand
schedule is adopted. (See section 6, Maintenance.)

1.7 Nameplate and safety labels

1.7.1 Nameplate

For details of nameplate, see the Declaration of
Conformity, orseparate documentation included with

these User Instructions.

1.7.2 Safety labels

Oil lubricated units only:

1.8 Specific machine performance

For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies

these to be incorporated into User Instructions these
are included here. Where performance data has
been supplied separately to the purchaser these
should be obtained and retained with these User
Instructions if required.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 9 of 32 flowserve.com

1.9 Noise level

Attention must be given to theexposure 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 cantake the
appropriate action in your plant.

Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBAtolerance and
cannot be guaranteed.

Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected fromstandard
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 “pumponly” noise
levels in the table should be combined with the level
for the driver obtained from the supplier. Consult
Flowserve or anoise specialist if assistance is
required in combining the values.

It is recommended that where exposure approaches
the prescribedlimit, thensite noise measurements
should be made.

The values are in sound pressure level LpAat 1 m
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.

For estimating sound power level LWA (re1 pW)
then add 17 dBA to the soundpressure value.

TypicalsoundpressurelevelLpAat1 m reference 20 μPa, dBA

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

Motor size
and speed

kW (hp)

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

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)     85 87 83 85
300 (400) 87 90 85 86

 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/minreduce 1 450 r/min values by 2dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 10 of 32 flowserve.com

In areas where the staff has to intervene, remember
that whenthe level of thesound pressure is:
 below 70 dBA: it is not necessary to take special

precautions.

 above 70 dBA: people working continuously in

the machine room must be supplied with
protective devicesagainst noise.

 below 85 dBA: no particular measures need to

be taken for casual visitors stayingin the room
during a limited period.

 above 85 dBA: the room must be considered as

a dangerous area because of the noise and a
warning sign must be fixed at each entry
warning the people cominginto the room, even
for a short period, thatthey must wear hearing
protection.

 above 105 dBA: special hearing protection

adapted to this noise level and to the spectral
noise components must be installed and a
warning sign to this effect erected at each entry.
The staff in the room must wear ear protection.

Make sure that the noise, which travels through the
walls andwindows, does not generate too high
noise levels in the machine room's surroundings.

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of theequipment it must be
checked against the delivery and shipping
documents forits completeness and that there has
been no damage in transportation.

Any shortage and or damage must be reported
immediately to the Flowserve and received in writing
within one month of receiptof the equipment. Later
claims cannot be accepted.
Check any crates, boxes andwrappings for any
accessories or spare parts which may be packed
separately withthe equipment or attached to side
walls of the box orequipment.

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

2.2 Handling

2.2.1 General instructions concerning handling

Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size andconstruction. See 2.3.1 for positioningof
slings.

To lift heavy pieces above 25 kg (55 lb), use a winch
adapted to the mass and in accordance with the
current local regulations.

To lift machines or pieces with oneor several
suspension rings, only use hooks and chains in
compliance with the local regulations concerning
safety.

Never put cables, chains orropes directly on orin
the suspension rings. Cables, chains or liftingropes
must never present excessive bending.

Never bendthe lifting hooks, suspension rings,
chains, etc... which should only be made to endure
stresses within calculated limits. Remember that the
capacity of a lifting device decreases when the
direction of thelifting force direction makes an angle
with the device axis.

To increase the safety andthe efficiency of the lifting
device, allthe lifting elements must be as
perpendicular as possible. If necessary a lifting
beam can be placed between the winch and the
load.

When heavy pieces are lifted up, never stay or work
under the load or in the area which could be in the
path of the load if it were to swingor fall away.

Never leave aload hanging froma winch. The
acceleration or the slowing-down of lifting equipment
must stay in the safety limits for the staff.

A winch must be positioned in such a way that the
load will be raised perpendicularly. Where possible
necessary precautionsmust be taken to avoid the
swing of the load, usingfor example two winches
making approximately the same angle, below 30°,
with the vertical.

2.2.2 Pump masses

Unit Mass

FM

Motor Mass

Pump type

kg lb kg lb

50 FM 2E 51 112 16 35
50 FM 3E 61 134 21 46
50 FM 2L 57 126 21 46
50 FM 3L 63 139 26 57
50 FM 4L 77 170 36 79
50 FM 5L 107 236 43 95
65 FM 2aE 77 170 36 79
65 FM 2cE 85 187 43 95
65FM 3bE 120 265 63 139
65 FM 3cE 120 265 63 139
65 FM 4cE 155 342 72 159
65 FM 1cL 60 132 26 57
65 FM 2aL 77 170 36 79
65 FM 2cL 85 187 43 95
65 FM 3bL 120 265 63 139
65 FM 3cL 120 265 63 139
65 FM 4cL 155 342 72 159

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 11 of 32 flowserve.com

All motors (for masses see the motor

description plate) must be handled with a winch.

For masses above 25 kg(55 lb), manual

handling is forbidden.

2.3 Lifting

2.3.1 Slinging ofmotor pumpsunits

Use handling means in accordance with motor
pump unit mass mentioned on the CE plate. For the
masses of the pumps bare end of shaftsee table §

2.2.2 and nameplate.

To avoid distortion, lift up motor

pump unit as shown:

Motor pump unit

When handling always wear gloves, safety
boots andan industrial safety helmet.

For masses above 25 kg(55 lb), manual
handling is forbidden.

2.4 Storage

Store the pumpin a clean, dry
location away from vibration. Leave piping
connection coversin place to keep dirt and other
foreign material out of pump casing. Turn pump at
intervals to prevent brinelling of the bearings and the
seal faces, if fitted, fromsticking.

Do not storepumps starting on the fan guard.
The pump may be stored as above for up to 6

months. Consult Flowserve for preservative actions
when a longer storage periodis needed.

2.5 Recycling and end of product life

At the end of the service life of the productor its parts,
the relevant materials and partsshouldbe recycled or
disposed of using anenvironmentally acceptable
method and local regulations.

If the productcontainssubstances whichare harmful
to theenvironment, theseshouldbe removedand
disposed ofin accordance with current regulations.
This also includes theliquidsand or gases inthe
"sealsystem"or other utilities.

Makesure that hazardous substancesor toxic
fluids are disposed of safely and that the correct
personal protective equipment is used. The safety
specifications must bein accordancewith the current
regulations at alltimes.

3 PUMP DESCRIPTION

3.1 Description and restrictions of use

The multi-stage centrifugal pumpis designed for the
pumping of cold water or allclear liquids which are
not solid and liquid mixtures, non-corrosive, non­abrasive or non-explosive when in contact with the
pump motor unit and its working parts (Important: for
other liquids consult Flowserve for beforehand
advice).

The FM type is acentrifugal, multi-stage, close­coupled pump with an axial inlet anda vertical axis
outlet.

The pump must be stored in a non explosive,
ventilated location, sheltered frombad weather, dust
and vibrations.

The reliability of the delivered machine can only be
ensured if it is used accordingto the conditions
given in this manual. The maximum values specified
in this manual must never be exceeded.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 12 of 32 flowserve.com

 Maximumworking pressure at discharge

.................................................25 bar (363 psi)

 Maximumworking pressure at suction

.................................................16 bar (232 psi)

 Maximum pumped fluid temperature

(1)

105 °C (221 °F): Impeller and diffuser Cast iron
or Bronze

 Minimum pumped fluid temperature

.................................................-10 °C (14 °F)

 Maximumambient temperature

.................................................40 °C (104 °F)

 Maximumsolid suspension

....................................50 g/m3(0.003 lbm/ft

3

)

 Density............................... 1

 Viscosity............................. 1 mm2/s (31 SSU)

 Frequency.............................................50 Hz

 Maximumrotation speed ....................... 2850

min

-1

(1)

If mechanical seal: maximum temperature 80 °C

(176 °F)

The maximum speed is shown on the

pump nameplate.

3.2 Nomenclature

Characteristics shown on the nameplate fixed on the pumpare as shown below:
Each pump is supplied with the following nameplate:

Each pump unit is supplied with the following nameplate:

Mass of theset

Pump type

Speed of rotation

Flowrate

Year of construction +
Manufacture number

Head

Radial/thrust bearing

Mass
Maximum admissible

Pressure at 20 °C (68 °F)
Maximum / minimum

temperature

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 13 of 32 flowserve.com

3.3 Coverage charts

3.3.1 2850 min-1(50 Hz): Operating ranges (Q,H)

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 14 of 32 flowserve.com

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 15 of 32 flowserve.com

4 INSTALLATION

Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in

potentially explosive atmospheres.

All equipment must be grounded.

4.1 Location

The pump should be located to allow room for
access, ventilation, maintenance andinspection with
ample headroom for liftingand should be as close
as practicable to the supply of liquid to be pumped.

4.2 Foundation

There are many methods of installing
pump units to their foundations. The correct method
depends on the size of the pump unit, its location
and noise vibration limitations. Non-compliance with
the provision of correct foundation and installation
may lead to failure of the pumpand as such would
be outside the terms of the warranty.
Anchor bolts must be appropriate for the foot bolt
holes. Use anchor bolts of accepted standards and
sufficient length so that they may beclamped safely
in the grout.

NFE 27 811

Provide sufficient space in the foundation to
accommodate the anchor bolts. If necessary, provide
concrete gullets.

a) Levellingon the suction flange with a frame level

or on the discharge flange with a levelling
instrument.

b) Admissible defect 0.5 mmfor 1 meter (0.02 in

for 3.3 ft).

c) Wedge under the pump.

Level

Frame
level

4.3 Piping

The user must verify that the equipment is

isolated fromany external sources of vibration.

Protective coversare fitted tothe
pipe connections to prevent foreign bodies entering
during transportation and installation. Ensure that
these covers are removed from the pump before
connecting any pipes.

4.3.1 Suction and discharge piping

The dimensions of the pipes do not directly depend
on suction and discharge diameters of the pump:
a) First, choose a flow speed <2 m/s (7 ft/s) at

suction, andabout 3 m/s (10 ft/s) at discharge.

b) Take into account the available NPSH, which

must be superior to the required NPSH of the
pump.

Never use pump as a support for

piping.

Do not mount expansion joints in
such a way that their force, due to internalpressure,
may act on the pump flange.

Maximumforces and moments allowed on the pump
flanges vary with the pumpsize andtype. These
external strains may cause misalignment, heating of
the bearings, vibrations andthe possible failure of
the pumpcasing.

When designing the pipework (§ 5.3.1, § 5.3.2, §

5.3.3) take necessary precautions in order notto
exceed maximum allowed strains.

Forces andmoments applied to the pump flanges
must never exceed the values shown in the following
table:

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 16 of 32 flowserve.com

Forces

daN (lbf)

Moments

m.daN (lbf.ft)

DN

F

Y

F

Z

F

X F

M

Y

M

Z

M

X M

40

(1"1/2)

30

(67)

40

(90)

35

(79)

60

(135)

23

(170)

27

(199)

34

(251)

49

(361)

Vertical pipework

perpendicular to

the shaft

50

(2")

40

(90)

50

(112)

45

(101)

80

(180)

27

(199)

30

(221)

37

(273)

54

(398)

50

(2")

45

(101)

40

(90)

50

(112)

80

(180)

27

(199)

30

(221)

37

(273)

54

(398)

Axial pipework

parallel to the

axis

65

(2"1/2)58(130)

50

(112)

68

(153)

102

(229)

30

(221)

33

(243)

40

(295)

60

(443)

Forces and moments values are applied to the
whole flanges and not flange by flange.

Ensure piping and fittings are flushed

before use.

Ensure piping for hazardous liquids is
arranged to allow pump flushing before removal of
the pump

4.3.2 Suction piping

4.3.2.1 Design of a flooded suction line

The suction line must be as shortand direct as
possible, never mount an elbow directly on the inlet
flange of the pump.

Valve

Non-return valve

Motor

FM

Flooded suction pump

a) Avoid sharp elbows or sudden narrowing. Use

convergent 20° (total angle).

b) Arrange the pipingso that there are noair

pockets (no bulges).

c) If high points cannot be avoided in suction line,

provide themwith air reliefcocks.

d) If a strainer is necessary, its netarea shouldbe

three or four times the area of the suction pipe.

e) If an inlet valve is necessary, choose a model

with direct crossing.

Do not tighten flanges before the final

check (see § 4.3.4).

4.3.2.2 Design of a suction lift line

The inlet pipe must be as shortand as directas
possible, never place an elbow directly on the pump
inlet nozzle.

Valve

Non-return valve

Motor

FM

Sufficient
immersion: I

I 3x D

Sump suction configuration

a) Avoid sharp elbows or sudden narrowing. Use

convergent 20° (total angle) with upright
generating.

b) Arrange that the suction piping is inclined

upwards towards the pump ensuring that there
are no peaks.

c) If a foot valve is necessary, do not oversize it

because it would generate pulsations (valve
beating).

Do not tighten flanges before the final

check (see § 4.3.4).

4.3.3 Discharge piping

4.3.3.1 Design of a discharge line

a) If discharge line is provided with a divergent, its
total angle will be between 7° and 12°.
b) Install the discharge valve after the non-return
valve downstream.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 17 of 32 flowserve.com

The non-return valve will be set in the discharge
pipe to protect the pump from any excessive
pressure surge and from reverse rotation.

If necessary, acontrol manometer (pressure gauge)
can be connected on the piping.

Control manometer

Setting of the controlmanometer

Do not tighten flanges before the final

check (see § 4.3.4).

Never connect the electric motor

before the setting has been completely finished.

4.3.4 Final checks

a) Check the tightening of anchor bolts. Tighten

themif necessary.

b) Check that protective covers on suctionand

discharge flanges are removed.

c) Check that holes of piping flanges are parallel

and correspond to those of the pump.
d) Tighten suction anddischarge flanges.
e) If it is planned, connect piping(hydraulic,

pneumatic, sealing system).
f) Control seal andthe working of auxiliary piping.

4.4 Electrical connections

4.4.1 Safety conditions about electrical
connections

Electric connections must be carried
out by a qualified electrician, followingthe local rules
and regulations in force.

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

Avoid mechanical, hydraulic or electrical
overload by using motor overload trips ora power
monitor and make routine vibration monitoring.

Itisimportantto be awareof the EUROPEAN
DIRECTIVE on electromagnetic compatibility when
wiringupandinstallingequipment onsite. Attention
must be paid toensurethatthetechniques used during
wiring/installation do not increase electromagnetic
emissions or decreasethe electromagnetic immunity of
theequipment, wiringoranyconnecteddevices. If in
doubt, contactFlowserve for advice.

Before connecting the electric power supply, if the
device has been kept in a dampatmosphere, have
the insulation resistance of the electric motor
checked.

This resistance should have a value of not less than
5 000 ohms for each volt of the supply.

Carry out the ground connections according to the
current local regulations.

The motor must be protected. The protection must
therefore be ensured by a magneto thermal breaker
located between the section switch and the motor.

This breaker can beconnected to fuses.
Use a breaker sized and provisionally adjusted to

the current specified on the descriptionplate.
It is recommended to provide the power supply of

the electric motor with a monitoring device allowing
the machine to be shut down safely.

A device to provide emergency stopping shall be
fitted.

4.4.2 Electrical supply

Make sure that the voltage of the electricalsupply
line is correct for that specified on the motor
description plate.

Make sure that the supply wires have sufficient load
capacity for the correct running of the installation.

4.4.3 Wiring Instructions

The motorsareclosed typeIP 55 classE - 50 Hz
 230/ 400 V upto3.7 kW -50 H:

The motorscan be directlysuppliedwith230 or
400 V accordingto the coupling(starting with
230 V is possible but notadvised)

 400 Vfrom 5.5 kW -50 Hz:

The motorscan be directlysuppliedwith400 V
(starting with400Vis possible but not

advised).Astatoric startis advised.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 18 of 32 flowserve.com

Connection wiringdiagramforthree phase motors:

Delta connection

Wire up the motor terminals according to the voltage
supply, in accordance with the description plate fixed
on the motor and with the connection wiring diagram
mentioned on the terminal boxas opposite.

To avoid any risk of jamming, the
direction of rotation will be checked after primingof
the pump(§ 5.3.1, 5.3.2) andbefore the first start (§

5.4.2).

4.5 Protection systems

The following protection systems are
recommended particularly if the pump is installed in
a potentially explosive area or is handling a
hazardous liquid. If in doubt consult Flowserve. If
there is any possibility of the systemallowing the
pump to run against a closed valve or below
minimumcontinuous safe flow a protection device
should be installed to ensure the temperature of the
liquid does not rise to an unsafe level.

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

If leakage of product fromthe pumpor its associated
sealing systemcan cause a hazard it is
recommended that an appropriate leakage detection
system is installed.

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

5.5.4 and 5.5.5.
If a defect of coolingcan lead to temperature higher

than those acceptable a systemof cooling
surveillance must be installed.

Except whenexplicitly required by the customer in
the specifications, when a possibility of reverse
rotation exists the customer must install a reverse
rotation protection device.

The customer must install all equipment required to
avoid water hammer.

5 COMMISSIONING START-UP,
OPERATION AND SHUTDOWN

These operations must only be carried out

by qualified personnel.

5.1 Direction of rotation

Starting or operating pumps with the
wrong direction of rotation can be harmful to the
pumps. Ensure that the pumprotation is the same
as the arrowon the pump casing.

It is preferable to check the direction of rotation
before installing the coupling. If not, the pump must
be filled in with the liquid before start-up.

If maintenance work has been carried
out to thesite's electricity supply, the direction of
rotation should be re-checked as above in case the
supply phasing has been altered.

5.2 Guarding

Guarding is supplied fitted to thepump set.
If this has been removed or disturbed ensure that all
the protective guards aroundthe pumpcoupling and
exposed parts of theshaft are securely fixed.

5.3 Priming and auxiliary supplies

Where there is any risk of the pump being run
against a closed valve generating high liquid and
casing externalsurface temperatures it is
recommended that users fit an externalsurface
temperature protection device.

Ensure allelectrical, hydraulic,
pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.

Ensure the inlet pipe andpump
casing are completely full of liquid before starting
continuous duty operation.

These operations must be carried out by personnel
with approved qualifications.

5.3.1 Priming of a flooded pump

a) Close the discharge valve, fill the pump by

openingthe suction valve. Let air escape by
removing the plug located on the piping.

b) The discharge pipe is headed and there is a by-

pass valve on the checkvalve, open slightly the
discharge valve and the by-pass of the check
valve.

c) When the pump is totally free ofair bubbles,

replace the plugs.

Star connection

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 19 of 32 flowserve.com

Air escape

Priming of a flooded pump

5.3.2 Priming of a sump suction pump

* With foot valve:

a) Fill suction pipe and casing with liquid froman

independent source (pressure 1 to 2 bars or 15
to 30 psi).

b) Let air escape by removing the plugs located on

the piping.

c) When the pump is totally free ofair bubbles,

replace the plugs.

Air escape

External source

Priming of a sump suction configuration

with foot valve

* Without foot valve:

Priming may be accomplished by means of venting
system.

Foot valves are not recommended when
the pumped liquid has suspended solid particles.
They may lodge between foot valve seat and
shutter.

5.4 Starting the pump

5.4.1 Bring controls and preparation before the
first starting and after each service call

Necessarily:

a) Check the tightening of the different plugs.
b) Check that the gland lightly tightens the packing

rings.

c) Risk of seal ring overheating.
d) Check the direction of rotation of the motor.

Refer to the rotation arrow of the pump.

e) DO NOTFORGET TO REMOUNT THE

SHIELD GRID ON THE MOTOR STOOL
f) Open all inlet valves (if existing).
g) Close the outlet valve and the bypass valve.
h) Ensure inlet pipe andpump casing are

completely full of liquid.

5.4.2 First pump start-up

Suction valves must be fully open
when pump is running. Never run the pump dry, it
will cause damage.

a) Start motor and check outlet pressure.
b) If pressure is satisfactory,slowly OPENthe

outlet valve.

c) Do not run the pump with the outlet valve closed

for a period longer than 30 seconds.

d) If NOpressure, or LOW pressure, STOP the

pump. Refer to fault finding chart for fault
diagnosis.

The pump should run smoothly and without
vibration.

The pump must never run at a capacity less than
10 % of the best efficiency point.

Never remove a plugwhen the pump is

running.

5.5 Running the pump

5.5.1 Venting the pump

Vent the pump to enable all trapped air to
escape takingdue care with hot or hazardous
liquids.

Under normal operating conditions, after the pump
has been fully primed and vented, it should be
unnecessary to re-vent the pump.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 20 of 32 flowserve.com

5.5.2 Pump fitted with a stuffing box

If the pump has a packed gland there must be some
leakage fromthe gland. Gland nuts should initially
be finger-tight only. Leakage should take place soon
after the stuffing box is pressurized. If no leakage
takes place the packing will begin to overheat. If
overheating takes place the pump should be
stopped andallowed to cool before being re-started.
When the pumpis re-started it should be checked to
ensure leakage is taking place at the packed gland.

When adjusting an operating stuffing box
(shield grids removed for this operation), the
operator must be very careful. Safety gloves are
compulsory and loose clothes are not allowed
(above allto the arms) to avoid being caught by the
pump shaft.

The pump should be run for ten minutes with steady
leakage andthe gland nuts tightened by 10 degrees
at a time until leakage is reduced to an acceptable
level.

The temperature of the gland should be checked
after each roundof tightening. If the temperature
starts to climbrapidly then back off the gland nuts
until the temperature drops down. Wait for the
temperature to stabilize before tighteningagain.

The leakage must not be reduced below a rate of20
drops per minute. Bedding in of the packing may
take several hours.

Shield grids being removed during installation
of the gland packing, it must be ensured that they
are replaced as soon as this operation is completed.

5.5.3 Pump fitted with a mechanical seal

A mechanical seal ensures a seal without leakage
and does not need any adjustment. Nevertheless if a
light leakage occurs during start-up, it should
disappear after the initial running in of the friction
faces.

421342002445

424

4610

With a mechanical seal, the
maximumtemperature is limited to 80 °C(176 °F)
whatever the internal construction of the pump is
(Cast iron orBronze).

NEVER RUN A MECHANICAL SEAL

DRY, EVEN FOR A SHORT WHILE.

SAFETY INSTRUCTIONS WHEN THE PUMP IS
RUNNING:

If hot or freezingcomponents of the machine
can present a danger to operators, they must be
shielded to avoid accidental contact. If a 100 %
protection is not possible, the machine access must
be confined to the maintenance staff only.

If the temperature is greater than80 °C (176
°F), a warningplate must be clearly placed on the
pump.

It is strictly forbiddento open switch
cupboards, switch boxes, or all other live electric
equipment. If it is necessary to openthem in order to
take readings, to carry out tests or adjustments for
example, only a skilled technician may do themwith
adapted tools. Make sure that physical protections
against electrical risks are used.

5.5.4 Bearings

If the pumps are working in a potentially
explosive atmosphere, temperature or vibration
monitoring at the bearings is recommended. If
bearing temperatures are to be monitored it is
essential that a benchmark temperature is recorded
at the commissioningstage and after the bearing
temperature has stabilized.
 Record the bearing temperature (t) andthe

ambient temperature (ta)

 Estimate the likely maximum ambient

temperature (tb)

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 21 of 32 flowserve.com

 Set the alarm at (t+tb-ta+5) C [(t+tb-ta+10) F]

and the trip at 100 C (212 F) for oil lubrication

and 105 C(220 F)for grease lubrication
It is important, particularly with grease lubrication, to
keep a check on bearing temperatures. After start up
the temperature rise should be gradual, reaching a
maximumafter approximately 1.5 to 2hours. This
temperature rise shouldthen remain constant or
marginally reduce with time.

5.5.5 Normalvibration levels, alarm and trip

For guidance, pumps generally fall under a
classification for rigid support machines withinthe
International rotatingmachinery standards and the
recommended maximum levels below are basedon
those standards.

Alarm and trip values for installed
pumps should be based on the actual
measurements (N) taken on site on the bearing
housings of the pump in the fully commissioned as
new condition.

The example (N) value is given for the preferred
operating flow region (typically this may extend to 70
to 120 % of the pump best efficiency point);outside
the preferred flow region the actual vibration
experienced may be multiplied by up to 2.

These standard values can vary with the rotational
speed andthe power absorbed by the pump. For
any specialcase, do not hesitate to consult us.

Measuring vibration at regular intervals will then
show any deterioration in pump or systemoperating
conditions.

Vibration Velocity-

unfiltered

HorizontalConfiguration

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

Normal N 5.6 (0.22)
Alarm N x 1.25 7.1(0.28)
Shutdown Trip N x 2.0 11.2 (0.44)

5.5.6 Stop/start frequency

Pumpsets are normally suitable for the number of
equally spaced stop/starts per hourshownin the table
below. Checkactual capability of the driver and
control/starting systembefore commissioning.

Motor rating kW (hp)

Maximum start upsper

hour

Up to 15 (20) 15

Between 15 (20) and 90 (120) 10

90 (120) to 150 (200) 6

Above 150 (200) Refer

Where dutyand standby pumps are installed itis
recommended that they arerun alternately every
week.

5.6 Stopping and shutdown

According to hydraulic conditions of
the installation and its automation degree, stop and
restart procedures can have different forms.
Nevertheless allof them must respect imperatively
the following rules:

5.6.1 Stopping < 1 hour

a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure thatthe discharge line pressure does

not reach the foot valve.

5.6.2 Stopping < 1 month

a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does

not reach the foot valve.

d) Close the outlet valve. Eventually close the inlet

valve.

e) Switch off external power supply,

flushing/quench, cooling liquid.

5.6.3 Shutdown > 1 month

a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does

not reach the foot valve.

d) Close the outlet valve. Eventually close the inlet

valve.

e) Switch off external power supply,

flushing/quench, cooling liquid.

f) Keep the pumpfully filled with water. In case of

pumped liquid other than water, drain the pump
entirely.

g) Turn once per week the pumpshaft of one or

two turns.

h) Never restart the pump without carrying out the

verifications recommended before starting (see

§ 5.4.1).

When ambient temperatures are
likely to drop below freezing point, the pump and any
cooling andflushing arrangements must be drained
or otherwise protected.

5.6.4 Restarting in continuous running

a) Ensure that the pump is completely full of liquid.
b) Ensure a continuous supply with asufficient

available NPSH.

c) Ensure a backpressure so that the motor power

is not in excess.

d) Respect the starting frequency

imposed by the motor manufacturer.

e) Protect the pump against water hammer

when stoppingor starting.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 22 of 32 flowserve.com

5.7 Hydraulic, mechanical and electrical
duty

This product has been supplied to meet the
performance specifications of your purchase order,
however it is understood that duringthe life of the
product these may change. The following notes may
helpthe user decide how to evaluate the
implications ofany change. If in doubt contact your
nearest Flowserve office.

5.7.1 Specific gravity (SG)

Pumpcapacity andtotal head in meters (feet) do not
change with SG, however pressure displayed on a
pressure gauge is directly proportional to SG. Power
absorbed is also directly proportional to SG. It is
therefore important to check that anychange in SG
will not overload the pump driver or over-pressurize
the pump.

5.7.2 Viscosity

For a given flow ratethe total head reduces with
increased viscosityand increases with reduced
viscosity.Also for a given flow rate the power
absorbed increases with increased viscosity, and
reduces with reduced viscosity. It is important that
checks are made with your nearest Flowserve office
if changes in viscosity are planned.

5.7.3 Pump speed

Changing pump speed effects flow, total head,
power absorbed, NPSHR, noise andvibration. Flow
varies in direct proportion to pumpspeed, head
varies as speed ratio squared and power varies as
speed ratio cubed. The new duty, however, willalso
be dependent on the system curve. If increasing the
speed, it is important therefore to ensure the
maximum pump working pressure is not exceeded,
the driver is not overloaded, NPSHA> NPSHR, and
that noise andvibration are within local requirements
and regulations.

5.7.4 Net positive suction head (NPSHA)

NPSH available (NPSHA) is the head available at the
impeller inlet, above thevapor pressure of the
pumped liquid.

NPSHrequired(NPSHR)is the minimumheadrequired
at the impellerinlet,abovethevapor pressureof the
pumped liquid,toavoidexcessivecavitationand
extreme performance degradation.

Itis importantthat NPSHA> NPSHR. The margin
between NPSHA> NPSHRshould be as largeas
possible.

If any change in NPSHAis proposed, ensure these
margins are notsignificantly eroded. Refer to the
pump performance curve to determine exact
requirements particularly if flow has changed.

If in doubt please consult your nearest Flowserve
office for advice and details of the minimum
allowable margin for your application.

5.7.5 Pumped flow

Flow must not fall outside the minimumand
maximumcontinuous safe flow shownon the pump
performance curve and or data sheet.

5.8 Pumps for Food Use or Potable
Water

Ifthe pump has not been specificallyordered fora food
or drinking waterapplicationit must not be used for
these types ofapplications. If it has beenorderedfor
thistypeofapplication the following recommendations
are to be followed.

5.8.1 Cleaning prior to operation

Pumps thatare to be usedfor a foodor drinkingwater
applicationshouldbecleaned before being putinto
initialoperationandaftertheinstallationof spare parts
thatareincontactwiththe liquid.

Cleaningoncethepump has beencommissionedwill
dependontheapplicationand operatingconditions.
The user must ensure that the cleaning procedures are
suitable for the applicationandoperating conditions,
and local regulations.

6 MAINTENANCE

6.1 General

If a belt drive is used, the assembly and
tension of the belts must be verifiedduring regular
maintenance procedure.

In dirty or dusty environments, regular checks
must be made and dirt removed from areas around
close clearances, bearing housings and motors.

It is the plant operator's responsibility to
ensure that allmaintenance, inspection and
assembly work is carried out by authorized and
qualified personnel who have adequately
familiarized themselves with thesubject matter by
studying this manual in detail (see also section

1.6.2).
Any work on the machine must be performed whenit

is at a standstill. It is imperative that theprocedure
for shutting down the machine is followed, as
described in section 5.6.

On completion of work allguards and safety devices
must be re-installed and made operative again.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 23 of 32 flowserve.com

Before restartingthe machine, the relevant
instructions listedin section 5, Commissioning, start
up, operation and shut down must be observed.

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

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

When air orcompressed inert gas are used to clean
the machines, the operator and those people in the
vicinity must be careful and have appropriate gas­protection, wearingat least eye protectors.

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

clothes.
Before workingon the pump, take measures to

prevent an uncontrolled start. Put a warning board
on the starting device with the words:
"Machine under repair: do not start".

With electric drive equipment, lock the main switch
open andwithdraw any fuses. Put a warning board
on the fuse box or main switch with the words:

"Machine under repair: do not connect".

Never clean pieces with inflammable solvents or
carbon tetrachloride.

Protect yourself against toxic fumes when cleaning
pieces with cleaning agents.

6.2 Maintenance schedule

It is recommended that a maintenance plan
and schedule is adopted, in line with these User
Instructions. It should include the following:
a) The pump must be completely vented and

drained and rendered inert before any
disassembly operation.

b) Any auxiliary systems installed must be

monitored, if necessary, to ensure they function
correctly.

c) During cleaning of the pump ensure the

compatibility between the cleaning products and
the gaskets.

d) Verify the condition of the gaskets
e) Gland packing must be adjusted correctly to give

visible leakage and concentricalignment of the
gland follower to prevent excessive temperature
of the packingor follower. Mechanical seals
should present no leakage.

f) Check for any leaks from gaskets and seals.

The correct functioning of the shaftseal must be
checked regularly.

g) Check bearing lubricant level, and if the hours

run show a lubricant change is required.

h) Check that the duty condition is in the safe

operating range for the pump.

i) Check vibration, noise level andsurface

temperature at the bearings to confirm

satisfactory operation.
j) Check the tightness of the connections,.
k) Check dirt and dust is removed from areas

around close clearances, bearing housings and

motors.
l) Check couplingalignment and re-align if

necessary.
m) Verify the correct operation of thesystem.

The equipment used for maintenance and
disassembly in an ATEX zone must be in conformity
with the requirements zone.

Our specialist service personnel can help with
preventative maintenance records and provide
condition monitoring for temperature andvibration to
identify the onset of potential problems.

If any problems are found the followingsequence of
actions should take place:
a) Refer to section 7, Faults; causes and remedies,

for fault diagnosis.
b) Ensure equipment complies with the

recommendations in this manual.
c) Contact Flowserve if the problem persists.

6.2.1 Standard maintenance

Roller bearing

MAINTENANCE

OPERATION

FREQUENCY OBSERVATIONS

Start (example of a

stand-by pump)

Weekly

Check therunning

state

Evacuation of

condensation

water closed motor

Weekly

- Increase

frequency for

frequent

stops/starts

Lubrication of all

bearingtypes

Greased for life

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 24 of 32 flowserve.com

6.2.2 Routine inspection (daily/weekly)

The following checks should be made
and the appropriate action taken to remedy any
deviations:
a) Check the behavior of the pump while running:

noise level,vibrations, bearings temperature,
flow rate and pressure.

b) Pumpfitted with a stuffing box: leakage of 20

drops per minute.
c) Pump fitted with a mechanical seal: no leakage.
d) Check the level and condition of oil lubricant. On

grease lubricated pumps, check running hours

since last recharge of grease or complete

grease change.

6.2.3 Periodic inspection (6 monthly)

Check pump running records for hourly usage to
determine if bearing lubricant requires changing.

If a check shows a bad running of the
motor pump unit, the user must:
a) Refer to the "fault finding chart" chapter 7 of this

leaflet to apply the recommended solutions.

b) Ensure that your equipment corresponds to the

arrangements of this leaflet

c) ContactFlowserve after-sales Department if the

problem persists.

6.2.4 Mechanical seals

The current maintenance is limited to seal control. It
is necessary to detect any small leakage which
announces the beginningof the deterioration of
friction faces or secondary seal elements (rings,
bellows, synthetic membranes). It is advisable to
stop the pump as soon as possible. Have an
approved seal vendor replace or repair the seal.

421342002445

42404610

6.2.5 Gland packing

6.2.5.1 Pump fitted witha packed gland

A well run in andcorrectly adjusted packing gland
requires little maintenance
If, after some time, the leakage becomes too great,
the gland should be tightened again in order to
return these to a normal level.

If re-tightening isnot possible, new packing must be
installed.

6.2.5.2 Gland packing inspection and removal

a) Remove the shieldguards
b) Slide back the gland
c) Remove the packing rings with an extractor

designed for this purpose (including the lantern
ring if it exists; note its position andits direction
of rotation).

d) Inspect the state of the sleeve surface; the

presence of many marked grooves willindicate
that it must be replaced.

e) Carefully clean the different pieces of the

packing gland.

6.2.5.3 Gland packing fitting

If the packingis supplied as cord the packing must
be cut so that the external diameter is lightly
tightened and there is an initial gap between the
sleeve and the packing ring.

For that purpose, windthe packing helically around
the shaft sleeve or a chuck of the same diameter.
(Take precautions to avoid damaging sleeve).

Exampleof straightcut Exampleof bevelcut

Ensure a tighteningon the stuffing

box housing and not on the sleeve.

SETTING OF PACKING

Follow the instructions:
a) Assembly of the packing in S.
b) Staggering by about 90° between two pickings.
c) Assemble packing after packing.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 25 of 32 flowserve.com

After settingthe last packing, fix the glandon the
packing and screw up the nut by hand.

After this screwingphase, the shaft should turn by
handas easily as before the setting of thepacking.

Dimensions in

mm (in.)

Packing

Pump

type

D1 D2 D3 D4 D5 L1 Lgth



50 FM

24

(0.94)30(1.18)46(1.81)70(2.76)

M10

48

(1.89)

600

(23.62)

8

65 FM

24

(0.94)30(1.18)46(1.81)

70-

2.76)

M10

48

(1.89)

600

(23.62)

8

6.2.6 Internal coating

If the pump has an internal coating, this coating
must be inspected periodically. Any wear or cracks
of the coating found must be immediately repaired.
Failure to dothis may lead to accelerated wearof
the coating during operation andcorrosion of the
exposed base metal, depending on the material and
pumped liquid. Special attention must be paid to the
coating edges. Any loss of coating material is
considered to be normal wear and tear on the pump
and is not considered as warranty. Flowserve has
applied the coatings according to the supplier's
instructions but will not be held responsible for
coating wear or cracks that may develop over time.

6.3 Spare parts

6.3.1 Ordering of spares

Flowserve keeps records of allpumps that have been
supplied. When orderingspares the following
information should be quoted:

(1) Pump serial number
(2) Pump size
(3) Part name
(4) Part number
(5) Number of parts required

The pump size and serial number are shownon the
pump nameplate.

To ensure continued satisfactory operation,
replacement parts to the original design specification
should be obtained from Flowserve.

Any change to the original design specification
(modification or use of a non-standard part) will
invalidate the pumps safety certification.

6.3.2 Storage of spares

Spares shouldbe stored in a clean dry area away
from vibration. Inspectionand re-treatment of
metallic surfaces (if necessary) with preservative is
recommended at 6 monthly intervals.

6.4 Recommended spares

[1410], [2250], [4610], [4130]
Destroy allthe gaskets after dismantling, replace

themwhen reassembling.
After serving during two years, replace the gland

packing.

6.5 Disassembly

Refer to section 1.6,Safety, and section 6

Maintenance, before dismantling the pump.

Before dismantling the pumpfor
overhaul, ensure genuine Flowserve replacement
parts are available. Refer to sectional drawings for
part numbers and identification.

REPAIR OF THE PUMP

If the pump presents abnormalities or a

persistent malfunction,contact immediately:

FLOWSERVE

After-sales Service
Tel.: [phone]

(33) 2 43 40 57 57

Fax.: [phone]

(33) 2 43 40 58 17

According to theAfter-sales Service instructions,
disassembly will be limited to the dismantling of the
pump.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 26 of 32 flowserve.com

a) DISCONNECT THE UNIT FROM

POWER

b) Closethe inlet valve (if fitted)andoutlet valve.
c) Wait for the moment whenthe pump casingis

cooledand at ambient temperature.

d) DRAIN PUMP
e) Dismantle inlet andoutletpipeworks as well as all

pipeworks.

f) REMOVE PUMP TAKING INTO

ACCOUNT SAFETY (§ 1) AND HANDLING
(§ 2.2) PROCEDURES.

ANYDISASSEMBLY, REPAIR OR
REASSEMBLYWILL BECARRIED OUT UNDER
FLOWSERVE' RESPONSABILITY, EITHER
DIRECTLY BYTHEAFTER-SALESSERVICE OR
BY OTHER FLOWSERVE-AGENTS WHOWILL
GET THE REQUIRED INSTRUCTIONS AND
APPROVALS. THIS IS THE CASE OF
AUTHORIZED REPAIRERS WHOSEADDRESSES
AND TELEPHONE NUMBERSWILL BE GIVENON
REQUEST.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 27 of 32 flowserve.com

7 FAULTS; CAUSES AND REMEDIES

Insufficient flow rate
Irregular pump running
Driver overloaded
Mechanical seal leak
Equipment vibration
Excessive pump casing temperature

POSSIBLE CAUSES SOLUTIONS

    Pump or suction pipe not completely filled - Check and complete filling
    Air bubbles in pipes - Check and deaerate the pipes
  

Suctionleveltoo low - Check: the available NPSH > the required NPSH

- Reduce geometrical suctionlift

- Reduce head losses in pipes and in fittings (diameter increase
and appropriate fitting positions)

- Check valves and strainers

- Check the immersionhead of the suction valve

  Wrong rotation - Reverse 2 phases on motor terminalboxes
   The motor is runningon 2 phases only - Check and control the motor electrical power supply


Motor running too low - Check the connectionin the terminal boxaccording to the

voltage

  Total manometric head systemhigher than

pumpdifferential head

- Check the discharge head

- Check the head losses in discharge pipes (partly closed valve,
foreign particles, back pressure too high)

- Modify the installation or changethe pump set

  Total manometric head system lower than

pumpdifferential head

- Throttleatdischarge valve or trimthe impeller (contact our
localagent)

  

Pipes(valves, filter...) -Control, dismantle andclean

 

Insufficient flowrate - Check the suction anddischargepipes (valves, back pressure)



Worn wear-ring surfaces - Foresee pumpmending: CONSULT FLOWSERVE

   

Seizure, jamming - CONSULT FLOWSERVE

    Excessivestrainson flanges - Check the flangeconnections and eliminate strains (pipe

positioning or elastic sleeves mounting)



Defective mechanical seal - Check and replace all the mechanicalsealparts

- Mechanical seal: CONSULT FLOWSERVE

   

Defective motor bearings - CONSULT FLOWSERVE

 

Specific gravity or viscosity of liquid too high - Consultour localagent to analyze the problem

 Foundations not sufficiently rigid - Check the settingof baseplates: tightening, bad adjustment,

seal

Insufficient pressure
Pump looses prime after starting

POSSIBLE CAUSES SOLUTIONS



Rotation speed too low (check the driver) - Check the connectionin the terminal box according to the

voltage

 

Presence of air - Check and deaerate



Suctionpressure insufficient - Check: the available NPSH > the required NPSH



Mechanical defects - CONSULT FLOWSERVE



Air leak in the suctionpipe - Check suction pipe is airtight

 Restriction in suction pipe - Check diameter of suction pipe
 Suction level too low - Check the availableNPSH> the required NPSH

- Reduce geometrical suctionlift

- Reduce head losses in pipes and in fittings (diameter increase
and appropriate fitting positions)

- Check valves and strainers

- Check the immersionhead of the suction valve



Obstruction of suction pipe - Check condition of pipe

 Defectivegland packing on the shaft - Check and replace all the gland packing

- Mechanical seal: CONSULT FLOWSERVE

 Defectivegasket - CONSULT FLOWSERVE

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 28 of 32 flowserve.com

8 PARTS LIST AND DRAWINGS

8.1 Sectional drawing

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 29 of 32 flowserve.com

8.2 Sectional drawing parts list

ITEM NOMENCLATURE

1130 Suctioncasing

1140 Dischargecasing

1150 Stage casing

1410 Diffuser

1470 Diffuser plate

2250 Radialimpeller

2410 Interstage sleeve

2450 Shaftsleeve

2540 Thrower

2905 Washer

2910 Shaftnut

4120 Gland

4130 Gland packing

4132 Stuffingboxbushing

4590 Gasket

4610 O-ring

6515 Drain plug

6571 Tiebolt

6572 Stud

6577 Hexagon head bolt

6578 Threaded plug

6581-01 Hexagon nut

6581-02 Hexagon nut

6700 Key

6812 Grooved pin

8020 Motor for close coupling

9331 Cover plate

8.3 General arrangement drawing

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

9 CERTIFICATION

Certificates determined fromthe Contract
requirements are provided with these instructions
where applicable. Examples are certificates for CE
marking, ATEX markingetc. If required, copies of
other certificatessentseparately to the Purchaser
should be obtained from the Purchaser for retention
with these User Instructions.

10 OTHER RELEVANT
DOCUMENTATION AND MANUALS

10.1 Supplementary User Instructions
manuals

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

10.2 Change notes

If anychanges, agreedwithFlowserve, are made to
the productafter its supply, a record of the details
shouldbe maintained with these User Instructions.

10.3 Additional sources of information

Reference 1:

NPSHforRotor dynamicPumps: a reference guide,
Euro pump Guide No.1,Euro pump&WorldPumps,
ElsevierScience,United Kingdom,1999.

Reference 2:

PumpingManual,9thedition,T.C. Dickenson,
ElsevierAdvancedTechnology, UnitedKingdom, 1995.

Reference 3:

Pump Handbook, 2ndedition, Igor J. Karassik et al,
McGraw-HillInc., New York, 1993.

Reference 4:

ANSI/HI 1.1-1.5, Centrifugal Pumps - Nomenclature,
Definitions, Application and Operation.

Reference 5:

ANSI B31.3 - Process Piping.

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 30 of 32 flowserve.com

Nota:

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 31 of 32 flowserve.com

Nota:

FM USER INSTRUCTIONS ENGLISH 71576526 - 03/07

Page 32 de 32 flowserve.com

FLOWSERVEREGIONAL
SALES OFFICES:

USAand Canada

Flowserve Corporation
5215 North O’Connor Blvd.,
Suite2300
Irving, Texas 75039-5421 USA
Telephone [phone]
Fax [phone]

Europe, MiddleEast, Africa

Worthing S.P.A.
Flowserve Corporation
Via Rossini 90/92
20033 Desio (Milan) Italy
Telephone [phone]
Fax [phone]

LatinAmerica and Caribbean

Flowserve Corporation
6840Wynnwood Lane
Houston, Texas 77008 USA
Telephone [phone]
Fax [phone]

AsiaPacific

Flowserve Pte. Ltd
200 PandanLoop #06-03/04
Pantech 21
Singapore128388
Telephone [phone]
Fax [phone]

North America:
Flowserve Pump Division
5599 E Holmes Road
Memphis, TN 38118, USA

Telephone: [phone]
Fax: [phone]

South America:
Flowserve do Brasil Ltda
Av. Don Helder Camara, 5451
20771-001 Rio deJanerio, Brasil

Telephone: [phone]
Fax : [phone]

To findyour local Flowserve representative please
use the Sales Support Locator Systemfound at
www.flowserve.com

Flowserve factory contacts:

Flowserve Pompes
13, rue Maurice Trintignant
72234 Arnage Cedex, France

Telephone (24 hours): [phone]
Sales & Admin: [phone]

vice Fax:

43