Flowserve Guardian Sealless Metallic User Manual
USER INSTRUCTIONS
Guardian Sealless Metallic Pumps
ANSI Standard, Close-Coupled and Unitized Self-Primer
Single stage, end suction, centrifugal, chemical process
pumps
PCN=71569212 08-11 (E) (Based on P-20-502.)
Original instructions.
Installation
Operation
Maintenance
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
Page 1 of 68
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 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 Nameplate and warning labels .....................8
1.8 Specific machine performance......................8
1.9 Noise level ....................................................8
2 TRANSPORT AND STORAGE........................9
2.1 Consignment receipt and unpacking..............9
2.2 Handling........................................................9
2.3 Lifting.............................................................9
2.4 Storage........................................................10
2.5 Recycling and end of product life................11
3 DESCRIPTION...............................................11
3.1 Configurations.............................................11
3.2 Nomenclature..............................................11
3.3 Design of major parts..................................12
3.4 Performance and operation limits...............13
4 INSTALLATION..............................................16
4.1 Location ......................................................16
4.2 Part assemblies ..........................................16
4.3 Foundation..................................................16
4.4 Grouting ......................................................18
4.5 Initial alignment...........................................19
4.6 Piping..........................................................20
4.7 Electrical connections .................................27
4.8 Final shaft alignment check ........................28
4.9 Protection systems......................................28
6 MAINTENANCE.............................................35
6.1 Maintenance schedule................................36
6.2 Spare parts.................................................36
6.3 Recommended spares and consumables..37
6.4 Tools required.............................................37
6.5 Fastener torques ........................................37
6.6 Setting impeller clearance ..........................37
6.7 Disassembly ...............................................38
6.8 Examination of parts...................................44
6.9 Assembly of pump......................................47
7 FAULTS; CAUSES AND REMEDIES............56
8 PARTS LIST AND DRAWINGS.....................59
8.1 Cutaway – Guardian G & H Series – Group 1 –
long coupled ...............................................59
8.2 Cutaway - Guardian G & H Series - Group 2 –
long coupled ...............................................61
8.3 Cutaway - Guardian G & H Series - Group 1 –
close coupled..............................................63
9 CERTIFICATION ...........................................65
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS......................................................65
10.1 Supplementary User Instructions.......65
10.2 Change notes.....................................65
10.3 Additional sources of information.......65
Page
5 COMMISSIONING, STARTUP, OPERATION
AND SHUTDOWN .........................................30
5.1 Pre-commission procedure.........................30
5.2 Pump lubricants ..........................................30
5.3 Impeller clearance.......................................31
5.4 Direction of rotation.....................................32
5.5 Guarding .....................................................32
5.6 Priming and auxiliary supplies ....................33
5.7 Starting the pump........................................34
5.8 Running or operation ..................................34
5.9 Stopping and shutdown ..............................34
5.10 Hydraulic, mechanical and electrical duty
35
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GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
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,
utilising 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 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 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, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and
equipment put into service within certain regions of
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED) and Equipment for Potentially Explosive
Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
incorporates information relevant to these Directives
and Approvals.
To confirm the Approvals applying and if the product
is CE marked, check the serial number plate
markings and the Certification, (See section 9,
Certification.)
1.3 Disclaimer
Information in these User Instructions is believed to
be complete and reliable. However, in spite of all of
the efforts of Flowserve Corporation to provide
comprehensive instructions, good engineering and
safety practice should always be used.
Flowserve manufactures products to exacting
International Quality Management System Standards as
certified and audited by external Quality Assurance
organisations. 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 authorised Flowserve parts and
accessories is considered to be misuse. Damage or
failure caused by misuse is not covered by the
Flowserve's warranty. In addition, any modification of
Flowserve products or removal of original components
may impair the safety of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve Pump Division.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
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GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
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 seek
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 “strong magnetic
field” safety instructions where non-compliance would
affect personal safety, pacemakers, instruments, or
stored data sensitive to magnetic fields.
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
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.
HIGH MAGNETIC FIELDS
Great care should be taken when assembling/
dismantling magnetic rotors, where fitted, because of
the very high forces which can be created by the
magnets.
Persons with pacemakers and any instrumentation
etc sensitive to magnetic fields should be kept well
away from the magnetic drive unit during
dismantling.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
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
HOT (and cold) PARTS
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GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
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
immediate area.
Bearing housings must not be insulated and
drive motors and bearings may be hot.
If the temperature is greater than 80 °C (175 °F) o r
below -5 °C (23 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.
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.
ALWAYS USE THE JACKBOLTS TO
SEPARATE THE POWER END FROM THE WET
END ASSEMBLIES
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.
immediate damage to the containment shell and
bearings.
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 EXTENEDED PERIODS
BELOW THE MINIMUM CONTINUOUS FLOW
DO NOT START THE PUMP
WITHOUT PROPER LUBRICATION
Refer to bearing lubrication in Section 5.2.
THE PUMP SHAFT MUST TURN
CLOCKWISE WHEN VIEWED FROM THE MOTOR
END
It is absolutely essential that the rotation of the motor
be checked before installation of the coupling spacer
and starting the pump. Incorrect rotation of the pump
for even a short period can unscrew the impeller,
which can cause significant damage.
GUARDIAN G & H SERIES PUMPS
ARE SIZED BASED ON A SPECIFIC APPLICATION.
In the event the user elects to operate this pump in a
service other than what it was originally sized for, a
Flowserve sales engineer should be contacted to
evaluate the new application.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow
rate with no back pressure 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.
EXCESSIVE PUMP NOISE OR
VIBRATION
This may indicate a dangerous condition. The pump
must be shut down immediately.
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.
NEVER RUN THE PUMP DRY
OR WITHOUT PROPER PRIME (Casing Flooded)
Operating the magnetic coupling dry may cause
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GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
Temperature class
Temperature class
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
• Avoid excess temperature
• Prevent build up 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.
For ATEX, both electrical and non-electrical equipment
must meet the requirements of European Directive
94/9/EC. . Always observe the regional legal Ex
requirements eg Ex electrical items outside the EU may
be required certified to other than ATEX eg IECEx, UL.
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, 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, 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 effects in the motor. On pump
sets 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.
1.6.4.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = high level protection
3 = normal level of protection
Gas and/or dust
G = Gas
D = Dust
c = Constructional safety
(in accordance with EN13463-5)
Gas Group
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface
temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the ATEX
Ex rating on the nameplate. These are based on a
maximum ambient temperature of 40 °C (104 °F).
Refer to Flowserve for higher ambient temperatures.
Maximum permitted liquid temperature for pumps
to EN13463-1
T6
T5
T4
T3
T2
Maximum surface
temperature permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
Temperature limit of
liquid handled
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
Maximum permitted liquid temperature for pumps
with self priming casing
to EN13463-1
T6
T5
T4
T3
T2
* The tables only takes the ATEX temperature class into consideration.
Pump design or material, as well as component design or material, may
further limit the maximum working temperature of the liquid.
Maximum surface
temperature permitted
85 °C (185 °F)
100 °C(212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
Temperature limit of
liquid handled
Consult Flowserve
Consult Flowserve
110 °C (230 °F) *
175 °C (347 °F) *
270 °C (518 °F) *
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The responsibility for compliance with the specified
maximum liquid temperature is with the plant
operator.
Temperature classification “Tx” is used when the
liquid temperature varies and the pump could be
installed in different hazardous atmospheres. In this
case the user is responsible for ensuring that the
pump surface temperature does not exceed that
permitted in the particular hazardous atmosphere.
Do not attempt to check the direction of rotation with the
coupling spacer fitted due to the risk of severe contact
between rotating and stationary components.
Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures fit an external surface
temperature protection device.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips or a power monitor and
perform routine vibration monitoring.
In dirty or dusty environments, make regular checks
and remove dirt from areas around close clearances,
bearing housings and motors.
Additional requirements for self-priming casing
pumps
Where the system operation does not ensure control of
priming, as defined in the User Instructions, and the
maximum permitted surface temperature of the T Class
could be exceeded, the user shall install an external
surface temperature protection device.
1.6.4.4 Preventing the build up 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 any heating and cooling systems
are properly filled.
If the operation of the system can not avoid this
condition fit an appropriate dry run protection device
(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 equipment.
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.
For ATEX the coupling must be selected to comply
with 94/9/EC. 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
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
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 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
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GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
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 be implemented. See section 6, Maintenance.
1.7 Nameplate and warning labels
1.7.1 Nameplate
For details of nameplate, see Declaration of
Conformity and section 3.
1.7.2 Warning labels
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, pipework 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.
For units driven by equipment other than electric
motors or units contained within enclosures, see the
Oil lubricated units only
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.
Page 8 of 68 flowserve.com
accompanying information sheets and manuals.
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”.
For estimating sound power level LWA (re 1 pW) then
add 14 dBA to the sound pressure value.
Motor size
and speed
kW (hp)
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
Typical sound pressure level, LpA at 1 m reference 20 µPa (dBA)
3550 r/min 2900 r/min 1750 r/min 1450 r/min
Pump
only
Pump and
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
<0.55 (<0.75)
0.75 (1)
1.1 (1.5)
1.5 (2)
2.2 (3)
3 (4)
4 (5)
5.5 (7.5)
7.5 (10)
11 (15)
15 (20)
18.5 (25)
22 (30)
30 (40)
37 (50)
45 (60)
55 (75)
75 (100)
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.
72 72 64 65 62 64 62 64
72 72 64 66 62 64 62 64
74 74 66 67 64 64 62 63
74 74 66 71 64 64 62 63
75 76 68 72 65 66 63 64
75 76 70 73 65 66 63 64
75 76 71 73 65 66 63 64
76 77 72 75 66 67 64 65
76 77 72 75 66 67 64 65
80 81 76 78 70 71 68 69
80 81 76 78 70 71 68 69
81 81 77 78 71 71 69 71
81 81 77 79 71 71 69 71
83 83 79 81 73 73 71 73
83 83 79 81 73 73 71 73
86 86 82 84 76 76 74 76
86 86 82 84 76 76 74 76
87 87 83 85 77 77 75 77
2 TRANSPORT AND STORAGE
2.3 Lifting
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 and must be
received in writing within 10 days of receipt of the
equipment. Later claims cannot be accepted.
Check all crates, boxes or wrappings for any
accessories or spare parts that may be packed
separately from the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check
that this number corresponds with that advised and
quote this number in correspondence as well as
when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork-lift vehicles or slings depending on their
size and construction.
lifting lugs or eye bolts. These are intended for use in
only lifting the individual piece of equipment. NEVER
use eye bolts or cast-in lifting lugs to lift pump,
motor and baseplate assemblies.
A crane must be used for all pump sets in
excess of 25 kg (55 lb). Fully trained personnel must
carry out lifting in accordance with local regulations.
The driver and pump weights are recorded on their
respective nameplates.
or assemblies above the center of gravity to prevent
the unit from flipping. The angle between slings or
ropes used for lifting must never exceed 60°.
2.3.1 Lifting pump components
2.3.1.1 Casing [1100]
Use a choker hitch pulled tight around the discharge
nozzle.
2.3.1.2 Bearing housing [3200]
Insert either a sling or hook through the lifting lug
Pumps and motors often have integral
Care must be taken to lift components
located on the top of the housing.
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GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
2.3.1.3 Power end
Same as bearing housing.
To avoid distortion, the pump unit
should be lifted as shown.
2.3.1.4 Bare pump
Sling around the pump discharge nozzle and around
the outboard end of the bearing housing with
separate slings. Choker hitches must be used at
both attachment points and pulled tight. Make sure
the completion of the choker hitch on the discharge
nozzle is toward the coupling end of the pump shaft
as shown in Figure 2-1. The sling lengths should be
adjusted to balance the load before attaching the
lifting hook.
Figure 2.1
Figure 2.3
The sling should be positioned so the weight is not
carried through the motor fan housing. Make sure the
completion of the choker hitch on the discharge
nozzle is toward the coupling end of the pump shaft
as shown in Figure 2-1.
2.4 Storage
2.3.1.5 Lifting pump, motor and baseplate
assembly
If the baseplate has lifting holes cut in the sides at the
end insert lifting S hooks at the four corners and use
slings or chains to connect to the lifting eye as shown in
Figure 2-2. Do not use slings through the lifting holes.
Figure 2.2
For other baseplates, sling around the pump discharge
nozzle, and around the outboard end of the motor frame
using choker hitches pulled tight. (Figure 2-1.)
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.
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
Normal packaging is designed to protect the pump
and parts during shipment and for dry, indoor storage
for up to six months or less. The following is an
overview of our normal packaging:
• All loose unmounted items are packaged in a
water proof plastic bag and placed under the
coupling guard. Larger items are boxed and
metal banded to the baseplate. For pumps not
mounted on a baseplate, the bag and/or box is
placed inside the shipping container.
• 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.)
Page 10 of 68 flowserve.com
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
Serial No.
Equipment No.
Purchase
• 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.
• Assemblies ordered with external piping, in some
cases components may be disassembled for
shipment.
• The pump must be stored in a covered, dry
location.
2.4.2 Long term storage
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.
After unpacking, protection will be the responsibility of
the user. Addition of oil to the bearing housing will
remove the inhibitor. 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 Durco G and H Series Magnetic Drive chemical
process pump are end suction, single stage,
centrifugal pumps. The horizontal family conforms to
ASME B73.3M, which has a centerline discharge and
is represented by our Standard long-coupled, Closecoupled (Group 1 only), and Unitized self-priming
variants.
3.2 Nomenclature
The pump size will be engraved on the nameplate
typically as below:
BG 1.5 x 1 - 62/5.00 RV
• “BG” refers to the magnetic coupling size – see
Table 3-2.
• “1.5” refers to the suction diameter (1.5 in.)
• “1” refers to the discharge diameter (1.0 in.)
• “62” refers to nominal impeller diameter (6 & 2/8 in.)
• “5.00” refers to actual impeller diameter (5.00 in)
• “RV” refers to Reverse Vane impeller. (Open
impeller design not available on Guardian G & H
series pumps.)
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).
An example of the nameplate used on the Guardian
G & H Series pump is shown below. This nameplate,
which is always mounted on the Guardian G & H
Series bearing housing, is shown in Figure 3-1.
Figure 3.1: Nameplate
Serial No.
Equipment No.
Purchase Order
Date DD/MMM/YY
Model
Size
MDP
Material
Page 11 of 68 flowserve.com
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
3.3 Design of major parts
3.3.1 Pump casing and impeller
Removal of the casing is not required when
performing maintenance of the rotating element. The
pump is designed with a gasket perpendicular to the
shaft allowing the rotating element to be easily
removed (back pull out). The impeller is reverse
vane; there is no option for an open impeller.
3.3.2 Magnetic coupling
See Figure 3-2 for magnetic coupling static torque
values. Outer and inner magnets are separated by a
containment shell which isolates the process fluid
from the atmosphere. When the motor drives the
outer magnet, the attraction between the outer and
inner magnet causes the pump shaft and impeller to
rotate. See Figure 3-3. This “magnetic coupling” is
produced by alternating polarities between the
magnet pairs on the inner and outer magnet
assemblies. The alternating magnet polarity also
causes repulsion between adjacent magnets and
prevents the coupling from slipping or decoupling.
(See Figure 3-4.)
Figure 3-2: Magnetic coupling static torque
values
Pump
size
Group
1
Group
2
Figure 3-3: Magnetic drive schematic (shaded
areas rotate)
Pump
prefix
AG/AH 0.5 in. 12 (110)
BG/BH 1.0 in. 33 (290)
CG/CH 1.5 in. 57 (500)
DG/DH 2.0 in. 75 (660)
JG/JH 2.5 in. 92 (810)
JG/JH 0.5 in. 23 (200)
KG/KH 1.0 in. 57 (500)
LG/LH 1.5 in. 99 (870)
MG/MH 2.0 in. 138 (1220)
NG/NH 2.5 in. 175 (1540)
PG/PH 3.0 in. 220 (1940)
QG/QH 3.5 in. 257 (2270)
Magnet
length
Torque at 20 ºC (68 ºF)
Nm (lbf٠in.)
Figure 3-4: Magnetic coupling
3.3.3 Inner rotating assembly
The wetted, inner rotating assembly consisting of the
inner magnet, pump shaft and impeller is supported
radially by bushings. The bushings also carry radial and
axial loading from the impeller. A small amount of
process fluid circulates in the containment area to
lubricate these bearings and cool the containment shell.
3.3.4 Lubrication and cooling path
Referring to Figure 3-5, the process fluid enters the
containment area through two lubrication holes in the
bearing holder (A). The fluid is divided at this point
with a small portion providing lubrication to the
inboard bushing and thrust journal before returning to
low pressure (B). The remaining portion moves
across the outboard bushing (C) at which point it is
divided with a portion lubricating the outboard thrust
journal (D) and the remaining passing through holes
in the inner magnet assembly (E). The process fluid
cools the containment shell (F) before mixing with
flow entering from two holes in the bearing holder
(G). The mixed flow then returns to the process flow
through the two return lubrication holes (H).
Two of the holes in the bearing holder (G) are located
at the six and twelve o’clock position to vent and drain
the containment area during startup and shutdown.
This circulation path ensures positive flow and
lubrication to the bushings and thrust journals with the
coolest fluid, i.e. before cooling the containment shell.
Page 12 of 68 flowserve.com
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
Figure 3-5: Lubrication and cooling path
3.3.5 Power end bearings and lubrication
Ball bearings are fitted as standard on long-coupled
pumps and may be either oil or grease lubricated.
Close coupled pumps utilize the motor bearings for
support of the outer magnet.
3.3.6 Bearing housing
Large oil bath reservoir. (Long-coupled pumps only.)
3.3.7 Driver
The driver is normally an electric motor. Different drive
configurations may be fitted such as internal combustion
engines, turbines, hydraulic motors etc driving via
couplings, belts, gearboxes, drive shafts etc.
3.3.8 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operation limits
This product has been selected to meet the
specification of your purchase order see 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, and material of construction may
influence this data. If required, a definitive statement
for your application can be obtained from Flowserve.
3.4.1 General temperature limits
See Figures 3-6 and 3-7 for general temperature
limits for Guardian G & H series pumps.
3.4.2 Pressure-temperature ratings
The pressure-temperature ratings for Guardian G & H
series pumps are shown in Figures 3-9A and 3-9B.
To determine which casing material group to
reference, identify the appropriate casing “Material
Group No.” in Figure 3-8. Interpolation may be used
to find the pressure rating for a specific temperature.
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.
The suction pressure limit for Guardian G & H series
pumps is limited by the P-T rating.
Example. The pressure temperature rating for a
Guardian pump with Class 300 flanges and CF8M
construction at an operating temperature of 149 ˚C is
found as follows:
a) From Figure 3-8, the correct material group for
CF8M is 2.2.
b) From Figure 3-9B, the pressure-temperature
rating is 21.5 bar.
3.4.3 Alloy cross reference chart
Figure 3-8 is the alloy cross-reference chart for all
Guardian G & H series pumps.
3.4.4 Minimum continuous flow
The minimum continuous flow (MCF) is based on a
percentage of the best efficiency point (BEP). Figure
3-10 identifies the MCF for all G & H series Guardian
pumps.
3.4.5 Minimum suction pipe submergence
The minimum submergence for Unitized self-priming
pumps is shown in Figure 3-11 and 3-12.
Page 13 of 68 flowserve.com
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
Figure 3-6: Temperature limitations, long coupled
pumps
Temperature Limitations
• G or H Series acceptable
• Group 1 or 2 pumps acceptable
-73 ºC to -29 ºC
(-100 ºF to -20 ºF)
-29 ºC to 121 ºC
(-20 ºF to 250 ºF)
121 ºC to 177 ºC
(250 ºF to 350 ºF)
177 ºC to 287 ºC
(350 ºF to 550 ºF)
• Review material and elastomer
limitations
• Replace iron and steel pressure
containing components with
stainless steel. Contact your
Flowserve representative for details
• G or H Series acceptable
• Group 1 or 2 pumps acceptable
• Review material and elastomer
limitations
• H Series only
• Group 1 or 2 pumps acceptable
• Review material and elastomer
limitations
• H Series only
• Group 1 rated to 287 ºC (550 ºF)
• Group 2 rated to 232 ºC (450 ºF)!
• Review material and elastomer
limitations
• Centerline mounting recommended
for services over 177 ºC (350 ºF)
• Labyrinth seals recommended for
services over 218 ºC (425 ºF)
• Finned oil cooler recommended for
services over 190 ºC (375 ºF)
Figure 3-7: Temperature limitations, close
coupled pumps (Group 1 only)
Temperature Limitations
• G or H Series acceptable
• Review material and elastomer
-73 ºC to -29 ºC
(-100 ºF to -20 ºF)
-29 ºC to 121 ºC
(-20 ºF to 250 ºF)
121 ºC to 177 ºC
(250 ºF to 350 ºF)
177 ºC to 204 ºC
(350 ºF to 400 ºF)
limitations
• Replace iron and steel pressure
containing components with stainless
steel. Contact your Flowserve
representative for details
• G or H Series acceptable
• Review material and elastomer
limitations
• H Series only
• Review material and elastomer
limitations
• H Series only
• Maximum allowable process fluid
temperature is 204 ºC (400 ºF)
• Review material and elastomer
limitations
• Centerline mounting recommended
for services over 177 ºC (350 ºF)
Figure 3-8: Alloy cross-reference chart
Flowserve
material code
E3020 Ductile iron DCI None None A395, Gr. 60-40-18 1.0
E3033 High chrome iron CR28 None None A532 class 3 Cr
E4027 High chrome iron CR29 None None None Cr
E4028 High chrome iron CR35 None None None Cr
C3009 Carbon steel DS None Carbon steel A216 Gr. WCB 1.1
C3062 Durco CF8 D2 CF8 304 A744, Gr. CF8 2.1
C3069 Durco CF3 D2L CF3 304L A744, Gr. CF3 2.1
C3063 Durco CF8M D4 CF8M 316 A744, Gr. CF8M 2.2
C3067 Durco CF3M D4L CF3M 316L A744, Gr. CF3M 2.2
C3107 Durcomet 100 CD4M CD4MCuN
C4028 Durimet 20 D20 CN7M Alloy 20 A744, Gr. CN7M 3.17
C4029 Durcomet 5 DV None None None 2.2
K3005 Durco CY40 DINC CY40
K3007 Durco M35 DMM M351
K3008 Nickel DNI CZ100 Nickel 200 A494, Gr. CZ100 3.2
K4007 Chlorimet 2 DC2 N7M
K4008 Chlorimet 3 DC3 CW6M
E3042
E4035
H3004 Titanium Ti None Titanium B367, Gr. C3 Ti
H3005 Titanium-Pd TiP None Titanium-Pd B367, Gr. C8A Ti
H3007 Zirconium Zr None Zirconium B752, Gr. 702C Ti
Duriron, Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation.
Ferralium is a registered trademark of Langley Alloys.
Hastelloy is a registered trademark of Haynes International, Inc.
Inconel and Monel are registered trademarks of International Nickel Co. Inc.
Note: some materials listed above may not be available for use in some parts of Guardian pumps.
Designation
Durichlor 51
Superchlor
Durco legacy
codes
D51 None None A518, Gr. 2 No load
SD51 None None A518, Gr. 2 No load
ACI
designation
Equivalent wrought
designation
Ferralium
Inconel 600
Monel 400
Hastelloy B
Hastelloy C
ASTM
specifications
A995, Gr. CD4MCuN 2.8
A494, Gr. CY40 3.5
A494, Gr. M35-1 3.4
A494, Gr. N7M 3.7
A494, Gr. CW6M 3.8
Group No.
Material
Page 14 of 68 flowserve.com
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
Figure 3-9A: All Guardian G & H series pumps with class 150 flanges
Temp
ºC
( ºF)
-73
(-100)
-29
(-20)
-18
(0)
38
(100)
93
(200)
149
(300)
171
(340)
204
(400)
260
(500)
316
(600)
1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti Cr
–
17.2
(250)
17.2
(250)
17.2
(250)
16.2
(235)
14.8
(215)
14.4
(209)
13.8
(200)
11.7
(170)
9.7
(140)
–
19.7
(285)
19.7
(285)
19.7
(285)
17.9
(260)
15.9
(230)
15.0
(218)
13.8
(200)
11.7
(170)
9.7
(140)
19.0
(275)
19.0
(275)
19.0
(275)
19.0
(275)
15.9
(230)
14.1
(205)
13.7
(199)
13.1
(190)
11.7
(170)
9.7
(140)
19.0
(275)
19.0
(275)
19.0
(275)
19.0
(275)
16.2
(235)
14.8
(215)
14.3
(207)
13.4
(195)
11.7
(170)
9.7
(140)
19.7
(285)
19.7
(285)
19.7
(285)
19.7
(285)
17.9
(260)
15.9
(230)
15.0
(218)
13.8
(200)
11.7
(170)
9.7
(140)
Material Group No.
bar (psi)
9.7
(140)
9.7
(140)
9.7
(140)
9.7
(140)
9.7
(140)
9.7
(140)
9.7
(140)
9.7
(140)
9.7
(140)
9.7
(140)
15.9
(230)
15.9
(230)
15.9
(230)
15.9
(230)
13.8
(200)
13.1
(190)
13.0
(188)
12.8
(185)
11.7
(170)
9.7
(140)
15.2
(220)
15.2
(220)
15.2
(220)
15.2
(220)
13.8
(200)
12.4
(180)
12.1
(176)
11.7
(170)
11.0
(160)
9.7
(140)
20.0
(290)
20.0
(290)
20.0
(290)
20.0
(290)
17.9
(260)
15.9
(230)
15.0
(218)
13.8
(200)
11.7
(170)
9.7
(140)
20.0
(290)
20.0
(290)
20.0
(290)
20.0
(290)
17.9
(260)
15.9
(230)
15.0
(218)
13.8
(200)
11.7
(170)
9.7
(140)
15.9
(230)
15.9
(230)
15.9
(230)
15.9
(230)
13.8
(200)
12.4
(180)
11.9
(172)
11.0
(160)
10.3
(150)
9.7
(140)
20.0
(290)
20.0
(290)
20.0
(290)
20.0
(290)
17.9
(260)
15.9
(230)
15.0
(218)
13.8
(200)
11.7
(170)
9.7
(140)
–
–
12.6
(183)
12.6
(183)
12.6
(183)
12.6
(183)
12.6
(183)
–
–
–
Figure 3-9B: All Guardian G & H series pumps with class 300 flanges
Temp
ºC
( ºF)
-73
(-100)
-29
(-20)
-18
(0)
38
(100)
93
(200)
149
(300)
204
(400)
260
(500)
316
(600)
Note: temperature limitations in these charts take into account material choice only. Actual temperature limitations of the Guardian pump
may be different depending on pump size, model, or elastomers used. Refer to Section 3.4.1 for specific temperature limitations of
Guardian pumps independent of material choice.
1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti
– –
24.1
(350)
24.1
(350)
24.1
(350)
22.6
(328)
21.3
(309)
19.8
(287)
18.7
(271)
17.5
(254)
24.1
(350)
24.1
(350)
24.1
(350)
22.0
(319)
21.4
(310)
20.7
(300)
19.6
(284)
17.9
(260)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
20.1
(292)
18.1
(263)
16.6
(241)
15.3
(222)
14.6
(211)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
20.8
(301)
18.8
(272)
17.3
(250)
16.1
(233)
15.1
(219)
(350)
(350)
(350)
(350)
(336)
(310)
(287)
(268)
(259)
Material Group No.
24.1
(252)
24.1
(252)
24.1
(252)
24.1
(252)
23.2
(252)
21.4
(252)
19.8
(252)
18.5
(252)
17.9
(252)
bar (psi)
17.4
17.4
17.4
17.4
17.4
17.4
17.4
17.4
17.4
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
21.3
(309)
19.9
(289)
19.3
(280)
19.1
(277)
19.1
(277)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
22.9
(332)
21.4
(310)
19.9
(288)
19.3
(280)
19.2
(278)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
23.5
(341)
22.7
(329)
21.4
(310)
19.5
(282)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
23.5
(341)
22.7
(329)
21.4
(310)
19.5
(282)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
20.9
(303)
18.7
(271)
16.9
(245)
15.7
(228)
14.5
(210)
24.1
(350)
24.1
(350)
24.1
(350)
24.1
(350)
21.4
(310)
18.7
(271)
15.9
(231)
13.2
(191)
10.5
(152)
Page 15 of 68 flowserve.com
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
Figure 3-10: Minimum continuous flow
MCF % of BEP
Pump size
1K3x2-6 20 % 10 % 10 %
2K3x2-8 20 % 10 % 10 %
2K4x3-8 20 % 10 % 10 %
2K3x2-10 30 % 10 % 10 %
2K4x3-10 30 % 10 % 10 %
2K6x4-10 40 % 10 % 10 %
2K6x4-10H n.a. 20 % 10 %
2K3x1.5-13 30 % 10 % 10 %
2K3x2-13 40 % 10 % 10 %
2K4x3-13 40 % 20 % 10 %
2K6x4-13 60 % 40 % 10 %
All other sizes 10 % 10 % 10 %
3 500/2 900
r/min
1 750/1 450
r/min
1 180/960
r/min
Figure 3-11: Minimum submergence
Figure 3-12: Minimum submergence
4 INSTALLATION
4.1 Location
The pump should be located to allow room for
access, ventilation, maintenance, and inspection with
ample headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped.
Refer to the general arrangement drawing for the
pump set.
4.2 Part assemblies
The supply of motors and baseplates are optional.
As a result, it is the responsibility of the installer to
ensure that the motor is assembled to the pump and
aligned as detailed in section 4.5 and 4.8.
4.3 Foundation
Protection of openings and threads
When the pump is shipped, all threads and all
openings are covered. This protection/covering
should not be removed until installation. If, for any
reason, the pump is removed from service, this
protection should be reinstalled.
4.3.1 Rigid baseplates - overview
The function of a baseplate is to provide a rigid
foundation under a pump and its driver that maintains
alignment between the two. Baseplates may be
generally classified into two types:
• Foundation-mounted, grouted design (Figure 4-1)
• Stilt mounted, or free-standing (Figure 4-2)
Figure 4-1: Foundation mounted baseplate
3.4.6 Viscosity limitations
The allowable viscosity range for Guardian G & H
series pumps is 0.25 cP to 300 cP. Please consult
your Flowserve representative for services with
viscosities less than 0.25 cP.
Figure 4-2: Stilt mounted baseplate
3.4.7 Entrained solids
For process fluids with entrained solids the following
restrictions apply to the solids particles:
• 300 micron (0.012 in.) maximum diameter
• Less than 3.0 % solids by weight
• 2 Moh hardness or less (roughly equivalent to
gypsum)
• No ferrous particles
Page 16 of 68 flowserve.com
GUARDIAN USER INSTRUCTIONS ENGLISH 71569212 08-11
Baseplates intended for grouted installation are
designed to use the grout as a stiffening member.
Stilt mounted baseplates, on the other hand, are
designed to provide their own rigidity. Therefore, the
designs of the two baseplates are usually different.
Regardless of the type of baseplate used, it must
provide certain functions that ensure a reliable
installation. Three of these requirements are:
• The baseplate must provide sufficient rigidity to
assure the assembly can be transported and
installed, given reasonable care in handling,
without damage. It must also be rigid enough
when properly installed to resist operating loads.
• The baseplate must provide a reasonably flat
mounting surface for the pump and driver. Uneven
surfaces will result in a soft-foot condition that may
make alignment difficult or impossible. Flowserve’s
experience indicates that a baseplate that has a top
surface flatness of 1.25 mm/m (0.015 in./ft) across
the diagonal corners of the baseplate provides such
a mounting surface. Therefore, this is the tolerance
to which we supply our standard baseplate. Some
users may desire an even flatter surface, which can
facilitate installation and alignment. Flowserve will
supply flatter baseplates upon request at extra cost.
For example, mounting surface flatness of
0.17 mm/m (0.002 in./ft) is offered on the Flowserve
Type E “Ten Point” baseplate shown in Figure 4-1.
• The baseplate must be designed to allow the
user to final field align the pump and driver to
within their own particular standards and to
compensate for any pump or driver movement
that occurred during handling. Normal industry
practice is to achieve final alignment by moving
the motor to match the pump. Flowserve’s
practice is to confirm in our shop that the pump
assembly can be accurately aligned. Before
shipment, the factory verifies that there is enough
horizontal movement capability at the motor to
obtain a “perfect” final alignment when the
installer puts the baseplate assembly into its
original, top leveled, unstressed condition.
4.3.2 Stilt and spring mounted baseplates
Flowserve offers stilt and spring mounted baseplates.
(See Figure 4-2 for stilt mounted option.) The low
vibration levels of Guardian G & H series pumps
allow the use of these baseplates - provided they are
of a rigid design. The baseplate is set on a flat
surface with no tie down bolts or other means of
anchoring it to the floor.
General instructions for assembling these baseplates
are given below. For dimensional information, please
refer to the appropriate Flowserve “Sales Print.”
4.3.2.1 Stilt mounted baseplate assembly
instructions
Refer to Figure 4-3.
a) Raise or block up baseplate/pump above the floor
to allow for the assembly of the stilts.
b) Predetermine or measure the approximate
desired height for the baseplate above the floor.
c) Set the bottom nuts (item 2) above the stilt bolt
head (item 1) to the desired height.
d) Assemble lock washer (item 3) down over the stilt
bolt.
e) Assemble the stilt bolt up through hole in the
bottom plate and hold in place.
f) Assemble the lock washer (item 3) and nut (item 2)
on the stilt bolt. Tighten the nut down on the lock
washer.
g) After all four stilts have been assembled, position
the baseplate in place, over the floor cups (item
4) under each stilt location, and lower the
baseplate to the floor.
h) Level and make final height adjustments to the
suction and discharge pipe by first loosening the
top nuts and turning the bottom nuts to raise or
lower the baseplate.
i) Tighten the top and bottom nuts at the lock
washer (item 3) first then tighten the other nuts.
j) It should be noted that the connecting pipelines
must be individually supported, and that the stilt
mounted baseplate is not intended to support
total static pipe load.
Figure 4-3: Assembly – baseplate stilt
4.3.2.2 Stilt/spring mounted baseplate assembly
instructions
Refer to Figure 4-4
a) Raise or block up baseplate/pump above the floor
to allow for the assembly of the stilts.
b) Set the bottom nuts (item 4) above the stilt bolt
head (item 1). This allows for 51 mm (2 in.)
upward movement for the final height adjustment
of the suction/discharge flange.
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c) Assemble the lock washer (item 6) flat washer
(item 5) and bottom spring/cup assembly (item 2)
down over the stilt bolt (item 1).
d) Assemble the stilt bolt/bottom spring up through
hole in the bottom plate and hold in place.
e) Assemble top spring/cup assembly (item 3) down
over stilt bolt.
f) Assemble flat washer (item 5), lock washer (item 6)
and nuts (item 4) on the stilt bolt.
g) Tighten down top nuts, compressing the top
spring approximately 12 mm (0.5 in.).
h) After all four stilts have been assembled, position
the baseplate in place, over the floor cups (Item 7)
under each stilt location, and lower the baseplate
down to the floor.
i) Level and make final height adjustments to the
suction and discharge pipe by first loosening the
top nuts, and turning the bottom nuts to raise or
lower the baseplate.
Figure 4-4: Assembly – baseplate stilt/spring
j) To make the stilt bolts more stable, tighten down
on the top nuts, compressing the top spring
approximately 12 mm (0.5 in), and lock the nuts
in place.
k) It should be noted that the connecting pipelines
must be individually supported, and that the
spring mounted baseplate is not intended to
support total static pipe loads.
4.3.2.3 Stilt/spring mounted baseplates - motor
alignment
The procedure for motor alignment on stilt or spring
mounted baseplates is similar to grouted baseplates.
The difference is primarily in the way the baseplate is
leveled.
a) Level the baseplate by using the stilt adjusters.
(Shims are not needed as with grouted
baseplates.) After the base is level, it is locked in
place by locking the stilt adjusters.
b) Next the initial pump alignment must be checked.
The vertical height adjustment provided by the
stilts allows the possibility of slightly twisting the
baseplate. If there has been no transit damage
or twisting of the baseplate during stilt height
adjustment, the pump and driver should be within
0.38 mm (0.015 in.) parallel, and 0.0025 mm/mm
(0.0025 in./in.) angular alignment. If this is not
the case, check to see if the driver mounting
fasteners are centered in the driver feet holes.
c) If the fasteners are not centered there was likely
shipping damage. Re-center the fasteners and
perform a preliminary alignment to the above
tolerances by shimming under the motor for
vertical alignment, and by moving the pump for
horizontal alignment.
d) If the fasteners are centered, then the baseplate
may be twisted. Slightly adjust (one turn of the
adjusting nut) the stilts at the driver end of the
baseplate and check for alignment to the above
tolerances. Repeat as necessary while maintaining
a level condition as measured from the pump
discharge flange. Lock the stilt adjusters.
The remaining steps are as listed for new grouted
baseplates.
4.4 Grouting
a) The pump foundation should be located as close to
the source of the fluid to be pumped as practical.
b) 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.
c) Recommended mass of a concrete foundation
should be three times that of the pump, motor
and base. Refer to figure 4-5.
Foundation bolts are imbedded in the
concrete inside a sleeve to allow some
movement of the bolt.
Figure 4-5: Baseplate anchoring
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d) Level the pump baseplate assembly. If the
baseplate has machined coplanar mounting
surfaces, these machined surfaces are to be
referenced when leveling the baseplate. This may
require that the pump and motor be removed from
the baseplate in order to reference the machined
faces. If the baseplate is without machined
coplanar mounting surfaces, the pump and motor
are to be left on the baseplate. The proper surfaces
to reference when leveling the pump baseplate
assembly are the pump suction and discharge
flanges. DO NOT stress the baseplate.
e) Do not bolt the suction or discharge flanges of the
pump to the piping until the baseplate foundation
is completely installed. If equipped, use leveling
jackscrews to level the baseplate. If jackscrews
are not provided, shims and wedges should be
used. (See Figure 4-5.) Check for levelness in
both the longitudinal and lateral directions. Shims
should be placed at all base anchor bolt locations,
and in the middle edge of the base if the base is
more than 1.5 m (5 ft.) long. Do not rely on the
bottom of the baseplate to be flat. Standard
baseplate bottoms are not machined, and it is not
likely that the field mounting surface is flat.
f) After leveling the baseplate, tighten the anchor
bolts. If shims were used, make sure that the
baseplate was shimmed near each anchor bolt
before tightening. Failure to do this may result in
a twist of the baseplate, which could make it
impossible to obtain final alignment.
g) Check the level of the baseplate to make sure
that tightening the anchor bolts did not disturb the
level of the baseplate. If the anchor bolts did
change the level, adjust the jackscrews or shims
as needed to level the baseplate.
h) Continue adjusting the jackscrews or shims and
tightening the anchor bolts until the baseplate is
level.
i) Check initial alignment. If the pump and motor
were removed from the baseplate proceed with
step j) first, then the pump and motor should be
reinstalled onto the baseplate using Flowserve’s
factory preliminary alignment procedure as
described in section 4.5, and then continue with
the following. As described above, pumps are
given a preliminary alignment at the factory. This
preliminary alignment is done in a way that
ensures that, if the installer duplicates the factory
conditions, there will be sufficient clearance
between the motor hold down bolts and motor foot
holes to move the motor into final alignment. If the
pump and motor were properly reinstalled to the
baseplate or if they were not removed from the
baseplate and there has been no transit damage,
and also if the above steps where done properly,
the pump and driver should be within 0.38 mm
(0.015 in.) FIM (Full Indicator Movement) parallel,
and 0.0025 mm/mm (0.0025 in./in.) FIM angular.
If this is not the case, first check to see if the driver
mounting fasteners are centered in the driver feet
holes. If not, re-center the fasteners and perform
a preliminary alignment to the above tolerances by
shimming under the motor for vertical alignment,
and by moving the pump for horizontal alignment.
j) Grout the baseplate. A non-shrinking grout
should be used. Make sure that the grout fills the
area under the baseplate. After the grout has
cured, check for voids and repair them.
Jackscrews, shims and wedges should be
removed from under the baseplate at this time. If
they were to be left in place, they could rust,
swell, and cause distortion in the baseplate.
k) Run piping to the suction and discharge of the
pump. There should be no piping loads
transmitted to the pump after connection is made.
Recheck the alignment to verify that there are no
significant loads.
4.5 Initial alignment
4.5.1 Horizontal initial alignment procedure
The purpose of factory alignment is to ensure that the
user will have full utilization of the clearance in the
motor holes for final job-site alignment. To achieve
this, the factory alignment procedure specifies that
the pump be aligned in the horizontal plane to the
motor, with the motor foot bolts centered in the motor
holes. This procedure ensures that there is sufficient
clearance in the motor holes for the customer to field
align the motor to the pump, to zero tolerance. This
philosophy requires that the customer be able to
place the base in the same condition as the factory.
Thus the factory alignment will be done with the base
sitting in an unrestrained condition on a flat and level
surface. This standard also emphasizes the need to
ensure the shaft spacing is adequate to accept the
specified coupling spacer.
The factory alignment procedure is summarized below:
a) The baseplate is placed on a flat and level
workbench in a free and unstressed position.
b) The baseplate is leveled as necessary. Leveling
is accomplished by placing shims under the rails
of the base at the appropriate anchor bolt hole
locations. Levelness is checked in both the
longitudinal and lateral directions.
c) The motor and appropriate motor mounting
hardware is placed on the baseplate and the
motor is checked for any planar soft-foot
condition. If any is present it is eliminated by
shimming
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d) The motor feet holes are centered on the motor
mounting fasteners. This is done by using a
centering nut as shown in Figure 4-6.
Figure 4-6: Motor centering fastener
e) The motor is fastened in place by tightening the
nuts on two diagonal motor mounting studs.
f) The pump is put onto the baseplate and leveled.
The foot piece under the bearing housing is
adjustable. It is used to level the pump, if
necessary. If an adjustment is necessary, add
or remove shims [3126.1] between the foot piece
and the bearing housing.
g) The spacer coupling gap is verified.
h) The parallel and angular vertical alignment is
made by shimming under the motor.
i) The motor feet holes are again centered on the
motor mounting studs using the centering nut.
At this point the centering nut is removed and
replaced with a standard nut. This gives
maximum potential mobility for the motor to be
horizontally moved during final, field alignment.
All four motor feet are tightened down.
j) The pump and motor shafts are then aligned
horizontally, both parallel and angular, by
moving the pump to the fixed motor. The pump
feet are tightened down.
k) Both horizontal and vertical alignment is again
final checked as is the coupling spacer gap.
See section 4.8 for Final Shaft Alignment
4.6 Piping
The 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.
4.6.1 4.6.1 Suction and discharge 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 or
compensate for misalignment. It should be possible
to install suction and discharge bolts through mating
flanges without pulling or prying either of the flanges.
All piping must be tight. Pumps may air-bind if air is
allowed to leak into the 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.
4.6.2 Suction piping
To avoid NPSH and suction problems, suction piping
must be at least as large as the pump suction
connection. Never use pipe or fittings on the suction
that are smaller in diameter than the pump suction size.
Figure 4-7 illustrates the ideal piping configuration with a
minimum of 10 pipe diameters between the source and
the pump suction. In most cases, horizontal reducers
should be eccentric and mounted with the flat side up as
shown in Figure 4-8 with a maximum of one pipe size
reduction. Never mount eccentric reducers with the flat
side down. Horizontally mounted concentric reducers
should not be used if there is any possibility of entrained
air in the process fluid. Vertically mounted concentric
reducers are acceptable. In applications where the fluid
is completely deaerated and free of any vapor or
suspended solids, concentric reducers are preferable to
eccentric reducers
Figures 4-7 and Figure 4-8
Avoid the use of throttling valves and strainers in the
suction line. Start up strainers must be removed shortly
before start up. When the pump is installed below the
source of supply, a valve should be installed in the
suction line to isolate the pump and permit pump
inspection and maintenance. However, never place a
valve directly on the suction nozzle of the pump.
Refer to the Durco Pump Engineering Manual and
the Centrifugal Pump IOM Section of the Hydraulic
Institute Standards for additional recommendations
on suction piping. (See section 10.)
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Refer to section 3.4 for performance and operating
limits.
4.6.2.1 Guardian self-priming pumps
The suction piping must be as short as possible and be
as close to the diameter of the suction nozzle as is
practical. The pump works by removing the air
contained in the suction piping. Once removed, it
operates exactly the same as a flooded suction
standard pump. Longer and larger suction pipes have a
greater volume of air that has to be removed, resulting
in longer priming time. The suction piping and seal
chamber must be airtight to allow priming to occur.
When possible, it is recommended that suction piping
be sloped slightly towards the casing to ensure no fluid
is lost down the suction line during priming.
4.6.3 Discharge piping
Install a valve in the discharge line. This valve is
required for regulating flow and/or to isolate the pump
for inspection and maintenance.
When fluid velocity in the pipe is high,
for example, 3 m/s (10 ft/s) or higher, a rapidly
closing discharge valve can cause a damaging
pressure surge. A dampening arrangement should
be provided in the piping.
4.6.3.1 Guardian self-priming pumps
During the priming cycle, air from the suction piping is
evacuated into the discharge piping. There must be
a way for this air to vent. If air is not able to freely
vent out the discharge pipe, it is typically
recommended to install an air bleed line. The air
bleed line is typically connected from the discharge
pipe to the sump. Care must be taken to prevent air
from re-entering suction pipe.
4.6.4 Allowable nozzle loads
Flowserve chemical process pumps meet or exceed
the allowable nozzle loads given by ANSI/HI 9.6.2.
The following paragraphs describe how to calculate
the allowable loads for each pump type and how to
determine if the applied loads are acceptable. The
configuration covered is for ASME B73.3 pumps,
including the Guardian G & H series.
4.6.4.1 Guardian G & H series pumps (ASME
B73.3)
The following steps are based upon ANSI/HI 9.6.2.
All information necessary to complete the evaluation
is given below. For complete details please review
the standard.
a) Determine the appropriate casing “Material Group
No.” from figure 3-8.
b) Find the “Casing material correction factor” in
Figure 4-9 based upon the “Material Group No.”
and operating temperature. Interpolation may be
used to determine the correction factor for a
specific temperature.
c) Find the “Baseplate correction factor” in Figure
4-10. The correction factor depends upon how
the baseplate is to be installed.
d) Locate the pump model being evaluated in Figure
4-14 and multiply each load rating by the casing
correction factor. Record the “adjusted Figure 4-14
loads”.
e) Locate the pump model being evaluated in
Figures 4-15 and 4-16 and multiply each load
rating by the baseplate correction factor. Record
the adjusted Figure 4-15 and 4-16 loads.
f) Compare the “adjusted Figure 4-14 loads” to the
values shown in figure 4-13. The lower of these
two values should be used as the adjusted figure
4-13 values. (The HI standard also asks that figure
4-13 loads be reduced if figure 4-15 or 4-16 values
are lower. Flowserve does not follow this step.)
g) Calculate the applied loads at the casing flanges
according to the coordinate system found in
figure 4-11. The 12 forces and moments possible
are Fxs, Fys, Fzs, Mxs, Mys, Mzs, Fxd, Fyd, Fzd,
Mxd, Myd and Mzd. For example, Fxd
designates Force in the “x” direction on the
discharge flange. Mys designates the Moment
about the “y”-axis on the suction flange.
h) Figure 4-12 gives the acceptance criteria
equations. For long coupled pumps, equation
sets 1 through 5 must be satisfied. For close
coupled pumps, only equation sets 1 and 2 must
be satisfied.
i) Equation set 1. Each applied load is divided by
the corresponding adjusted figure 4-13 value.
The absolute value of each ratio must be less
than or equal to one.
j) Equation set 2. The summation of the absolute
values of each ratio must be less than or equal to
two. The ratios are the applied load divided by
the adjusted figure 4-14 values.
k) Equation sets 3 and 4. These equations are
checking for coupling misalignment due to nozzle
loading in each axis. Each applied load is divided
by the corresponding adjusted load from figure 4-15
and 4-16. The result of each equation must be
between one and negative one.
l) Equation set 5. This equation calculates the total
shaft movement from the results of equations 3
and 4. The result must be less than or equal to
one.
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