Flowserve HED Worthington User Manual

USER INSTRUCTIONS

®

Worthington
pumps

HED/HED-DS centrifugal

Installation

Operation

Double stage, double suction, radially split volute type
centrifugal pumps

PCN=85392695 –06/14 (E) Original instructions

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

CONTENTS

PAGE

CONTENTS ............................................................... 2

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 ..................... ................................... 8

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

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

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

2.3 Lifting ................................. ............................. 10

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

2.5 Recycling and end of product life ................... 12

3 PUMP DESCRIPTION .......................................... 13

3.1 Configurations ................................................ 13

3.2 Nomenclature ................................................. 13

3.3 Design of major parts ..................................... 13

3.4 Performance and operating limits .................. 14

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

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

4.2 Part assemblies ............................................. 15

4.3 Foundation .................................................... 15

4.4 Grouting ......................................................... 17

4.5 Initial alignment ............................................ .. 18

4.6 Piping ............................ ................................ 20

4.7 Final shaft alignment check ........................... 22

4.8 Electrical connections .................................... 22

4.9 Protection systems ......................................... 22

PAGE

7 FAULTS; CAUSES AND REMEDIES .................... 45

8 PARTS LIST AND DRAWINGS ............................ 47

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

10 OTHER RELEVANT DOCUMENTATION AND

6.4 Recommended spares (according to API) ..... 35

6.5 Tools required ................................................. 35

6.6 Fastener torques .................... ........................ 36

6.7 Disassembly ................................................... 37

6.8 Examination of parts ....................................... 39

6.9 Assembly ........................................................ 42

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

10.1 Supplementary User Instruction manuals .... 62

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

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

5 COMMISSIONING, START-UP, OPERATION AND

SHUTDOWN .................................................... 23

5.1 Pre-commissioning procedure ....................... 23

5.2 Pump Lubricants ............................................ 28

5.3 Direction of rotation ....................................... 30

5.4 Guarding ....................................................... 31

5.5 Priming and auxiliary supplies ..... ... .... .... .... .. 31

5.6 Starting the pump .......................................... 31

5.7 Operating checks .......................................... 31

5.8 Normal Start Up ............................................. 33

5.9 Stopping the pump ......................................... 33

5.10 Hydraulic, mechanical and ........................... 33

electrical duty ....................................................... 33

6 MAINTENANCE .............................................. ...... 33

6.1 General ................................................ .......... 33

6.2 Maintenance schedule ................................... 34

6.3 Spare parts..................................................... 35

Page 2 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

INDEX

PAGE

Additional sources of information (10.3) ............. 62

Alignment methods (4.5.2) ................................. 18

Assembly (6.9) .................................................... 42

Associated equipment (2.4.1.5) .......................... 12

Avoiding excessive surface temperatures(1.6.4.3)7

Bearings (5.7.3) .................................................. 32

CE marking and approvals (1.2) ........................... 4

Certification (9) ................ .... ... .... .... .... .... ... .... .... . 62

Change notes (10.2) .................................. .... .... . 62

Commissioning, startup, operation (5)................ 23

Configurations (3.1) ............................................ 13

Consignment receipt and unpacking (2.1) .......... 10

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

Design of major parts (3.3) ................................. 13

Direction of rotation (5.3) .................................... 30

Disassembly (6.7) ............................................... 37

Discharge piping (4.6.3) ..................................... 21

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

Dismantling of thrust bearing (6.7.2) .................. 38

Dismantling of line bearing (6.7.3) ...................... 38

Disassembly of rotor (6.7.4) ............................... 39

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

Electrical connections (4.8) ................................ 22

Examination of parts (6.8) ......................... .... ..... 39

Fastener torques (6.6) ........................................ 36

Faults; causes and remedies (7) ........................ 45

Foundation (4.3) ..................... .... .... ........ ... .... .... . 15

Grouting (4.4) ...................................................... 17

Guarding (5.4) ..................................................... 31

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

Hydraulic, mechanical and electrical duty (5.10) . 33

Initial alignment (4.5) ......................................... . 18

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

Introduction and safety (1) .................................... 4

Inspection and maintenance (2.4.1.3) ................ 11

Lifting (2.3) .......................................................... 10

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

Long term storage (2.4.1) ................................... 11

Lubrication (5.1.1) ............................................... 23

Maintenance to avoid the hazard (1.6.4.7) ........... 8

Maintenance (6) .................................................. 33

Maintenance schedule (6.2) ............................... 34

Marking (1.6.4.2) ................................................... 7

Mechanical seals (6.8.3) ..................................... 40

Nameplate and safety labels (1.7) ............... ... .... . 8

Noise level (1.9) ................ ................................... 8

Ordering of spares (6.3.1) .................................. 35

Other relevant documentation and manuals(10) 62

Parts list and Drawings (8) ................................. 47

Performance and operating limits (3.4) .............. 14

Personnel qualification and training (1.6.2) .......... 5

Piping (4.6) ......................................................... 20

Pressure and/or flow control (3.4.8) ................... 15

Preventing the build up of explosive mix. (1.6.4.4) 7

Preventing sparks (1.6.4.5) .................................. 8

Preventing leakage (1.6.4.6) ............................... . 8

Products used in potentially explosive atm. (1.6.4)6

Protection systems (4.9) .................................... 22

Primary and auxiliary supplies (5.5) ................... 31

Pump description (3) .......................................... 13

Pumps with mechanical seals (4.6.5)................. 22

Recommended spares (6.4) ............................... 35

Recycling and end of product life (2.5)............... 12

Routine inspection (daily/weekly) (6.2.1) ........... 34

Safety (1.6) ............. .............................................. 5

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

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

Scope of compliance (1.6.4.1) ............................. 6

Spare parts (6.3) ................................................ 35

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

Starting the pump (5.6) ...................................... 31

Stopping the pump (5.9) ..................................... 33

Storage (2.4) ...................................................... 11

Storage of spares (6.3.2) ................................... 35

Suction piping (4.6.2) ........ .... .... ....... .... .... .... .... .. 21

Summary of safety markings (1.6.1) .................... 5

Supplementary user instructions (10.1) ............. 62

Thermal control (3.4.7) ....................................... 15

Tools required (6.5) ............................................ 35

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

Page 3 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

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's 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 installation and
operation or about its support products, repair and
diagnostic services.

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

These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow and
apply the present user instructions is considered
to be misuse. Personal injury, product damage,
delay or failures 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 Instruc tions is believed
to be reliable. In spite of all the efforts of
Flowserve to provide sound and all necessary
information the content of this man ual may appea r
insufficient and is not guaranteed by Flowserv e as
to its completeness or accuracy.

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
continued product quality and performance in use. A s
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 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 Corporation.

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.

Page 4 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

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 Flowserve’s written agreement before start up.

1.6 Safety

1.6.1 Summary of safety markings

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

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

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

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

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

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

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

1.6.3 Safety action

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

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 pressur e,
acts on the pump flange.

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

START THE PUMP WITH OUTLET
V ALVE PAR TLY OPENED
(Unless otherwise instructed at a specific point 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 where this situation
cannot occur. The pump outlet control valve may
need to be adjusted to comply with the duty following
the run-up process. (See section 5, Commissioning
start-up, operation and shutdown.)

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 used where non­compliance 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.

Page 5 of 64

NEVER RUN THE PUMP DRY

INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the seal.

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 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.

NEVER DO MAINTENANCE WORK

WHEN THE UNIT IS CONNECTED TO POWER

HAZARDOUS LIQUIDS

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

When the pump is handling hazardous liquids care must
be taken to avoid exposure to the liquid by appropriate
siting of the pump, limiting personnel access and by
operator training. If the liquid is flammable and/or
explosive, strict safety procedures must be applied.

Gland packing must not be used when pumping
hazardous liquids.

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

FLUORO-ELASTOMERS (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.

GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
The unit must not be operated unless coupling guard is
in place. Failure to observe this warning could result in
injury to operating personnel.

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 lubrican t or vap our could c ause an ex plosion .

HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action m ust 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 entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.

If the temperature is greater than 80 °C (175 °F) or
below -5 °C (20 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.

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 poten tially exp losive at mosph eres
must be followed to help ensure explosion protection.
Both electrical and non-electrical equipment must meet
the requirements of European Directive 94/9/EC.

1.6.4.1 Scope of compliance

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

Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the pump set shall
select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.

The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so, for
pumps sets with a VFD, the ATEX Certification for the
motor must state that it is covers the situation where
electrical supply is from the VFD. This particular
requirement still applies even if the VFD is in a safe
area.

Page 6 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

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

Maximum surface temperature (Temperature Clas s )
(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 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 and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.

Temperature

class to

EN 13463-1

T6
T5
T4
T3
T2
T1

Maximum

surface

temperature

permitted

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

Temperature limit of liquid

handled (* depending on

material and construction

variant - check which is

lower)

Consult Flowserve
Consult Flowserve

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

The responsibility for compliance with the
specified maximum liqu id 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 its actual installed location.

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 high temperature resulting from
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 it is recommended that
users fit an external surface temperature protection
device.

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

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

1.6.4.4 Preventing the build up of explosive
mixtures

ENSURE THE PUMP IS PROPERLY FILLED

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

pipeline system is totally filled with 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 the system cannot avoid this
condition the fitting of an appropriate dry run
protection device is recommended (eg liquid
detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.

Page 7 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking
and anti-static for Category 2.

To avoid the potential hazard from random
induced current generating a spark, the earth contact
on the base plate must be used.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth ensure cloth is damp.
The coupling must be selected to comply with
2006/42/EC and correct alignment must be
maintained.

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 ancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.

1.6.4.7 Maintenance to avoid the haz ard

1.7 Nameplate and safety labels

1.7.1 Nameplate

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

these User Instructions.

1.7.2 Safety labels

CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION

The responsibility for compliance with maintenance
instructions is with the plant operator.

To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials; maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)

Page 8 of 64

1.8 Specific machine performance

For performance parameters see section 1.5, Duty
conditions. Pump performance data are summarised

on pump data sheet which is included in proper
section of “Job User’s Instruct ion”.

1.9 Noise level

When pump noise level exceeds 85 dBA attention
must be given to prevailing Health and Safety
Legislation, to limit the exposure of plant operating
personnel to the noise. The usual approach is to
control exposure time to the noise or to enclose the

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

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 machines above a
certain power level will exceed 85 dBA. In such
situations consideration must be given to the fitting of
an acoustic enclosure to meet local regulations.

If a pump unit only has been purchased, for fitting
with your own driver, then the "pump only" noise
levels should be combined with the level for the driver
obtained from the supplier. If the m otor is driven by
an inverter, it may show an increase in noise level at
some speeds. Consult a Noise Specialist for the
combined calculation.

Pump noise level is dependent on a number of
factors - the type of motor fitted, the operating
conditions, pipework design and acoustic
characteristics of the building. The levels specified in
the table 1.1 are estimated and not guaranteed.

The dBA values are based on the noisiest ungeared
electric motors that are likely to be encountered.
They are Sound Pressure levels at 1 m (3.3 ft) from
the directly driven pump, for "free field over a
reflecting plane".

 For units driven by equipment other than

electric motors or units contained within enclosures,
see the accompanying information sheets and
manuals.

Typical sound pressure level, dBA, L

Motor size
and speed

kW (hp)

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

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

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

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

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

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

7.5 (10) 76 77 72 75 66 67 64 65

11 (15) 80 81 76 78 70 71 68 69

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

18.5 (25) 81 81 77 78 71 71 69 71
22 (30) 81 81 77 79 71 71 69 71
30 (40) 83 83 79 81 73 73 71 73
37 (50) 83 83 79 81 73 73 71 73
45 (60) 86 86 82 84 76 76 74 76
55 (75) 86 86 82 84 76 76 74 76
75 (100) 87 87 83 85 77 77 75 77
90 (120) 87 88 83 85 77 78 75 78

110 (150) 89 90 85 87 79 80 77 80
132 (175) 89 90 85 87 79 80 77 80
150 (200) 89 90 85 87 79 80 77 80
160 (215) (1) (1) (1) (1) 83 84 81 83
200 (270) (1) (1) (1) (1) 85 87 83 85
300 (400) 87 90 85 86
315 (422) 87 90 85 86
355 (475) 87 90 86 87

500 (670) 88 (1) 86 (1)
1000 (1300) 90 (1) 88 (1)
1500 (2000) 90 (1) 90 (1)

(1) Noise levels of machines in this range should be based on actual equipment selected

For 1180 and 960 r/min reduce the 1450 r/min values by 2dBA

For 880 and 720 r/min reduce the 1450 r/min values by 3dBA

3500 rpm 2900 rpm 1750 rpm 1450 rpm

Pump

only

dBA

B

B at 1 m reference 20 μPa (LBwAB sound power 1pW where LB

pA

Pump &

motor

dBA

Pump

only

dBA

Pump &

motor

dBA

Pump

only

dBA

Pump &

motor

dBA

Pump

only

dBA

B >85 dBA)

pA

Pump &

motor

dBA

Page 9 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be
checked against the delivery and 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 received in writing
within one month of receipt of the equipment. Later
claims cannot be accepted.

Check any crates, boxes and wrappings for any
accessories or spare parts which may be packed
separately with 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
always quote this number in correspondence as well
as when ordering spare p a rts or further accessories.

2.2 Handling

2.2.1 General instructions concerning handling

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

To lift machines or pieces with one or several
suspension rings, only use hooks and chains in
compliance with the local regulations concerning
safety. Never put cables, chains or ropes directly on
or in the suspension rings. Cables, chains or lifting
ropes must never present excessive bending.

Never bend the 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 the lifting force direction makes an angle
with the device axis.

To increase the safety and the efficiency of the lifting
device, all the lifting elements must be as
perpendicular as possible. If necessary a lifting b eam
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 swing or fall away.

Never leave a load hanging from a 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 precautions must be taken to avoid the
swing of the load, using for example two winches
making approximately the same angle, below 30°,
with the vertical.

2.3 Lifting

Make sure that any equipment used to
lift the pump or any of its components is capable of
supporting the weights encountered. Make sure that
all parts are correctly rigged before attempting to lift.

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
general arrangement drawing included into the job
user’s instruction.

2.3.1 To Lift unit

Pump, driver and baseplate can be lifted as a unit.
Sling from all four (4) eye bolts provided on baseplate
side rails. Failure to use all four (4) could result in
permanent distortion of the baseplate. Use as long a
sling as possible, or use a spreader arrangement.

Coupling bolting and spacer piece

must be removed from between pump and driver
half couplings before lifting baseplate with
pumping element.
To lift pump and baseplate, less driver, or
baseplate alone, sling from all four (4) eye bolts.

Do not lift pump, motor, base plate
unit by slinging from pump casing and/or eye bolt
on motor.

2.3.2 To lift driver

Refer to Manufacturers Instructions.

2.3.3 To lift complete pump only

Rig lifting straps at coupling end bearing bracket and
outboard bearing bracket. Make sure straps are
adjusted to obtain an even lift.

Page 10 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

2.4 Storage

Store the pump in a clean, dry location
away from vibration. Leave piping connection covers
in 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,
from sticking.
Electric Motors (Pump Driver) should not be stored in
damp places without special protection (Refer to
Motor manufacturers instructions).

The pump may be stored as above for up to 6
months.

2.4.1 Long term storage

During extended periods of storage prior to
installation, precautions must be taken to protect the
pump from deterioration. The various parts of the
pump are protected prior to shipment by applying
varying grades of preservative to the parts. However,
during shipment and handling the preservatives are
subjected to conditions that can cause their removal.
Also, during extended periods of time the
preservatives may deteriorate. The listed procedures
(2.4.1.1 to 2.4.1.5) should be followed to prevent
deterioration of the pump during the extended
storage period. These procedures may also be
supplemented by the experience of the person(s)
performing the tasks.

2.4.1.1 Inspection upon arrival

When the pump is received it should be inspected for
damage or other signs of rough handling. If any
damage is found it should be reported to the carrier
immediately. Inspect the preservative coating on
various parts. If necessary, renew preservative in
areas where it has been rubbed or scraped.
Inspect all painted surfaces. If necessary, touch up
the areas where paint has been chipped or scraped.

Inspect all covers over pump openings and piping
connections. If covers or seals for the covers are
damaged or loose, they are to be removed, and a
visual inspection made of the accessible interior
areas for accumulation of foreign materials or water.
If necessary, clean and preserve the interior parts as
noted above to restore the parts to the "as sh ipped"
condition. Install or replace covers and fasten
securely.

2.4.1.2 Storage

If at all possible, the pump and its

component parts should be stored indoors where
they will be protected from the elements. In no case
should any pump element be subjected to extended
periods of submergence or wetting prior to start up. If
it is not possible to store the pump and its
components indoors, precautions must be taken to
protect them from the elements. Regardless of
whether storage is indoors or outside, the storage
area should be vibration free. All boxes marked for
indoor storage should be stored indoors. When
stored outdoors the pump and its components should
be protected from dirt, dust, rain, snow, or other
unfavourable conditions by heavy plastic sheets,
canvas, waterproof burlap or other suitable coverings.
All equipment must be placed upon skids or blocks to
prevent contact with the ground and surface
contaminants. Equipment must be adequately
supported to prevent distortion and bending.
The pump shaft should be rotated, in the direction of
rotation, at least 1 and 1/4 turns each week during
the storage period and any other periods of stand by.
When selecting a storage area the following should
be taken into
consideration.

a) The deterioration of the equipment will be

proportionate to the class of storag e pr ov ide d.

b) The expenses involved in restoring the

equipment at time of installation will be
proportionate to the class of storag e pr ov ide d.

2.4.1.3 Inspection and maintenance

The stored equipment has to be placed on a periodic
inspection schedule by the purchaser.
The responsibility for setting up an inspection
schedule rests with the purchaser and will be
dependent upon the class of storage provided. It
would be expected initially, inspection would occur
weekly, then depending upon the inspection reports
being favourable or unfavourable, inspection would
continue weekly, monthly, or quarterly, as may be
determined.

Page 11 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

Each inspection should consist of a general surface
inspection to assure that:

a) Pump supports are firmly in place.
b) Pump covers over openings are firmly in place.
c) Pump coverings, plastic or tarps are firmly in

place. Any holes or tears must be repaired to
prevent entrance of dirt or water.

d) Pump covers are periodically removed from

openings and interior accessible areas inspected.
If surface rusting has occurred, clean or coat with
preservative.

e) If rusting occurs on exterior surfaces clean and

repaint or coat with preservative.

f) Check individually wrapped parts for signs of

deterioration. If necessary, renew preservative
and wrapping.

Six months prior to the scheduled installation date, a
FLOWSERVE representative is to be employed to
conduct an inspection. This inspection may include,
not necessarily in its entirety and not limited to the
following:

a) An inspection of all periodic inspection r ecords as

kept on file by the purchaser, and all inspection
reports that have been compiled during the
storage period.

b) An inspection of the storage area to determine

the "as stored" condition of the equipment prior to
any protection covers being removed.

c) An inspection of the equipment with protective

covers and flange covers removed.

d) Depending upon the length of time the equipment

was stored, the type of storage provided (i.e.
Indoor: heated, unheated, ground floor, concrete
floor. Outdoors: under roof, no roof, waterproof
coverings, on concrete, on ground) and as a
result of the inspection of (a),( b) & (c) above the
FLOWSERVE representative may require a
partial or complete dismantling of the equipment.

e) Dismantling may necessitate restoration of

painted or preserved surfaces, and, or
replacement of gaskets, "O" rings, packing and
bearings.

f) All costs involved during inspection, dismantling,

restoration, replacement of parts and reassembly
will have to the accounted to the purchaser. All
necessary labour, tools and cranes will be
supplied by the purchaser.

Upon completion of the inspection the FLOWSERVE
representative shall submit a report to the purchaser,
and to the Manager of Customer Service, stating in
detail the results of the inspection.

One month prior to installation of the equipment, a
FLOWSERVE representative is to be employed to
conduct a final inspection.
This inspection will be made to assure that the
requirements of the six months inspection report were
satisfactorily completed and that the equipment is
ready for installation.
Upon completion of this inspection the FLOWSERVE
representative shall submit a final report to the
purchaser, and to the Manager of Customer Service,
advising the results of the final inspection.
All costs involved in conducting the final inspection
will have to the accounted to the purchaser.
Prior to and during start up, any requirements for the
services of an FLOWSERVE representative will
revert back to the original contract agreement for
equipment purchased, with revised costing.

2.4.1.4 Painting and preservation

Paints and preservatives used are either
FLOWSERVE standard or 'special' as required by the
contract specification. Refer to FLOWSERVE for the
description of paints and preservatives used on this
order if needed.

2.4.1.5 Associated equipment

Motors, Turbines, Gears, etc., being supplied by
FLOWSERVE.
Generally rotors of associated equipment should be
blocked to relieve bearing loads. Storage should be
indoors and dry. See the specific manufacturers
storage requirement s.

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 local regulations. If the
product contains substances which are harmful to the
environment, these should be removed and disposed
of in accordance with current regulations. This also
includes the liquids and or gases in the "seal system"
or other utilities.

Make sure that hazardous substances o r
toxic fluids are disposed of safely and that the
correct personal protective equipment is used.
The safety specifications must be in accordance
with the current regulations at all times.

Page 12 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

3 PUMP DESCRIPTION

3.1 Configurations

HED pumps are horizontal two stage, radially split,
top/top flanged, between bearings centerline
mounted for heavy duty process services in full
compliance with API 610 standard. All sizes are
suitable for both 50 and 60 cycle operation. To
reduce NPSH requirements the HED can be fitted
with an inducer in front of the first impeller (HED-I) or
with a double suction first stage (HED-DS).

3.2 Nomenclature

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

6-HED-17-A

Nominal discharge branch size
Pump type
Nominal full size impeller diameter
Casing pattern type
The typical nomenclature above is the general guide

to the HED/HED-DS description. Identify the actual
pump size and serial number from the pump
nameplate. Check that this agrees with the applicable
certification provided.

3.3 Design of major parts

3.3.1 Pump casing

The casing is radially split with top suction and
discharge nozzles integrally cast.
This construction simplifies piping layout reducing
space requirements. Side/side or side/top
arrangements are available on request for particular
applications.
The mounting is centerline to retain alignment even at
elevated temperatures, permitting equal expansion in
all directions, and to give positive support to the
pump.
The first and second stage single volutes are
opposed to reduce hydraulic radial thrust and shaft
deflection, and the liquid is conveyed from the one to
the other by an integral cast crossover. The
interstage diaphragm too is integrally cast with the
casing. All the flow passages are accurately designed
to minimize efficiency losses.

3.3.2 Impeller

The standard impellers, single suction of the closed
type, are keyed to the shaft and secured by positive

locking devices. They are mounted face to face to
balance the hydraulic axial forces.
Impellers first and then the complete rotor are
dynamically balanced to avoid vibrations and assure
long trouble free life to seals and bearings.
Ceramic core castings are used to assure smooth
passages and the highest efficiency. Large eye areas
and low-entrance velocities give the pump very low
NPSH requirements, when extremely low NPSH
requirements are encountered, HED pumps can be
fitted with an inducer or with a double suction first
stage impeller.
Some pump sizes have more than one impeller
design, with differentiated B.E.P. capacities, for
maximum flexibility and operation with high
efficiencies throughout the coverage.

3.3.3 Wearing Rings

The casing and the impellers are fitted with
replaceable wear rings of hardened material. The
rings are held in place by a press fit with locking pins
on the casing and with threaded dowels on the
impellers.

3.3.4 Rotors

Rotors are of the stiff shaft design.
Shafts are of ample diameter, combined with the
minimum bearing span to minimize shaft deflectors
especially when the pump is operating at off peak
conditions.
Shafts are designed to meet API 610 deflection and
vibration requirements. Fully assembled rotors are
dynamically balanced can accommodate a wide
variety of single or dual seal arrangements as
standard.

3.3.5 Casing Covers

Two covers, one full size at the outboard pump end
which permits rotor removal and one reduced size
cover at inboard end provide circular type joints and
easy pump sealing with confined gaskets.
The metal to metal fit with confined controlled
compression gasket insures proper alignment
between casing and cover.

3.3.6 Bearing Housings

HED/HED-DS pumps are fitted as standard with
antifriction bearings. The radial bearing is a deep
groove type, while the thrust bearings are dual single
row angular contact type.
Lubrication is provided by an oil slinger in conjunction
with a TRICO constant level oiler, both provided as
standard. In case of particularly severe operating
conditions sleeve line with antifriction or tilting pad
thrust bearing are available with self-contained or
external lube system.

Page 13 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

Special bearing isolators (INPROSEAL or equivalent)
are available on request. Bearing housings can also
be adapted for optional oil mist or purge mist
lubrication systems.

3.3.7 Shaft seals

The mechanical seals, attached to the pump shaft,
seals the pumped liquid from the environment.

3.3.8 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 etc.

3.3.9 Coupling/Coupling guards

Flexible spacer couplings are provided in various
makes and models to suit custome r preference.
(Aluminium non- hinged guards are provided).

3.3.10 Baseplate

Standard baseplates are welded steel, drain pan type
in conformance with API 610 standardized
dimensions. Horizontal driver alignment screws and
vertical baseplate leveling screws are provided when
required by API.
Special baseplates can be supplied to suit individual
installation circumstances.

3.3.11 Accessories

Accessories may be fitted when specified by the
customer.
Baseplates are fabricated and machined so to
guarantee the flatness and parallelism of pads as
required by API standard. The requirement is met by
supporting and clamping the baseplate at the
foundation bolt holes only.

3.4 Performance and operating limits

This product has been selected to meet the
specifications of your purchase order see section 1.5.
These pumps are furnished for a particular service
condition. Changes in the hydraulic system may
affect the pump's performance adversely.
This is especially true if the changes reduce the
pressure at the suction flange or if the liquid
temperature is increased. In case of doubt, contact
the nearest FLOWSERVE office.

3.4.1 Effect of specific gravity

Pump capacity and total 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 any change in SG

will not overload the pump driver or over-pressurize
the pump.

3.4.2 Effects of viscosity

The pump is designed to deliver rated capacity and
rated head for a liquid with a particular viscosity.
For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity. Also for a given flow rate the power
absorbed increases with increased viscosity, and
reduces with reduced viscosity.
When contemplating operation at some viscosity
other than the one for which the pump was originally
designed and/or applied, the changed conditions
should be referred to FLOWSERVE for
recommendations.

When pump is handling heavy

viscous liquid, the temperature of the liquid must
allow it to be pumped easily. Liquid may have to
be heated prior to pump start-up.

3.4.3 Changing the pump speed

Changing pump speed effects flow, total head, power
absorbed, NPSH

, noise and vibration. Flow varies in

R

direct proportion to pump speed. Head varies as
speed ratio squared. Power varies as speed ratio
cubed. If increasing speed it is important therefore to
ensure the maximum pump working pressure is not
exceeded, the driver is not overloaded,
NPSH

>NPSHR, and that noise and vibration are

A

within local requirements and regulations.

3.4.4 Net Positive Suction Head (NPSH)

Any liquid, hot or cold, must be pushed into the
impeller of the pump by absolute pressure, such as
the atmospheric or vessel pressure from which the
pump takes its suction.
The head in feet of liquid necessary to push the
required flow into the pump is called Net Positive
Suction Head. This value, more commonly called
NPSH, is measured above the vapour pressure of the
liquid at the pumping temperature.
There are two kinds of NPSH: the NPSH

is the head

R

required by the pump to cover the losses in the pump
suction - that is shown on the pump characteristic
curve.
The second, NPSH

, is the head available in the

A

system, taking into account friction loss in suction
piping, valves, fittings etc. In all cases the NPSH

,

A

measured above vapour pressure, must exceed the
NPSH

in order to push the liquid into the pump.

R

Failure to have this will result in both bad
performance and mechanical damage to the pump,
and in certain cases actual pump failure.

Page 14 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

If any change in NPSHA is proposed, ensure its
margin over NPSH
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.

3.4.5 Minimum Continuous Stable Flow

The Minimum Continuous Stable Flow for the pump is
stated on the Data sheet.

3.4.6 Minimum flow control

In all cases, it is the customer's responsibility to
supply a system and/or control which assures that
any pump within a system is not operated below its
minimum flow condition.
In many cases, this is not a problem because the
system is operating within its own flow range to
assure product delivery. A simple high pressure
alarm, shut down and/or bypass control can be used .
However, in systems where product demand has high
swings or where more than 100% capacity units are
desired to support a product system, additional care
must be taken.

3.4.7 Thermal control

A thermal control of the unit can be provided by
thermal sensors which read direct or "related to" fluid
temperatures and respond accordingly by opening
additional flow paths until the given unit re­establishes the acceptable temperature rise, and sets
off alarms if not achieved within reasonable/normal
time periods. (High limit could actually shut down
unit).

3.4.8 Pressure and/or Flow Control

Pressure and/or flow sensors can be used to hold the
unit at higher flows by opening additional flow paths
once a "high pressure limit" or " low flow limit" was
indicated.
Upon system reaching increased flow a "low pressure
limit" or "high flow limit" setting would close the
bypass flow path. Care must be taken to allow for
signal spread to avoid cyclic conditions.

3.4.9 Operating at Reduced Capacity

prolonged operations at capacities less than MCSF
as stated in Data Sheet.

is not significantly eroded. Refer

R

Damage to pump may result from

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.

4.1 Location

The pump should always be located as near as
possible to the suction supply.
Install the unit close to the source of the liquid to be
pumped. It is desired to simplify the suction and
discharge piping layout. When selecting the location,
be sure to allow adequate space for operation as well
as for maintenance operations involving dismantling
and inspections of parts.
Head room is an important consideration as an
overhead lift of some type is required

4.2 Part assemblies

Motors may be supplied loose. It is the responsibility
of the installer to ensure that the motor is assembled
to the pump and lined up as detailed in section 4.5.2.

Prior to grouting, an initial alignment
check in accordance with the alignment section of
this document shall be performed to verify that
coupling spacing and final alignment can be achieved
without modifying the hold down bolts or the machine
feet. This is necessary to ensure that the baseplate
was not damaged during the transportation.

4.3 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 pump and, as such, would be
outside the terms of the warranty.
The foundation should be sufficiently rigid and
substantial to prevent any pump vibration and to
permanently support the baseplate at all points.

The most satisfactory foundations are made of
reinforced concrete. These should be poured well in
advance of the installation to allow sufficient time for
drying and curing.
The General Arrangement Drawing (In Job’s User
Instruction) will furnish overall outline of pump
baseplate, anchor bolt locations, size of bolts, etc in
order to provide proper shape to the primary
concrete. Anchor bolts can be positioned or by a
special template (not supplied by FLOWSERVE see
figure 4.1) or by the baseplate itself if proper pockets
have been provided in primary concrete.

Page 15 of 64

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

Template for Hanging Foundation Bolts

Figure 4.1

Figure 4.2 below illustrates an alternative foundation
bolt arrangement which can be used in lieu of
standard foundation bolts. Notice the large washer
with lugs at the bottom. It should be welded to the
bolt and pipe sleeve to prevent turning. Allow a little
more than the specified threaded bolt length above
the rail of the baseplate. The excess can always be
cut off if it is not needed. A rough finish top surface is
best when applying grout.

ALLOW AMPLE THREADED
BOLT LENGTH ABOVE
ROUGH CONCRETE

ROUGH FINISH

STUFF WASTE AROUND
BOLT WHILE POURING
CONCRETE

FOR GROUT

In case of installation over a steel structure (platform)
ensure that the top of the steel structure is cleaned
and degreased.

In order to obtain the parallelism and
flatness of pads required by API standard, baseplate
has to be properly levelled by levelling screws
provided on it and clamping the baseplate at the
foundation bolts only (For proper detailed procedure
refer to Chapter 5 para 3.9.4 of API RP 686 ).

Coupling bolting and spacer piece must
be removed from between the pump and driver half
couplings before lifting baseplate with pumping
element.

When the unit is mounted directly on
structural steel framing, it should be located directly
over as near as possible to the main building
members, beams, or walls. A soleplate should be
bolted or welded to the steel frame to guara ntee the
proper surface.

When lifting baseplate with pumping
element, sling baseplate from all lifting lugs provided.
Refer to Section 2.3.1

Prepare sufficient steel plates to be placed below
each baseplate jacking screw furnished with the
baseplate. The purpose of the plate is to spread the
load of the screw without crushing the concrete
below.

PIPE SLEEVE TO BE
THREE TIMES DIAMETER
OF ANCHOR BOLT

WELD A LARGE WASHER
WITH LUGS TO THE
BOTTOM OF BOLT
AND PIPE SLEEVE TO
PREVENT TURNING

Figure 4.2

4.3.1 Baseplate levelling

Before putting the unit on the foundation, thoroughly
clean the top of the foundation. Break off any loose
pieces of cement and roughen the top with a chisel to
afford a good hold for grout.

Page 16 of 64

Not supplied

Figure 4.3

4.3.2 Method of levelling baseplate using wedges
or shims

a) Level the baseplate by using a machinist's level

on the machined surfaces of the pump and driver

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

pads. Levelling is best achieved by adjusting the
shim pack thickness under each holding bolt.
Carefully raise the baseplate by using eith er the
baseplate jacking screws provided or by levering
with a suitable pinch bar or by installing a low
level hydraulic jack.

b) Adjust the shim pack thickness and lower the

baseplate.

c) Repeat this procedure in a logical manner at

each bolt position until the baseplate is both
straight and levelled. A degree of 0.25 mm per
metre (0.0035 inch per foot) length is achievable
on most units with a maximum of 0.40 mm per
meter length (0.005 inch per foot).

d) In case of installation on steel structures (like

platforms) proceed with these extra steps:
 Using a calibrated pin with a cone p oint mark

the centre of baseplate support pads
mounting holes on the soleplate.

 Lift and move away the pump skid.
 Drill and tap the soleplate fixing holes.
 Replace the pump skid so that the soleplate

fixing holes align with the baseplate support
pads mounting holes.

 Level the unit like done previously (see points

a, b, c).

e) When the baseplate is level, pull down the

foundation bolts so they are snug or tighten the
fixing bolts in case of installation on steel
structure. This may have disturbed the baseplate,

so re-check the levels.
Ensure that shaft alignment per Section 4.5 can be
achieved prior to grouting the baseplate.

4.4 Grouting

Build a dam around the foundation as shown in
Figure 4.4 after levelling the baseplate. It is a matter
of personal preference whether the levelling wedges
under the baseplate should be removed after
grouting. If you do not want to remove the wedges,
carefully mark their locations before pouring grout.

Before grouting, level machined

pads of baseplate in both directions and perform
a rough shaft/coupling alignment. Alignment after
grout has set will not be possible if above is not
satisfactorily completed.

4.4.1 Fully Grouted Baseplates

FINISHED GROUT

LEAVE TOP OF
FOUNDATION ROUGH
DO NOT FINISH
WITH TROWEL

DAM

Figure 4.4

GROUTING 1 TO 2
INCHES DEEP

CONCRETE

Use a good, high strength, non shrink grout mix and
install as per manufacturer's instructions.
Holes are provided in the baseplate to permit pouring
the grout and stirring while acting as air vents. Fill
under the baseplate completely, stirring to assure
correct distribution of the grout. Check to see that the
grout flows under the edges of the base plat e even ly.

Do not vibrate baseplate when grouting,
making sure baseplate is vented correctly and all
areas are thoroughly puddle to preven t any resonant
problems.
When the grout is thoroughly hardened, remove the
dam and wedges, if desired, filling in the holes they
leave with grout.

Pour grout until level reaches top of dam.
Allow to dry sufficiently to prevent grout from
overflowing while completing the remaining grouting.

4.4.2 Baseplate not Intended for Grouting but
Installed on Concrete Foundations

According to the figure 4.3.1 and 4.4.1 the baseplate
will not be grouted but only a sealing shall be
provided. During the preparation, as indicated on the
General Arrangement drawing a certain number of
openings into the sealing must be guaranteed. After
the sealing the blocks used to realise the openings
must be removed. Blocks have to be wider than the
baseplate longitudinal beam in order to guarantee the
opening for the drainage.

Page 17 of 64

Not supplied

BLOCK TO BE REMOVED

AFTER THE SEALING

Figure 4.5

SEALING

TOP OF FOUNDATION

Figure 4.6

4.5 Initial alignment

4.5.1 Thermal expansion

PRIMARY

CONCRETE

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

4.5.2.1 Shaft/Coupling alignment

Shaft alignment must be correct for

successful operation. Rapid wear, noise, vibration
and actual damage to the equipment may be
caused by shaft misalignment. The shafts must
be aligned within the limits given within this

section.

Adjustment to correct the alignment in one
direction may alter the alignment in another direction.
Always check in all directions after making any
adjustment.
Coupled equipment must be aligned to minimise
unnecessary stresses in shafts, bearings and
coupling. Flexible couplings will not compensate for
appreciable misalignment. Foundation settling,
thermal expansion or nozzle loads resulting in
baseplate/foundation deflection and vibration during
operation may require the full coupling misalignment
capability.

4.5.2.1.1 Types of misalignment

There are two types of shaft misalignment: angular
and offset. Therefore, two sets of measurements and
corrections are required. Both types of misalignment
can occur in horizontal and vertical planes and are
present in most applications.

A) Angular misalignment
In angular misalignment, the centre line of the shafts
intersects, but are not on the same axis.

The pump and motor will normally
have to be aligned at ambient temperature and
should be corrected to allow for thermal expansion at
operating temperature.

4.5.2 Alignment methods

Ensure pump and driver are isolated

electrically and the half couplings are disconnected

The alignment MUST be checked.
Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.

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Figure 4.7

B) Offset misalignment
In offset misalignment, the shaft centre lines are
parallel but do not intersect.

Figure 4.8 – offset misalignment

HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

Figure 4.9 – combination of offset and angular misalignment

4.5.2.2 Alignment using the reverse dial Indicator

The following practices are recommended when
using the reverse method of alignment. These should
be carried out prior to main alignment.

The alignment MUST be checked.
Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.
The alignment is achieved by adding or removing
shims under the motor feet and also moving the
motor horizontally as required. In some cases where
the alignment cannot be achieved it will be necessary
to move the pump before recommencing the above
procedure.

For couplings with narrow flanges use a dial in dicator
as shown on figure 4.11 to check both parallel and
angular alignment.

For detailed alignment procedure refer to API RP686.

Figure 4.10

CHECK FOR SOFT FOOT
This is a check to ensure that there is no undue

stress on the driver holding down bolts; owing to non­level baseplate or twisting. To check, remove all
shims and clean surfaces and tighten down driver to
the baseplate. Set a dial indicator as shown in sketch
and loosen off the holding down bolt while noting any
deflection reading on the Dial Test Indicator - a
maximum of 0.05 mm (0.002 in.) is considered
acceptable but any more will have to be corrected by
adding shims, for example, if the Dial Test Indicator
shows the foot lifting 0.15 mm (0.006 in.) then this is
the thickness of shim to be placed under that foot.
Tighten down and repeat the same procedure on all
other feet until all are within tolerance.

If the driver is an electric motor with sleeve
bearings then the magnetic centre at which the rotor
will run must be set. This is usually done by lining up
a groove in the shaft to a pointer fixed to the motor
body (refer to Motor Manufacture’s instructions).

Ensure pump and driver are isolated

electrically and the half couplings are disconnected.

Figure 4.11

Maximum permissible misalignment at working
temperature:
Parallel 0.05 mm (0.002 in.) TIR
Angular 0.05mm/100mm (0.0005In/In)

Pumps with thick flanged non-spacer couplings can
be aligned by using a straight-edge across the
outside diameters of the coupling hubs and
measuring the gap between the machined faces
using feeler gauges, measuring wedge or calipers.

When the electric motor 4has sleeve bearings it is
necessary to ensure that the motor is aligned to run
on its magnetic centreline.

 Refer to the motor manual for details.

A button (screwed into one of the shaft ends) is
normally fitted between the motor and pump shaft
ends to fix the axial position.

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HED/HED-DS USER INSTRUCTIONS ENGLISH 85392695 – 06/14

If the motor does not run in its
magnetic centre the resultant additional axial force
may overload the pump thrust bearing.

Complete piping as below and see sections 4.7,
“Final shaft alignment check” up to and including
section 5, “Commissioning, start-up, operation and
shutdown” before connecting driver and checking
actual rotation.

4.5.3 Shims

The shims between the equipment feet and mounting
surface should be clean and dry. This is especially
critical for pumps in service for sometime and need to
be realigned. Water, dirt and rust may change the
height of the shim pack over a period of time. Shim s
should be made large enough to support the weight
of the equipment on its mounting foot. Do not use
many thin shims as this may result in a spongy
mounting.

Figure 4.12

Recommended shim design

Move the equipment vertically by adding or removing
the calculated thickness of shims. Torque holding
down bolts to required values.

4.5.4 Hot alignment – Pump and driver dowels

Pump hold down bolts are to be torqued down and
dowel pins are to be located in pump feet. (This is
only applicable if Hot Alignment is required).
Refer to driver outline drawing and/or driver
instructions for driver doweling information.
A hot check can only be made after the unit has been
in operation a sufficient length of time to assume its
NORMAL operating temperature and conditions. If
the unit has been correctly cold set, the offset
misalignment will be within within the limits stated on

par 4.5.2.2 when in operation.

If not make adjustments.

Do not attempt any maintenance,

inspection, repair or cleaning in the vicinity of
rotating equipment. Such action could result in
injury to operating personnel.

Before attempting any inspection or repair

on the pump the driver controls must be in the
"off" position, locked and tagged to prevent
restarting equipment and injury to personnel
performing service on the pump.

4.5.5 Assemble coupling

a) Assemble coupling as per the manufacturer's

instructions included in Appendix of this manual.

b) Install coupling guard

4.5.6 Installation check list

a) Level Baseplate?
b) Grout Baseplate - Check Foundation Bolts?
c) Alignment Shaft/Coupling?
d) Piping Installed - Correct Vent, Gauge, Valve,

Suction Strainer Locations?

e) All Flange Bolting Correctly Torqued with

appropriate gaskets in place?
f) Check Shaft/Coupling Alignment again.
g) Coupling guard correctly installed ?

4.6 Piping

Never use the pump as a support for

piping.

4.6.1 General

These units are furnished for a particular service
condition. Changes in the hydraulic system may
affect performance adversely. This is especially true if
the changes reduce the pressure at the suction or if
the liquid temperature is increased. In case of doubt
contact FLOWSERVE.
Suction and discharge piping should be of ample
size, be installed in direct runs, and have a min imum
of bends. Double bends must be avoided in suction
line and a straight run of pipe, equal 7 to 10 times the
pipe diameter is desired directly upstream of the
suction nozzle.
In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose
pipework that is one or two sizes larger than the
pump suction and discharge. Typically main pipework
velocities should not exceed 2 m/s (6 ft/sec) suction
and 3 m/s (9 ft/sec) on the discharge.

Provision must be made to support piping
external to the pump to prevent excessive nozzle
loads, maintain pump/driver alignment and avoid pipe
induced vibrations.

Take into account the available NPSH which must be
higher than the required NPSH of the pump.

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