To establish Approvals and if the product itself is CE
Marked check the serial number plate and the
Certification.
1.1 General
These Instructions must always be kept
close to 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,
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 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 failure caused by misuse are not covered
by the Flowserve warranty.
1.3 Disclaimer
Information in these User Instructions is believed
to be reliable. In spite of all the efforts of
Flowserve Corporation to provide sound and all
necessary information the content of this manual
may appear insufficient and is not guaranteed by
Flowserve 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 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 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.
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.
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.
Page 3 of 40
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order
are going to be changed (for example liquid pumped,
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.
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
field" safety instructions where non-compliance would
affect personal safety, pacemakers, instruments or
stored data sensitive to magnetic fields.
This symbol indicates safety
This symbol indicates "strong magnetic
HWX USER INSTRUCTIONS ENGLISH - 07/14
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 co-ordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws/regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
help prevent injury to personnel and damage to
the environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
PREVENT EXCESSIVE
EXTERNAL PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints so that their force, due to
internal pressure, acts on the pump flange.
ONLY CHECK DIRECTION OF
MOTOR ROTATION WITH COUPLING ELEMENT/
PINS REMOVED
Starting in reverse direction of rotation will damage
the pump.
This symbol indicates explosive atmosphere
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.
The sign is not a safety symbol but
indicates an important instruction in the assembly
process.
This symbol indicates potential risks
connected with extremely high temperatures.
This symbol indicates potential risks
connected with extremely low temperatures.
ENSURE CORRECT
LUBRICATION
(See section 5 Commissioning, startup, operation and shutdown.)
START THE PUMP WITH
OUTLET VALVE PART OPENED
(Unless otherwise instructed at a specific point in the
user instructions.)
This is recommended to avoid 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. Pump outlet valve shall be adjusted to comply
with the duty following the run-up process (See
section 5 Commissioning, startup, operation and shutdown).
START THE PUMP WITH
OUTLET VALVE FULLY OPEN
This is recommended to avoid the risk of overloading
and damaging the pump motor where greater power
is taken at low or shut off flow. Pump outlet valve
shall be adjusted to comply with the duty following the
Page 4 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
run-up process (See section 5 Commissioning,
startup, operation and shutdown).
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 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.
When ambient temperatures are
likely to drop below freezing point, the pump and any
cooling and flushing arrangements must be drained
or otherwise protected.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wear ring of appropriate safety gloves and
equipment is required when handling these
components. To lift heavy pieces above 25 kg (55
lbs) use a crane corresponding to the mass and in
accordance with current local regulations.
NEVER DO MAINTENANCE WORK WHILST THE
UNIT IS CONNECTED TO POWER
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate sitting 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.
condition these are extremely dangerous and skin
contact must be avoided.
GUARDS MUST NOT BE REMOVED WHILE
PUMP IS OPERATIONAL
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
in damage or breakage of components and should be
avoided.
NEVER APPLY HEAT TO REMOVE
IMPELLER
Trapped lubricant or vapour could cause an
explosion.
If hot or freezing components or auxiliary heating
supplies can present a danger to operators, they
must be shielded to avoid accidental contact. If
complete protection is not possible, the machine
access must be limited to maintenance staff only.
Note: bearing housings must not be insulated and
drive motors and bearings may be hot.
If the temperature is greater than 68 °C (155 °F) o r
below 5 °C (41 °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 potentially explosive atmospheres
must be followed to help ensure explosion protection.
Both electrical and non-electrical equipment must
meet the requirements of European Directive
94/9/EC.
1.6.4.1 Scope of compliance
HOT AND COLD PARTS
DRAIN PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted)
When a pump has experienced temperatures over
250 °C (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this
Page 5 of 40
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
HWX USER INSTRUCTIONS ENGLISH - 07/14
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 pump sets with a VFD, the ATEX Certification for
the motor must state that it covers the situation where
electrical supply is from the VFD. This is 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 IIC135ºC (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)
b = Control of ignition source
(in accordance with EN13463-6)
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 an ambient in the range of -80 to +55 ºC (-112 to
+131 ºF); refer to Flowserve for ambient
temperatures outside this range for this product.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends on
the ATEX temperature class and must not exceed the
values in the table that follows.
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 table only takes the ATEX temperature class into
consideration. Pump design or material, as well as component
design or material, may further limit the maximum working
temperature of the liquid.
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
Temperature classification “Tx” is used when the
liquid temperature varies and when the pump is
required to be used in differently classified potentially
explosive 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.
Do not attempt to check the direction of rotation with
the coupling element/pins fitted due to the risk of
severe contact between rotating and stationary
components.
Where there is any risk of the pump being run against
a closed valve generating high liquid 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 or a Power Monitor and
make routine vibration monitoring.
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
Page 6 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
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.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact the coupling guard must be non-sparking and
anti-static.
To avoid the potential hazard from random induced
current generating a spark the earth contact on the
baseplate must be used.
Avoid electrostatic charge: do not rub nonmetallic surfaces with a dry cloth; ensure cloth is
damp.
The coupling must be selected to comply with
94/9/EC and correct alignment must be maintained.
1.6.4.5 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.
1.6.4.6 Maintenance to the centrifugal pump to
avoid the hazard
CORRECT MAINTENANCE IS REQUIRED
TO AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with
maintenance instructions is with the plant
operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted (see section 6, Maintenance).to
include the following.
a) Any auxiliary systems installed must be
monitored, if necessary, to ensure they function
correctly.
b) Gland packings must be adjusted correctly to
give visible leakage and concentric alignment of
the gland follower to prevent excessive
temperature of the packing or follower.
c) Check for any leaks from gaskets and seals. The
correct functioning of the shaft seal must be
checked regularly
d) Check bearing lubricant level, and if the hours run
show a lubricant change is required.
e) Check that the duty condition is in the safe
operating range for the pump.
f) Check vibration, noise level and surface
temperature at the bearings to confirm
satisfactory operation.
g) Check dirt and dust is removed from areas
around close clearances, bearing housings and
motors.
h) Check coupling alignment and re-align if
necessary.
Page 7 of 40
1.7 Warning label
HWX USER INSTRUCTIONS ENGLISH - 07/14
Page 8 of 40
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. When the Contract requirement specifies
these to be incorporated into user instructions these
are included here. Where performance data has been
supplied separately to the purchaser these should be
obtained and retained with these user instructions if
required.
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.
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.
(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
Pump &
motor
dBA
Pump
only
dBA
Pump &
motor
dBA
Pump
only
dBA
Pump &
motor
dBA
Pump
only
dBA
Pump &
motor
dBA
Page 10 of 40
1.10 CE Declaration
HWX USER INSTRUCTIONS ENGLISH - 07/14
Page 11 of 40
2.0 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/ shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and or damage must
be reported immediately to Flowserve and received in
writing within one month of receipt of the equipment.
Latter claims cannot be accepted.
Check any create/boxes/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 parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
Four lifting lugs are provided on the baseplate to lift
the complete unit.
Take care by applying slings or ropes about
auxiliary piping and seal systems.
HWX USER INSTRUCTIONS ENGLISH - 07/14
A crane must be used for all pump sets in
excess of 25kg (55lb). Fully trained personnel must
carry out lifting, in accordance with local regulations.
The driver and pump weights are recorded on their
respective nameplates.
2.4 Storage
If the unit will not be put immediately into service, it
should be stored in a dry room. To avoid any damage
during the storage period, the influence of any low or
high frequency vibration must be totally inhibited. If
the pump is delivered sealed in a plastic-wrapper, it is
of max. importance to avoid any damage of that
wrapper, because this will protect the pump against
humidity. Therefore it must be checked if this wrapper
has become cracked and if so, the wrapper must be
renewed.
2.4.1 Long period storage
If the pump is delivered in a plastic bag, the
preservations stands up for one year. If the storage
period exceeds this time, the preservation must be
checked and renewed. Also the air tight plastic bag
must be changed. Moreover we recommend to order
a Flowserve Service Engineer for checking the pump
before the first start up.
Page 12 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
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 are
disposed of safety and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the current
regulations at all times.
3.0 DESCRIPTION
3.1 Configuration
The HWX pump is a vertical, single-stage, single
suction, radially split centrifugal process pump. The
pump conforms to the specifications outlined in API
610/682 and is intended for continuous duty service
in all process and industrial applications within
specified pressure and temperature limitations.
Maintenance of the pump is facilitated by the in-line
configuration, use of cartridge mechanical seals, and
a spacer coupling designed to allow a back pull-out
disassembly of the internal pump parts.
The sense of rotation of the pump is counter
clockwise (CCW), looking from the coupling to the
shaft end of the pump.
3.2 Nomenclature
The pump size will be engraved on the nameplate
typically as below:
3x4x7 A-HWX
Nominal discharge branch size
Nominal suction branch size
Nominal full size impeller diameter
Casing pattern type
Pump type
The typical nomenclature above is the general guide
to the HWX 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 of single or dual volute design that
reduces forces on the rotating element thereby
minimizing vibration and shaft deflection.
Dual volute is standard on many 3 inch discharge
pumps and on all pumps above 3 inch discharge.
Single volute is standard on some 3 inch discharge
pumps and on all smaller sizes.
The fluid passages are designed to prevent
turbulence and emphasize streamline flow.
Motor support heads are mounted directly on the
casing for a true back-pull-out of the pump rotor
without disturbing the driver electrical connections,
nor casing.
3.3.2 Impeller
The HWX impeller is a fully shrouded, radial flow,
single suction design. All sizes are precision cast to
assure the highest attainable efficiency. All impellers
are dynamically balanced keyed to the shaft and
secured by locknut and lockscrew. Renewable wear
rings are press fit onto the impeller hubs (front and
back) and positively secured with axial screws or tack
welding.
3.3.3 Casing cover
The casing cover is either fabricated from plate or
cast, depending on the material of construction.
Designed to the dimensional standards within the API
682 specification, the seal chamber can
accommodate a wide variety of single or dual seal
arrangements as standard.
3.3.4 Shaft
The shaft is of ample strength and rigidity. It is
precision machined over its entire length and has
generous fillet radii at each change of section to
reduce stress concentrations. Shaft deflections at the
seal chamber are minimal and fall within the
guidelines stated in API 610.
3.3.5 Bearing housing
There are two types of bearing housing, depending
on the desired lubrication: pure oil mist, and Oil Cascade sump. To maximise parts interchangeability,
there are only two sizes of bearing housings and
bearings used for all pump sizes. Operating speeds
are from 900 to 3600 r.p.m. TRICO constant level
oiler is supplied as standard for Oil Cascade sump
and no constant level oiler is supplied for pure oil
mist.
Page 13 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
Fan cooling is supplied always as a standard for Oil
Cascade sump. No cooling is required for pure oil
mist application.
3.3.6 Pump bearings and lubrication
The standard bearing arrangement for all HWX
pumps is angular contact deep groove ball thrust
bearings arranged back to back and a deep groove
ball radial bearing able to ensure long life under the
most severe operating conditions.
Thrust Bearings are brass cage design and line
bearing is metal cage design in accordance with
normal oil industry preferences and API 610
requirement. Bearing manufacturers must be FPD
approved suppliers.
Lubrication of the bearings is provided by oil cascade
or pure oil mist.
3.3.7 Shaft seal
The mechanical seal is a cartridge type design for
single, tandem, and double seals to control the
leakage of liquid to the environment. The cartridge
design provides for proper axial alignment of the seal
faces and minimises the contamination of sensitive
seal faces during installation.
Lubrication of the mechanical seal is provided by the
pumped liquid or by an auxiliary seal-flush system. A
vent connection is provided to eliminate the possibility
of the seal becoming vapour bound.
3.3.8 Driver
The driver is normally an electric motor mounted on a
support head and coupled to the pump by a flexible
spacer coupling.
3.3.9 Coupling/Coupling guards
Flexible spacer couplings are provided in various
makes and models to suit customer preference.
(Aluminium non- hinged guards are provided)
3.3.11 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operating limits
In the interest of operator safety
the unit must not be operated above the nameplate
conditions. Such operation could result in unit failure
causing injury to operating personnel. Consult
instruction book for correct operation and
maintenance of the pump and its supporting
components.
4.0 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 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 pumps are delivered completely mounted and
prealigned with the motor. Also the shaft seal is in the
correct position. Final alignment after complete
installation is necessary. If drivers and/or seal systems
are delivered separately, follow the assembly
procedure in section 6.8.
3.3.10 Mounting Plate and Motor Support Head
HWX pumps are supplied with a mounting plate as a
standard, already suitable for levelling screws
installation.
Extended dimension mounting plates are available on
request for applications where coolers or seal pots
are required and need to be contained within the
mounting plate.
The motor support head is a heavy duty, register-fit
motor mount with generous openings allowing easy
accessibility for field maintenance. The open
compartments allow easy access to all bolting and
removal of the entire rotor with the bearing housing
from either side.
Page 14 of 40
4.3 Foundation
The foundation shall be located on a place that allows
a minimum of pipe work and that is easily accessible
for inspection during operation. According to the
environment the foundation may consist of concrete
or of steel. It must be rigid and heavy enough to
absorb normal vibrations and shocks.
4.3.1 Horizontal alignment of the baseplate
Horizontal alignment is done with levelling screws.
Use a spirit level for correct horizontal alignment of
the baseplate.
The max. misalignment is 0.5 mm/m
baseplate length.
HWX USER INSTRUCTIONS ENGLISH - 07/14
4.3.2 Steel foundation
When the pump unit is mounted directly on structural
steel frame, it shall be well supported by constructural
beams. It is recommended to check the natural
frequency of the steel frame, because it shall not
coincide with the pump speed. The exact horizontal
alignment is very important!
4.3.3 Concrete foundation
A concrete foundation must have an exact horizontal
alignment and must be placed on solid ground. First a
basic foundation shall be built with square shaped
holes for embedding the foundation bolts. After
putting the base plate into the foundation the proper
alignment can be obtained by adjusting it with shims
under the base plate. Now insert the foundation bolts
and grout the space between the basic foundation
and the base plate with grouting cement (refer to
illustration)
It is very helpful to use a properly made and stable
wooden frame around the base plate. So the grouting
cement will not flow side. When the grouting is totally
set and hardened the foundation bolts shall be
tightened in a firm and symmetrical way.
Align the motor to the pump, not the pump to the
motor. Alignment of the motor is achieved by using
the adjustment screws.
4.4.1 Permissible misalignment limits at working
temperature
When checking parallel alignment, the total indicator
read-out (TIR) shown is twice the value of the actual
shaft displacement.
The pump is only pre-aligned! Carefully check
and readjust alignment before start of the unit.
Take out the spacer of the coupling and check the
alignment of shafts end of pump and driver. The
maximum parallel offset should not exceed 0.05 mm
(0.002 in.)and the axially offset can be ± 1 mm (0.04
in.).
instruction manual of coupling.
For more details refer to the manufacturer’s
a)
4.4 Initial alignment
The adjustment of motor and pump must be checked
(if necessary, make a new adjustment) before first
start up of the unit.
b)
a) Parallel Offset: The median lines run parallel. The
maximum allowable parallel offset depends on
the size of coupling and is indicated in the
instruction manual of manufacturer of coupling
b) Axially Offset: Another offset is the displacement
of one or both of the shafts. A typical example is
thermal expansion.
The DBSE (distance between shaft ends)
is shown on the General Arrangement Drawing and is
larger than the length of the coupling spacer. This is
necessary to compensate all manufacturing
tolerances of line shafts and column pipes.
For installation of the coupling spacer the coupling
hub on the pump shaft must be axially moved to
match the spacer. This results in an axial clearance
"x" between coupling hub and shaft end, which is
taken into account by the coupling selection.
Ensure pump and driver are isolated electrically and
the half couplings are disconnected.
Page 15 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
How the alignment of the coupling should be done
you can see on the sketches and explanations below!
a) b)
a) Fix the dial gauge on the driven shaft and check
the concentricity by turning of both hubs; correct it if
necessary.
b) Fix the dial gauge on the driving shaft and check
the concentricity by turning of both hubs; correct it if
necessary.
If the pump is handling hot liquid, the alignment must
be rechecked in warm condition of the unit.
4.5 Piping
4.5.1 General
Protective covers are fitted to the pipe connections to
prevent foreign particles entering during
transportation and installation. Ensure that these
covers are removed from the pump before connecting
any pipes.
Maximum forces and moments allowed on the pump
flanges vary with the pump size and type. To
minimize these forces and moments which may
cause misalignment, hot bearings, worn couplings,
vibration and a possible failure of the pump, the
following points shall be strictly followed:
a) Prevent excessive external pipe load.
b) Do not connect piping by applying external force
(use of wrenches, crane,...). Piping shall be
aligned without residual stress.
c) Do not mount expansion joints so that their force,
due to internal pressure, acts on the pump flange.
Fitting an isolator and non-return valves can allow
easier maintenance. Never throttle pump on suction
side and never place a valve directly on the pump
inlet nozzle.
A non-return valve shall be located in the discharge
pipework to protect the pump from excessive back
pressure and hence reverse rotation when the unit is
stopped.
Piping and fittings shall be flushed before use. To
avoid damages of the pump install a Y-strainer or a
strainer of 40 mesh.
Piping for corrosive liquids shall be arranged to allow
pump flushing before removal of a unit.
Refer to GA drawing for details of the drain
connection.
By pumping toxic or explosive
media, provide the necessary security actions, e.g.
flushing with nitrogen.
4.6 Electrical connections
Electrical connections must be made by a qualified
Electrician in accordance with the relevant local
national and international regulations.
It is important to be aware of the EUROPEAN
DIRECTIVE on hazardous areas where compliance
with IEC60079-14 is an additional requirement for
making electrical connections.
It is important to be aware of the EUROPEAN
DIRECTIVE on electromagnetic compatibility when
wiring up and installing equipment on site. Attention
must be paid to ensure that the techniques used
during wiring/installation do not increase
electromagnetic emissions or decrease the
electromagnetic immunity of the equipment, wiring or
any connected devices. If in any doubt contact
Flowserve for advice.
The motor must be wired up in accordance with the
motor manufacturer's instructions (normally supplied
within the terminal box) including any temperature,
earth leakage, current and other protective devices
as appropriate. The identification nameplate should
be checked to ensure the power supply is
appropriate.
A device to provide emergency stopping must
be fitted.
If not supplied pre-wired to the pump unit the
controller/starter electrical details will also be supplied
within the controller/starter.
For electrical details on pump sets with controllers
see the separate wiring diagram.
rotation before connecting the motor to the electrical
supply.
See section 5.3, Direction of
4.5.2 Drain
This connection is used for total drainage of the pump
casing. A flanged drain is standard and can be
optionally equipped with various kinds of valves.
Page 16 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
4.7 Final shaft alignment check
After connecting piping to the pump, rotate the shaft
several times by hand to ensure there is no seizure
and all parts are free.
Recheck the coupling alignment, as previously
described, to ensure no pipe strain. If pipe strain
exists, correct piping.
5.0 COMMISSIONING START-UP,
OPERATION AND SHUTDOWN
These operations must be
carried out by fully qualified personnel.
5.1 Precommissioning procedure
The following steps should be followed at initial start
up and after the equipment has been overhauled:
a) Prior to installing the pump, flush the suction side
of the system to remove all deposit (slag, bolts
etc).
b) Ensure the pump and piping is clean. Before
putting the pump into operation, the piping should
be thoroughly back flushed to remove any foreign
matter which may have accumulated during
installation. Take all possible care not to
contaminate your system.
c) Fill the bearing housing with the appropriate oil to
the correct level (if applicable). Bearing must
receive a small amount of oil prior to starting to
ensure adequate lubrication at start up. (Refer to
Section 5.2).
d) Turn pump rotor by hand or with a strap wrench
to make sure it turns smoothly.
e) Assure that correct seal piping has been installed
and has not been damaged.
f) Prior to coupling installation, bump start motor to
check for correct rotation. If rotation is not correct
refer to motor manual for appropriate connections
to change rotation (Shut down all power prior to
change).
g) Ensure coupling is correctly aligned and
lubricated. (Refer to Section 4.4).
h) Ensure coupling guard is correctly installed.
The unit must not be operated unless
coupling guard is securely and completely
bolted in place. Failure to observe the
warning could result in injury to operating
personnel.
Check torque of all bolting and the plugs for
tightness.
started after a longer storage period, the bearing
housing should be first flushed and cleaned with
gasoline. It is not necessary to remove the
preservation oil as this will mix up thoroughly with the
lubrication oil.
Lubrication is provided by the pumping effect of the
rotating ball bearings. Maintaining the correct oil level
(middle of the oil sight glass) ensures that the lower
ball bearing is covered with oil.
For recommended lubricating oils refer to the
lubrication table 5.2.6
5.2.2 Oil change
After first start up, the oil shall be changed after 200
service hours.
Every further oil change shall take place after about
2000 service hours or at least every 6 month.
To change the oil, use the following procedure:
a) Remove the reservoir (for some type of oilers you
must loose a fixing screw or lock nut, refer to
section 5.2.4 Oil level).
b) Open the oil drain on the bearing housing to
remove the oil.
c) Close the oil drain and fill in Oil through the oiler
until the oil level reaches the bottom of the sight
glass.
d) Fill the reservoir and put it quickly to the body of the
oiler. Observe the level in the reservoir. It will
decrease until the required oil level is reached
(middle of the sight glass). Ensure that enough oil
remains in the reservoir.
e) If necessary, the oil level can be adjusted by
refering to section 5.2.4 Oil level.
5.2.3 Oil level
The correct oil level is in the middle of the oil sight glass
and shall be checked when pump is not in operation.
Periodically check if the lubricating oil is mixed with any
condensed water. Careful opening of the oil drain
during a stop of the pump will show any water.
During operation the level will decrease
due to circulation of the oil through the bearings.
A too high oil level will result in higher bearing
temperatures and therefore poorer lubrication.
5.2.3.1 Adjusting of TRICO Constant Level Oiler
If the pump is fitted with a Constant Level Oiler type
„TRICO“, the correct oil level has to be checked after
fitting the pump!
5.2 Pump Lubricants
5.2.1 Lubrication
The bearing housing shall be filled with proper
lubricating oil prior to start up. If the pump will be
loosen the thumb screw and remove the
reservoir. Turn the adjusting nut until you reach
0.35 to 0.43 in. (9 to 11mm) distance from the top
of the adjusting nut to the centerline of the side
port.
b) Additionally you can check the correct oiler
adjustment by an oil sight glass (minimum oil
level is the middle of the oil sight glass).
c) After a correct oiler adjustment, reinstall the
reservoir and the oiler body and tighten the thumb
screw.
5.2.4 Oil quality
Oil used for lubrication should only be of high quality.
The viscosity of the oil at working temperature must
be at least 10 cSt. The pouring point of the oil must
be in accordance with the lowest expected
temperature of the bearing housing during a stop of
the pump. For recommended lubricating oils refer to
the lubrication table.
Having selected the corresponding oil quality the
actual oil temperature at the bearing housing must be
checked after two service hours of the pump.
Considering this measured oil temperature the actual
viscosity must be determined by using the data sheet
of the oil, to verify the minimum required viscosity of
10 cSt. Do not forget, the oil temperature in the
bearing itself is about 10 °C ( ∆ 18 °F) higher than the
oil temperature at the bearing housing. On the
following table the oil viscosity is given at 40 °C (104
°F). Determining the correct lubricating oil one mu st
take into consideration that all bearings will have
higher temperatures during the first 20 service hours.
In constant operation the bearing temperature will
decrease about 10 °C (50 °F). The oil temperature
shall be lower than 85 °C (185 °F) after this runni ngin time. The bearing outer race temperature should
not exceed 95°C (203°F). If the temperature is high er,
the reason may be a wrong oil quality, wrong oil level
or overload of the pump because of excessive wear.
If the humidity at the site is high, the roller bearings
become easily rusty during stand still periods. To
avoid that, we recommend to mix the lubricating oil
with a corrosion inhibitor contact your lubrication oil
supplier for proper additives inhibitors.
5.2.5 Oil quantity
The bearing housing size can be identified from the
thrust bearing size indicated by nameplate.
Housing Size
Page 18 of 40
Bearing
#1 7311 0.86 (29.1)
#2 7313 1.52 (51.4)
Bearing
Designation
Oil quantity
l (Fl.oz)
2000 hours or at least every
2000 hours or at least every
2000 hours or at least every
2000 hours or at least every
5.2.6 Lubrication Table
Oil
Lubrication service
Type
Ambient temperature
°C (°F)
Oil temperature range*
°C (°F)
Viscosity
mm²/s 40°C [cSt]
First Oil Change200 hours
Centrifugal Pump Lubrication
Further Oil Changes
Designation according to
DIN51502 ISO VG
BP
CASTROL
-20 to 35
(-4 to 95)
-5 to 65
(23 to 149)
32
200 hours
6 months
32
BP Energol HL32
BP Energol HLP32
Perfecto T32**
HWX USER INSTRUCTIONS ENGLISH - 07/14
Oil Bath and Purge Oil Mist Lubrication
Ball bearing
Mineral Oil
(Petroleum Based)
(95 to 140)
up to 85
(up to 185)
46
200 hours
6 months
46
BP Energol HL46
BP Energol HLP46
Perfecto T46**
35 to 60
up to 100
(up to 212)
68
200 hours
6 months
68
BP Energol HL68
BP Energol HLP68
Perfecto T68
Pure Oil Mist
Lubrication
Mineral Oil
(Petroleum Based)
-5 to 60
(23 to 140)
15 and above
(59 and above)
100
6 months
100
-
-
OMV
Aral
Esso
LSC
(for oil mist)
Mobil
Oil Companies and Lubricants
* Note that it normally takes 2 hours for bearing temperature stabilize and the final temperature will depend on the ambient, r/min, pumpage temperature and pump size.
Viscosity index shall be at least 95.
** For ambient temperature from -12°C (10 °F) upwar ds
For temperatures below -5 °C (-23 °F) use lubricat ion oil class SAE 5W-50 or API-SJ.
Shell
Texaco
Total
Wintershall
(BASF Group)
Barrier/Buffer Fluid for
Mech. Seal
OMV turb HTU 32**
Aral Vitam GF 32
NUTO H32
LSO 32
Synthetic oil
Mobil Nuto H32
Mobil DTE13M
Mobil DTE24
Shell Tellus 32
Shell Turbo T32**
Rando HD 32
Azolla ZS32
Wiolan HN32
Wiolan HS32
Seal System / Pumped LiquidQuench-OilGeneral Features
Tandem Seal to -40 °C (-40 °F)
Back to back Seal with gascoffer-dam
Conventional back to back Seal
The sequence of the suppliers of the lubricants does not represent any indication of their superiority.
¹ Viscosity at 40 °C (104 °F) in cSt [mm²/s] DIN 5 1562
Page 19 of 40
5.3 Direction of rotation
The sense of rotation of the
pump is counter clockwise (CCW); looking from the
coupling to the shaft end of the pump.
The rotation of the driver shall be checked.
HWX USER INSTRUCTIONS ENGLISH - 07/14
Check the discharge and suction pressure gauge
to verify the pumps delivered head.
The pump must operate smoothly, and the
vibration must be below 5 mm/s (0.2 in./sec) (API
610 vibration limits).
If a minimum flow valve is installed, take pressure
gauge readings to verify the correct operation.
c) Check the pipe system against any leakage.
d) Check the mechanical seal against any leakage.
5.4 Guarding
Be sure that the coupling guard is mounted correctly
at the baseplate prior to start up.
5.5 Priming and auxiliary supplies
The pump must be completely primed prior to start
up.
a) The pump casing is considered as self venting,
so no vent connections are provided.
b) Auxiliary systems, e.g. barrier /buffer fluid
systems, cooling circuits, shall be filled according
to the user instructions.
5.6 Starting the pump
a) Start the driver according to the specification.
(Refer to driver IOM).
Pumps are usually started against
closed discharge valve.
b) Check the discharge and suction pressure gauge
to verify the pumps delivered head. Open the
discharge valve slowly, until the pump reaches the
specified operation point. The pump must operate
smoothly, and the vibration must be below 5 mm/s
(0.2 in./sec) (API 610 vibration limits).
The discharge valve must be opened
within 30 sec. after start up. Longer operation
against closed discharge valve will damage the
pump. If a minimum flow valve is installed, take
pressure gauge readings to verify the correct
operation.
If the backpressure of the discharge
pipe is sufficient, pumps can be started against
open valve.
Right after start up a minor leakage
of the mechanical seal is quite normal. Normally
this leakage disappears after few minutes of
operation.
5.7 Operation
a) Verify that the pump is operating within the
specified limits, min/max flow, pressure,
temperature, vibration, power
b) The bearing housing temperature shall not exceed
80 °C (176 °F). If higher bearing temperature are
observed, check the viscosity grade of the used
lubrication oil.
The minimum viscosity is 10
cSt at the expected oil temperature.
(Oil temperature = bearing gland temperature
+ 10 °C (50 °F))
c) From time to time check the pump shaft seal.
Leakage of 10 - 20 drops per hour is also with a
mechanical shaft seal unavoidable.
d) Observe the power consumption of the pump to
detect excessive wear.
5.8 Stopping and Shutdown
a) Close the outlet valve, but ensure that the pump
runs in this condition for no more than a few
seconds.
b) Stop the pump.
c) Switch off flushing and/or cooling/ heating liquid
supplies at a time appropriate to the process.
d) For prolonged shut-downs and especially when
ambient temperatures are likely to drop below
freezing point, the pump and any cooling and
flushing arrangements must be drained or
otherwise protected.
Ensure that your driver is capable deliver
the higher torque required by starting against
open valve.
To prevent the pump from reverse rotation
after shut down, the installation of a check valve
is recommended.
Although the pump is not affected by reverse
rotation because of spezial couppling design , it
can be an issue with the driver.
Page 20 of 40
For automatic start/stop operation of the
pump, ensure that all steps described in chapter 5.5,
5.6, 5.7 and 5.8 are implemented in the control logic.
5.9 Hydraulic, mechanical and electrical
duty
This product has been supplied to meet the
performance specifications of your purchase order,
however it is understood that during the life of the
product these may change. The following notes will
HWX USER INSTRUCTIONS ENGLISH - 07/14
help the user to decide how to evaluate the
implications of any change. If in doubt contact your
nearest Flowserve office.
5.9.1 Specific gravity (SG)
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 overpressurize the pump.
5.9.2 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. It is important that
checks are made with your nearest Flowserve office if
changes in viscosity are planned.
5.9.3 Pump speed
Changing pump speed effects flow, total head, power
absorbed, NPSHR, noise and vibration. Flow varies
in 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,
NPSHA>NPSHR, and that noise and vibration are
within local requirements and regulations.
5.9.4 Net positive suction head (NPSHA)
NPSH available (NPSHA.) is a measure of the
energy available in the pumped liquid, above its
vapour pressure, at the pump suction branch.
NPSH required (NPSHR.) - is a measure of the
energy required in the pumped liquid, above its
vapour pressure, to prevent the pump from cavitating.
It is important that NPSHA >NPSHR. The margin
between NPSHA >NPSHR should beas large as
possible. If any change in NPSHA is proposed,
ensure these margins are not significantly eroded.
Refer to the pump performance curve to determine
exact requirements particularly if flow has changed. If
in doubt please consult your nearest Flowserve office
for advise and details of the minimum allowable
margin for your application.
5.9.5 Pumped flow
Flow must not fall outside the minimum and
maximum continuous safe flow shown on the pump
performance curve and/or data sheet.
6.0 MAINTENANCE
6.1 General
It is the plant operator's responsibility to
ensure that all maintenance, inspection and assembly
work is carried out by authorized and qualified
personnel who have adequately familiarized
themselves with the subject matter by studying this
manual in detail.
(See also section 1.6.2.)
Any work on the machine must be performed when it
is at a standstill. It is imperative that the procedure
for shutting down the machine is followed, as
described in section 5.9.
On completion of work all guards and safety devices
must be re-installed and made operative again.
Before restarting the machine, the relevant
instructions listed in section 5, Commissioning, start up, operation and shut down must be observed.
Oil and grease leaks may make the ground
slippery. Machine maintenance must always
begin and finish by cleaning the ground and the
exterior of the machine.
If platforms, stairs and guard rails are required for
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
carried out. The positioning of these accessories
must not limit access or hinder the lifting of the part to
be serviced.
When air or compressed inert gas is used in the
maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
protection.
Do not spray air or compressed inert gas on skin.
Do not direct an air or gas jet towards other people.
Never use air or compressed inert gas to clean
clothes.
Before working on the pump, take measures to
prevent an uncontrolled start. Put a warning board
on the starting device with the words:
"Machine under repair: do not start".
With electric drive equipment, lock the main switch
open and withdraw any fuses. Put a warning board
on the fuse box or main switch with the words:
"Machine under repair: do not connect".
Page 21 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
6.2 Maintenance schedule
It is recommended that a maintenance plan
and schedule is adopted, in line with these User
Instructions, to include the following:
a) Any auxiliary systems installed must be monitored,
if necessary, to ensure they function correctly.
b) Gland packings must be adjusted correctly to
give visible leakage and concentric alignment of
the gland follower to prevent excessive
temperature of the packing or follower.
c) Check for any leaks from gaskets and seals. The
correct functioning of the shaft seal must be
checked regularly.
d) Check bearing lubricant level, and if the hours run
show a lubricant change is required.
e) Check that the duty condition is in the safe
operating range for the pump.
f) Check vibration, noise level and surface
temperature at the bearings to confirm
satisfactory operation.
g) Check dirt and dust is removed from areas
around close clearances, bearing housings and
motors.
h) Check coupling alignment and re-align if
necessary.
Our specialist service personnel can help with
preventative maintenance records and provide
condition monitoring for temperature and vibration to
identify the onset of potential problems.
If any problems are found the following sequence of
actions should take place:
a) Refer to section 8, Faults; causes and remedies,
for fault diagnosis.
b) Ensure equipment complies with the
recommendations in this manual.
c) Contact Flowserve if the problem persists.
6.2.1 Routine Inspection (daily/weekly)
The following checks should be
made and the appropriate action taken to remedy any
deviations.
a) Check operating behavior; ensure noise, vibration
and bearing temperatures are normal.
b) Check that there are no abnormal fluid or
lubricant leaks (static and dynamic seals) and
that any sealant systems (if fitted) are full and
operating normally.
c) Check that shaft seal leaks are within acceptable
limits.
d) Check the level and condition of lubrication oil.
On grease lubricated pumps, check running
hours since last recharge of grease or complete
grease change.
e) Check any auxiliary supplies eg. heating/cooling
(if fitted) are operating correctly.
f) Refer to the manuals of any associated
equipment if routine checks needed.
6.2.2 Periodic Inspection (every 6 Month)
a) Check foundation bolts for
security of attachment and corrosion.
b) Check pump operation hours to determine if
bearing lubricant shall be changed.
c) The coupling should be checked for correct
alignment and worn driving elements.
Refer to the manuals of any associated
equipment for periodic checks needed.
6.3 Spare parts
6.3.1 Ordering of spares
When ordering spare parts we need the following
information:
1. pump type and pump size
2. serial number of the pump
3. number of the required spare parts
4. reference number and name of the part as listed
in the part list or in the sectional drawing
Example: for HWX pump: HWX, serial number G202222/01
1 piece impeller Pos. 2200
The serial number of each pump is indicated on the
name plate. If the material should be changed from
the original delivered one, additionally indicate the
exact material specification. If ordered impellers shall
have smaller or larger outer diameter, indicate also
with your order. Without a special remark the spare
impellers will be delivered with the diameter of the
original impellers.
If you need the wear rings oversized or undersized,
please indicate, otherwise the wear rings will be
delivered with standard size.
To ensure continuous satisfactory operation,
replacement parts to the original design specification
should be obtained from Flowserve.
Any change to the original design specification
(modification or use of a non-standard parts) will
invalidate the pump’s safety certification.
6.3.2 Storage of spares
Spares should be stored in a clean dry area away from
vibration. Inspection and retreatment of metallic
surfaces (if necessary) with preservative is
recommended at a 6 monthly interval.
Above mentioned torques are for all screwed unions, which works under dynamical load. For all other
connections you can use a corresponding smaller torque.
Anchor bolts are usually made of 4.6 material. Tightening torques indicated in above table shall not be
exceeded.
Page 24 of 40
6.6 Disassembly
Refer to section 1.6, Safety, before
dismantling the pump.
Before dismantling the pump for
overhaul, ensure genuine Flowserve replacement
parts are available.
Refer to sectional drawings for part numbers and
identification.
Before attempting to disassemble the pump,
the pump must be isolated from the system, by
closing suction and discharge system valves,
drained of liquid and cooled, if pump is handling
hot liquid.
Before attempting any maintenance work on
pumps in vacuum service, the pumps must be
isolated from suction and discharge system then
carefully vented to return pressure in pump
casing to atmospheric pressure.
Remove the pipe plug(s) from the
top of the bearing housing(s) and check to see
that oil rings are riding free on the pump shaft
and are not hung up. Failure to observe this
caution could result in damage to or destruction
of equipment.
HWX USER INSTRUCTIONS ENGLISH - 07/14
suitable protective materials must be worn when
draining the pump.
b) Remove coupling guard [7450] from bearing
lantern [3140] by removing bolts and washers.
c) Disassemble and remove coupling spacer in
accordance with the manufacturer’s instructions
in the back of this manual.
d) In case of Oil Lubrication drain the bearing
housing of oil. This can be done by removing the
drain plug situated at the bottom of the bearing
housing.
Use caution when draining hot oil from
bearing housing to prevent burns/injury to
personnel
e) Remove the hex bolts clamping the casing cover
[1221] to the casing [1110].
f) Use the jacking bolts provided on the casing
cover [1221] flange to lift the cover from the
casing [1110] and raise the cover above the
lower flange of the bearing lantern [3140].
g) Attach the pullout element lifting tool to the
pullout element, then lift the element out of the
casing [1110]. (See figure 6.2).
6.6.1 Pull Out Element Removal
This pump has a pull-out element, which consists of
the pump shaft [2100], mechanical seal assembly,
casing cover [1221], impeller [2200], and bearing
housing assembly, as well as their attached parts.
This pull-out element makes it unnecessary to
remove the driver, bearing lantern [3140], or casing
[1110] to service the bearing housing assembly,
mechanical seal, impeller [2200], wear rings
[2300.1/2300.2–1500.1/1500.2], stuffing box bushing
[2430], and gaskets.
For an illustrative part reference, see the Pump
Assembly drawing in the back of this manual.
a) Remove all seal piping, related instrumentation
and electrical equipment that will interfere with
disassembly. Drain pump casing.
When pump is handling "hot" liquid extreme
care must be taken to ensure safety of personnel
when attempting to drain pump. Hot pumps must
be allowed to cool before draining.
When pump is handling "caustic" liquid
extreme care must be taken to ensure safety of
personnel when removing auxiliary piping or
when draining pump. Protective devices of
Figure 6.2
The lifting tool is not part of the pump. It
must be ordered separately.
h) Raise the pullout element upward until the
impeller clears the lower flange of the bearing
lantern [3140] and remove through the large
opening.
i) Remove the casing cover gasket [4590] from the
casing [1110] or casing cover [1221] and discard.
j) Move the pullout element to a safe, clean work
area for further disassembly.
6.6.2 Pull Out Element Disassembly
All gaskets and O-rings removed
during maintenance are to be discarded and
replaced with new ones to ensure proper sealing
during subsequent operation.
Page 25 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
As a reminder of the orientation of the
casing cover and the bearing housing you might
match mark these parts before separating them;
however, the OUTLINE drawing shows the factory
orientation.
To disassemble the pullout element, soft cable (or
equivalent) and lifting equipment should be handy
and used for heavy parts. Proceed as follows:
a) Secure bearing housing [3200] to workbench in a
position that will allow impeller [2200] and casing
cover [1221] to be pulled away from shaft [2100]
and bearing housing [3200].
b) Secure shaft [2100] to prevent rotation.
The impeller cap nut [2912] is lefthand threaded. To remove the impeller cap
nut, turn it to the right (clockwise) while
facing the impeller.
c) Untight the security dowel of the cap nut [2912]
and remove it from shaft.
d) Use heat, if necessary, on impeller [2200] and
remove it from shaft.
e) Remove impeller key [6700.1].
f) Install the mechanical seal spacers to lock the
shaft sleeve to the seal plate. Then loosen the set
screws which hold the shaft sleeve to the shaft.
g) Unscrew cap screws that hold bearing housing
[3200] to casing cover [1221] and tap casing
cover and bearing housing with mallet to break
cover loose from housing.
The impeller cap nut [2912] is lefthand threaded. To remove the impeller cap
nut, turn it to the right (clockwise) while
facing the impeller.
h) Hold shaft sleeve in place and carefully slide
casing cover [1221] with sleeve and mechanical
seal parts off shaft and clear of bearing housing
[3200].
The stuffing box bushing [4133] is
pressed into the casing cover [1221] and
should not be removed unless worn or badly
scratched or gouged, in which case the old
bushing must be pressed out and a new one
pressed in.
i) Set casing cover [1221] on workbench with
bearing-housing side up.
follow the seal manufacturer's instructions in
the Appendix.
To disassemble a mechanical seal
j) Remove the seal plate nuts and the mechanical
seal.
k) If no pumpage has got into bearing
housing and you plan to replace just the
mechanical seal, omit the remaining steps;
otherwise continue to disassemble pump as
outlined.
l) Evenly heat pump half-coupling using a welding
torch with a Rosebud head until you are able to
pull half-coupling off with a coupling puller, then
remove half-coupling and key [6700.4].
m) Remove outboard fan [if applicable 8161.1] and
screws [6577.4]. Loosen screw [6579.4] on vent
ring [2500] and slide off shaft.
n) Unscrew bearing housing end cover cap screws
and slide end cover [1220] off shaft. If your pump
is oil lubricated, remove and retain the cover
plate [3260].
Although not necessary, it may be
worthwhile to lift the bearing housing and
block it in a vertical position with the thrust
bearing up to facilitate removal of the shaft
and bearings. Support shaft as it is moved out
of bearing housing by soft cables and hoist or
wood blocks.
o) Remove shaft [2100], with thrust bearings [3013]
and radial bearing [3010] installed, from bearing
housing [3130].
p) Proceed as follows:
•Loosen the set screws which hold the screw
pump to the shaft, then slide the screw pump
[4223] off of the shaft.
q) Place shaft in a vice which is covered with a soft
material such as copper to prevent marring; then
clamp it just enough to keep it from turning when
thrust bearing lock nut [3712] is broken loose.
r) Bend back tab on thrust bearing lock washer
[6541]. Unscrew thrust bearing lock nut [3712].
Facing the bearing nut, turn it clockwise to
loosen. Remove lock nut and lock washer from
shaft.
s) Remove shaft from vice and press bearings
[3013 – 3010] off shaft with hydraulic press, if
available; otherwise, leave shaft in vice and pull
bearings off shaft with a bearing puller.
t) If your pump is oil lubricated: The grease catcher
[3865] should only be removed if there is
evidence of leakage. If the cover is to be
removed, remove the cap screws and slide the
cover out of the bearing housing.
6.7 Examination of parts
Used parts must be inspected
before assembly to ensure the pump will
subsequently run properly.
Page 26 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
In particular, fault diagnosis is essential to
enhance pump and plant reliability.
To perform a good visual inspection and to obtain the
highest degree of cleanliness, which is essential to
the correct fit and balance of all rotating parts, the
shaft must be stripped of all parts. The visual
inspection consists of examining the following parts
for those conditions that commonly impair pump
operation. Where the corrective action may not be
apparent to a journeyman millwright or a more
extensive examination is required, the inspection item
is cross-referenced to a detailed procedure. Unless
noted below, all damaged parts should be replaced
rather than repaired.
6.7.1 Cleaning Agents
When the pump is used in the steam generator feed,
the boiler feed, the reactor feed, or other such steam
(or water) circuit, all internal metal parts of the pump
including the case should be cleaned with a nonpetroleum-base cleaning agent such as alcohol or
acetone or a steam cleaner that uses steam from
demineralised water. The basic concern should be to
insure that the solvent is compatible with the
pumpage. Petroleum-base agents such as dry
cleaning solvent and kerosene may be used for
cleaning internal parts when such agent will dissolve
in the liquid being pumped without inducing an ill
effect. Petroleum-base agents should be used to
clean the bearings and their housings.
Fumes from alcohol, acetone, petroleum
solvents and other such chemicals are injurious
to health and may ignite from a spark; make
certain that the area where they are used is well
ventilated and have a fire extinguisher handy.
6.7.2 Casing, seal housing and impeller
a) Inspect for erosion, foreign object damage and
cracks; erosion and damage must be corrected
before final assembly.
b) Inspect impeller cap nut [2912] and impeller
[2200] for nicks, gouges, galling and rust.
c) Inspect impeller bore for correct fit with shaft (See
Section 6.8.2 ”Checking Fit Between Impeller
Bore and Shaft”).
d) Inspect running surfaces of stuffing box bushing
[4133], shaft [2100], case wear ring [1500.1],
casing cover wear ring [1500.2], and impeller
wear ring [2300.1–2300.2] for nicks, burrs,
scratches, scouring and excessive wear.
Concentric and smooth surfaces are required
(See Section 6.8.1 “Wear Rings”).
e) Replace as necessary.
6.7.3 Mechanical seal
a) Mechanical seal stationary and rotating faces
should be inspected for signs of wear or cracks
and replaced as necessary.
b) It is recommended that when reassembling
mechanical seal new "O" rings and gaskets be
used.
c) Refer to manufacturers drawing for assembly of
mechanical seal. Refer to mechanical seal
section within this manual for further details.
6.7.4 Throat Bush (If fitted)
a) Check the throat bush and replace if required.
Note that the bush outside diameter should be
the same diameter as the adjacent impeller wear
ring.
6.7.5 Shaft
Shaft [2100] for scratches, nicks, burrs, and
distortion; absolutely smooth surfaces and a straight
shaft are required.
After the shaft is inspected for damage as described
above, it must be checked for straightness before
reassembling the rotating parts. When making the
check do not turn the shaft in its lathe centers. It is
possible for the lathe centers of a straight shaft to be
off center slightly, resulting in a false indication of a
bent shaft.
1. Set shaft in soft-faced V-blocks, precision rollers
(or equivalent).
2. Check straightness by taking dial indicator
readings all along the shaft while it is rotated; total
runout of shaft must not exceed 0.04 mm (0.0015
in). If runout is exceeded shaft must be coldstraightened or replaced.
Application of heat to straighten
shaft will cause more distortion.
The term "soft-faced V-blocks" refers to
V-blocks faced with metal that is softer than the
shaft, for example, V-blocks faced with copper.
6.7.6 Gaskets and O-rings
After dismantling, discard and replace.
6.7.7 Bearings
a) It is recommended that bearings are not re-used
after any removal from the shaft. In any case the
bearings must be replaced not after 25000
operating hours.
b) If the bearing cannot be removed with the tools
available never use a torch under any
circumstances. Split the outer ring with a small
hand grinder, saw through the ball/roller retainer,
and split the inner ring about three quarters
through with a grinder and break with a cold steel
chisel.
Page 27 of 40
Do not attempt to inspect condition
of bearings until they have been cleaned.
c) Solvent for cleaning bearings should be in a
clean container. Place bearings in solvent and let
soak for a short time. Agitate the bearing around
near the top of the container, giving it a turn now
and then until it is clean. Rinse in a clean
container of fresh solvent.
Do not spin dirty bearings. Rotate
them slowly while washing.
d) Dry thoroughly cleaned bearings. If an air hose is
used for drying, make sure it is clean dry air.
Do not allow the bearings to spin by
force of air. Hold the inner and outer rings to
prevent bearing from spinning.
e) Inspect bearings immediately. If there is any
question as to the condition of a bearing do not
hesitate to replace it. There are many conditions
that contribute to the deterioration of the
bearings. A qualified bearing representative
should be consulted if there is any question of
bearing condition.
f) Inspected bearings which will be reused should
be packed with new grease or dipped in clean
lubricating oil, covered with clean lint free rags or
other suitable covering and placed in a clean box
or carton until ready for installation.
Under no circumstances the
bearings are to be left exposed.
6.7.8 Labyrinths or bearing isolators (if fitted)
a) The lubricant, bearings and bearing housing
seals are to be inspected for contamination and
damage. If oil bath lubrication is utilised, these
provide useful information on operating
conditions within the bearing housing.
b) If bearing damage is not due to normal wear and
the lubricant contains adverse contaminants, the
cause should be corrected before the pump is
returned to service.
c) Labyrinth seals and bearing isolators should be
inspected for damage but are normally non-wear
ring parts and can be re-used.
Bearing seals are not totally leak free devices.
Oil from these may cause staining adjacent to the
bearings.
6.8 Assembly
To assemble the pump consult the sectional
drawings.
Ensure threads, gasket and O-ring mating faces are
clean.
6.8.1 Wear rings
The impeller may be fitted with both front and rear
wear rings or front ring only.
HWX USER INSTRUCTIONS ENGLISH - 07/14
The impeller ring(s) are renewable and should be
replaced when badly grooved, and/or when pump
performance does not meet the system requirements.
Whenever it becomes necessary to replace either
wear ring, both rings involved (impeller and
casing/casing cover) must be ordered and replaced
as a set as they are furnished standard size only.
Spare impeller wear rings are supplied with a material
stock over outside diameter which has to be
machined off after rings fitting on impeller. If an
impeller with its wear rings is ordered as spare, it will
be supplied fully machined, including wear rings
outside diameter, to original dimensions. Casing wear
rings are always supplied fully machined. Be sure to
re-establish the original running clearance between
the two wear rings involved by machining the fitted
impeller ring.
Running clearance is determined by measuring the
inside diameter of the stationary part and the outside
diameter of the rotating part (for example, the inside
diameter of the case wear ring and outside diameter
of the related wear ring ring on the impeller), and
taking their difference to get the running clearance;
that is, the diameter of the stationary part minus the
diameter of the rotating part equals the actual running
clearance.
Measurement should be taken with a micrometer and
each part should be checked for trueness or
roundness by taking diametrical readings 90 degrees
apart. To determine whether the actual running
clearance has increased to a point where
replacement of a part is advisable, compare the
actual clearance with the design clearance that is
given in the cross sectional drawing. Then consider
the wear with respect to mechanical and hydraulic
efficiency and decide whether to restore the design
clearance.
Before final assembly, the trueness and the running
clearance of the following should be checked:
1. Stuffing box bushing [4133].
2. Case wear ring [1500.1], casing cover wear ring
[1500.2], and impeller wear rings [2300.1–
2300.2]; restore running clearance that is given in
cross sectional drawing and roundness as
outlined in section 6.8.1.1 and 6.8.1.2.
6.8.1.1 Impeller wear rings
a) To remove impeller wear rings, mutually remove
wear ring set screws or ground off tack weld.
Rings can be machined off or grind two slots
diametrically opposite across the width of the ring
so it can be split apart. Use caution if ring is
removed by grinding so as not to damage
impeller hubs.
Page 28 of 40
IMPELLER
IMPELLER
HAND
GRINDER
Figure 6.3
RING
b) Determine that impeller has cooled to ambient
temperature by feeling with hand; then heat wear
ring using a torch until ring will slip into place on
impeller.
c) Verify trueness of wear ring to impeller fit as
outlined below or by an equivalent technique:
•Make sure ring fits on impeller are free of
nicks or burrs. Heat new ring to 107 °C
(225 °F).Set impeller with wear ring face up
on table of vertical lathe and parallel with
face of table.
•Align centerline of impeller (that is, centerline
of impeller bore) with centerline of table using
bore as true surface for dial indicator.
Alignment should be within 0.03 mm (0.001
in.).
•Clamp impeller in centered and parallel
position.
•Set up dial indicator to run outside diameter
of wear ring ring and rotate table. Total runout
must not exceed 0.04 mm (0.0015 in.).
d) Drill and tap new holes in impeller spaced half the
circular distance from the previously used holes in
the impeller. See sketch below (If tack welding
ring, use ER308 or ER309 rod and gas-tungsten
arc.
HWX USER INSTRUCTIONS ENGLISH - 07/14
Sectional drawing for the requested running
clearance.
6.8.1.2 Case wear rings (and casing cover wear
ring when fitted)
Each wear ring is locked against rotation with a
cylindrical pin.
a) To remove the wear ring, press it out. If this
method does not easily effect removal of the ring,
it can be split apart. First, however, drill one or
more holes in the face of the worn ring.
b) New rings to be installed must be shrunk by
freezing when installing in casing or casing cover.
See that temperature of casing / casing cover is
above 21 °C (70 °F).
c) Subcool new wear ring in dry ice to shrink it; then,
bottom ring squarely in bore of parent part by
using aluminium drift and mallet to strike evenly
around circumference of wear ring ring.
d) Determine that wear ring ring and parent part
have warmed to ambient temperature by feeling
with hand.
e) Verify trueness of wear ring-ring-to-part fit as
outlined below or by an equivalent technique:
•Set up parent part in lathe or milling machine
so that register face of part can be used as
true side for dial indicator. The centreline of
part must be aligned with centreline of
machine's table and it must also be parallel
with table within 0.03 mm (0.001 in).
•Set up dial indicator to run on inside diameter
of wear ring ring and rotate table (or chuck).
Total runout must not exceed 0.04 mm
(0.0015 in).
f) Fit and secure with a locking pin. Replacement
wear rings are furnished standard size in the
bore. Check the running clearance between
impeller and casing ring against the appropriate
value.
Figure 6.4
Impeller wear rings when installed must
be machined to establish original diameter and
running clearance. Whenever an impeller has new
wear rings fitted it must be dynamically balanced
before being reassembled. Refer to the Cross
Page 29 of 40
6.8.2 Checking Fit Between Impeller Bore and
Shaft.
The fit between the impeller bore and the shaft must
be correct or vibration is apt to occur.
To check the fit, proceed as follows:
a) Verify shaft straightness (See Section 6.7.5).
A three-point micrometer is the
preferred instrument for measuring bore; a stick
micrometer is its alternate. When measuring with
the three-point micrometer, measure close to the
keyway. With stick micrometer, measure three
places at 120-degree intervals.
b) Determine nominal fit of impellers with shaft:
•by using micrometers to measure diameter of
bore under thickest metal near each end of
keyway of impeller and the corresponding
diameter of shaft,
HWX USER INSTRUCTIONS ENGLISH - 07/14
•then by comparing diameter of bore of
impeller with corresponding diameter of shaft.
Diameter of bore of impeller should be 0.013
mm (0.0005 in.) to 0.38 mm (0.0015 in.)
oversize of the corresponding diameter of
shaft.
The diameter of the impeller bore
must never be oversize of its counterpart on shaft
by more than the allowable tolerance. If the
impeller bore is not within tolerance, you should
contact the nearest FLOWSERVE Pump Sales
Office for recommendations concerning your
particular circumstance.
6.8.3 Oil Thrower (if applicable)
In case of Oil Cascade Lubrication, install thrower
onto shaft. Secure thrower to shaft by tightening set
screws into the location groove in the shaft.
6.8.4 Bearings Housing
The ball bearings require correct handling and
installation to ensure optimum performance. The
following information is intended as a minimum to
ensure that the bearings are handled and installed
correctly. As you assemble the pullout element, keep
soft cables or nylon lifting straps and hoist handy for
heavy parts.
If you have not match-marked the casing
cover, the bearing housing, and seal plate to identify
their orientation, you should determine their correction
orientation by studying the OUTLINE drawing before
commencing assembly of the pullout element.
If the intent is to replace only the Mechanical Seal
Part proceed to section 6.8.4.1
1. Make certain that all visual inspection
requirements have been met, including
verification of shaft straightness, wear ring
running clearance, stuffing box bushing running
clearance, and fit between impeller and shaft
(see Section 6.7 “Examination of parts”).
2. Place shaft in a soft-faced vise (that is, a vise with
faces covered with a soft material such as
copper) to prevent marring; then clamp it so that
the radial and thrust bearings can be slipped onto
shaft.
and keep covered. Never expose bearings on a
dirty bench or floor.
c) Do not wash a new bearing. It is already clean
and the preservative should not be removed.
d) Before mounting, be sure shaft bearing areas are
clean and free of nicks and burrs. Check the
dimensions of these areas to ensure correct fit of
bearings.
6.8.4.2 Bearing installation
Install the thrust and radial bearings in the same
sequence and direction as removed.
Figure 6.5 - Oil Cascade and Oil Mist Lubrication -
There are two simple methods of providing a heat
source for expanding the inner race of the bearings to
facilitate mounting.
a) In the first method, bearings still wrapped in their
original intimate wrap are placed on a shelf in a
temperature controlled oven, or in an enclosure
lined with foil and heated with electric light bulbs.
A temperature of 66 °C (150 °F) for one half hour
should be sufficient.
b) A second method consists of locating a light bulb
100 to 150 Watt (0.13 to 0.15 hp) in the bore of
the bearing. The light bulb will heat, primarily, the
inner ring and the bearing can usually be handled
by the outer ring without special gloves. Care
must be taken to keep the bearing clean and
uncontaminated.
The old and once popular method of
heating bearings in an oil bath is DEFINITELY
DISCOURAGED. HEATING INNER RING WITH
A GAS TORCH IS PROHIBITED. In either
case, it is difficult to control the heating rate
and final temperature and even more difficult
to keep the oil and/or bearing clean.
c) When bearings are installed on the shaft make
sure the bearing is installed squarely and is firmly
seated. Hold bearing in place until it has cooled
sufficiently so that it will not move from position.
Cover bearings to protect them from dirt.
6.8.4.1 Bearings handling
a) Do not remove new bearings from their storage
package except for inspection, when stored for a
long period of time or just prior to their
installation.
b) Work area must be clean to ensure that no dirt or
other contaminates will enter the bearings.
Handle bearings with clean, dry hands and with
clean, lint free rags. Lay bearings on clean paper
Page 30 of 40
When installing the bearings the
mounting pressure should never be applied in
such a manner that it is transmitted through
the rolling element. Apply the mounting force
directly against, and only against, the inner
ring.
Inner thrust bearing must be
assembled against shoulder on shaft with the
HWX USER INSTRUCTIONS ENGLISH - 07/14
wide flange of the outer race towards the
coupling. The outer thrust bearings is to be
placed on the shaft with the wide flange of the
outer race towards the inner bearing
.
d) When installing bearings on shaft, heat thrust
bearing, radial bearing and screw pump (oil
cascade lubricated bearing housing) to 200-230°F
(95-110°C) and slide them up against their
shoulders on shaft (thrust bearing on coupling
end of shaft and radial bearing and screw pump
on impeller end). Heat for approximately 20 - 30
minutes.
e) Install the lock washer and locknut as per figure
6.6 (oil cascade and oil mist lubrication).
Figure 6.6 - Oil Cascade and Oil Mist Lubrication -
•Slide thrust bearing lock washer onto shaft,
then thread lock nut onto shaft hand tight.
•Spin outer races of thrust bearing several
times, then tighten the lock nut. The lock nut
should be tightened such that the outer races
of the thrust bearing do not turn
independently when spun, but can be moved
independently by hand.
•Allow the thrust bearings to cool to ambient
temperature.
•Loosen the thrust bearing lock nut to hand
tight, then re-torque the lock nut to 122 Nm
(90 ft-lb).
•Mount a dial indicator on the shaft to read on
the outer thrust bearing races. Runout on the
outer thrust bearing races should not exceed
0.04 mm (0.0015 in.). Tap the bearing races
into place with a soft-faced mallet if
necessary.
•When bearing nut has been properly
tightened and runout are within specification,
bend a lock washer tab into a slot on the lock
nut.
f) Remove shaft from vise.
g) Place the bearing housing in a vertical position on
blocks in preparation for installation of shaft
assembly. Make sure blocking is of sufficient
height so that shaft will not contact the floor.
There should be 0.03 mm (0.001 in.) diametrical
clearance between outer race of each bearing
and its bore in the bearing housing.
h) Suspend shaft vertically for installation into
bearing housing.
i) If your pump is oil lubricated, and the inner
bearing housing cover [3260] has been removed,
then install a new O-ring, or coat the mating
surfaces of the bearing housing [3200] and cover
with Loctite Gasket Eliminator 504 sealant (or
equivalent], as indicated in the Cross Sectional
Drawing in the back of this manual. Install bearing
housing end cover and evenly tighten cap screws.
j) Lubricate outer races of thrust bearings [3013]
and radial bearing [3010]; then slide the shaft with
bearings installed into the bearing housing [3200].
Push or tap on the outer thrust bearing race with
a soft brass or plastic rod to position bearings in
their bores in bearing housing.
k) Install the bearing isolator [4330] in the bearing
housing end cover [3260.2].
l) Coat the mating surfaces of the bearing housing
[3200] and bearing housing end cover [1220] with
Loctite Gasket Eliminator 504 sealant (or
equivalent]. If your pump is oil lubricated, then
coat and install the cover plate [3260] as well.
Install bearing housing end cover (and cover
plate, if applicable) and evenly tighten cap
screws.
m) Determine thrust bearing axial play as follows:
•Mount a dial indicator to read on end of shaft.
Push on coupling end of shaft until shaft is all
the way toward impeller end; then set the dial
indicator to "0".
•Thrust shaft toward coupling end and read
indicator: Repeat the procedure to confirm
reading.
•Clearance is correct if dial indicator is
between 0.05 mm (0.002 in.) and 0.100 mm
(0.004 in.).
•If dial indicator indicates play less than 0.05
mm (0.002 in.) or more than 0.100 mm
(0.004 in.), correct by machining end cover or
installing appropriate gasket between bearing
housing and end cover gasket.
n) Install inboard fan [2540] and tighten cap screw.
Install vent ring [2500] and secure it with screws
[6579.4]. Mount the fan [8161] on the vent ring
[2500] with screw [6577.4]
o) Determine shaft and impeller wear ring runout as
follows:
•With bearing housing clamped in position, fix
dial indicator to bearing housing [3200] and
touch dial indicator button to shaft [2100].
Indicator must be fixed tightly to housing.
•Slowly, rotate shaft and record readings at
12, 3, 6, and 9 o'clock points. Total indicated
reading (TIR) shall not exceed 0.04 mm
(0.0015 in.). If readings are excessive, set up
may not be rigid.
If runout (i.e., TIR) at any surface is
excessive, check all parts for burrs, dirt and
rough surfaces; register face of bearing
housing for squareness, and its bore for
roundness; bearings for bottoming against
shaft shoulders.
Page 31 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
If you disassemble bearing housing,
reassemble it in accordance with the
procedure outlined above
• Remove the dial indicator.
• Install the impeller key [6700.1] and impeller
[2200].
As you face the impeller end of the
shaft, thread the impeller cap screw by
turning it counter-clockwise.
• Remove the dial indicator.
• Install impeller washer [2430] and impeller
lock washer against impeller [2200] and
screw impeller cap screw [2912] tightly
against washer, but do not bend a lock
washer tab. The impeller must be tight
against the shaft shoulder with no play.
•Fix dial indicator to bearing housing register
face or another point so that it is rigid and
touch indicator button to either wear ring
[2300.1 – 2300.2].
•Slowly, rotate shaft and record readings at
12, 3, 6, and 9 o'clock points; TIR shall not
exceed 0.04 mm (0.0015 in).
•Repeat the two steps above to verify
concentricity of other wear ring.
If runout is excessive, check fit of
impeller on shaft (see Section 6.9.2) and
wear ring installations (see Section 6.9.1).
Should you be unable to determine the cause
of excessive runout, contact the nearest
FLOWSERVE Pump Sales Office.
•Remove impeller cap screw [2912], impeller
lock washer, impeller washer, and impeller
[2200].
b) Use heat, if necessary, on impeller and slide it
over key [6700.1] and against shaft shoulder.
c) Secure shaft [2100] so that it will not move.
d) Install impeller washer and impeller lock washer
against impeller and tightly screw impeller cap
screw [2912] against washer to hold impeller on
shaft without any play. Bend a tab of the lock
washer against a face of the cap screw to secure
it in place.
e) Rotate the mechanical seal setting washers which
hold the shaft sleeve to the seal plate out of the
way and secure them for future use.
f) Heat half-coupling in dry heat convection oven to
300°F (149°C). Install the coupling key [6700.4]
on shaft, then slide the half-coupling onto the
shaft until it is positioned as shown by the Outline
Drawing.
g) Wrap soft cables or nylon lifting strap around
casing cover [1221] and bearing housing [3200],
then raise pullout element and transport it to
pump casing [1110].
the mechanical seal.
6.8.6 Pullout Element Installation
a) Install a new casing cover gasket [4590] in the
b) Attach the pullout element lifting tool to the pullout
c) Raise the pullout element upward until the
d) Install the hex bolts clamping the casing cover
e) Turn shaft by hand to ensure that rotor turns
f) Install coupling spacer in accordance with the
g) Install all seal piping, related instrumentation, and
h) Perform an alignment check of the pump in
Ensure that bearing lubrication is provided prior to
operating the pump in accordance with Section 5.2,
“Pump Lubricants”.
Refer to any special instructions supplied with
casing [1110].
element, then install rigging gear to lift the
element.
Ensure that the pullout element is
properly aligned with the casing and auxiliary
equipment in accordance with the Outline
Drawing.
impeller clears the lower flange of the bearing
lantern [3140] and install through the large
opening in the support head.
[1221] to the casing [1110]. Torque the bolts
evenly in a star pattern to the torque value
specified on Section 6.5.
freely without binding or rubbing.
Use of odd size bolts and nuts
to couple half-couplings and spacer will cause
imbalance; use only bolts and nuts specified
by the coupling manufacturer.
manufacturer’s instructions in the back of this
manual.
electrical equipment that was removed prior to
disassembly.
accordance with Section 4.5, “Initial Alignment”
7.0 AUXILIARIES
7.1 Seal and seal systems
7.1.1 Single Mechanical Seal with API–Plan 11+61
Refer to mechanical seal drawing and
auxiliary piping drawing.
The pump is equipped with a single mechanical seal.
The cartridge design allows to change the
mechanical seal without taking it apart.
Page 32 of 40
Try to turn the rotor by hand.If the
rotor cannot be turned, the pump must be
disassembled, refer to section 6.6 Dismantling HWX.
Actions after start up:
Check all connections to the seal gland and the
mechanical seal itself against leakage. It is usual that
at the seal faces a small leakage occurs after start
up, which decreases with the time of operation and
should stop after the seal is run in. Check the
temperature of the seal gland. I slight increase of
temperature may be observed during the run in
period. The mechanical seal is flushed by an API
Plan 11 and the temperature at the seal gland should
be max. 10 °C (18 °F) above the pumped liquid
temperature, unless otherwise specified by
mechanical seal supplier.
In Plan 11, product is routed from the pump
discharge via an orifice to the seal chamber to
provide cooling for the seal and to vent air or vapors
from the seal chamber. Fluid then flows from the seal
cavity back into the process stream.
API Plan 61 has tapped and plugged connections for
the purchaser´s use. Typically this plan is used when
the purchaser is to provide fluid (such as steam, gas, or
water) to an external sealing device.
Refer to the GA - drawing for the
required quench medium, pressure and flow.
Disassembly of the seal cartridge
is only allowed by authorized personal. Contact
Flowserve for any service of the mechanical seal. We
recommend to have a spare cartridge seal on stock
for easy replacement.
7.1.2 Single Mechanical Seal with API–Plan 23+62
Refer to mechanical seal drawing and
auxiliary piping drawing.
The pump is equipped with a single mechanical seal.
The cartridge design allows to change the
mechanical seal without taking it apart.
Try to turn the rotor by hand.If the
rotor cannot be turned, the pump must be
disassembled, refer to section 6.6 Dismantling HWX.
Actions after start up:
Check all connections to the seal gland and the
mechanical seal itself against leakage. It is usual that
at the seal faces a small leakage occurs after start
up, which decreases with the time of operation and
HWX USER INSTRUCTIONS ENGLISH - 07/14
should stop after the seal is run in. Check the
temperature of the seal gland. I slight increase of
temperature may be observed during the run in
period. The mechanical seal is flushed by an API
Plan 23 and the temperature at the seal gland should
be below the pumped liquid temperature (refer to
mechanical seal drawing for temperature limit).
Plan 23 is the plan of choice for all hot water
services, and it is also disirable in many hydrocarbon
and chemical services where it is necessary to cool
the fluid establish the required margin between fluid
vapor pressure (at the seal chamber temperature)
and seal chamber pressure. In a Plan 23, the cooler
only removes seal face-generated heat plus heat
soak from the process.
Additionally the mechanical seal is equipped with a
Plan 62.
The mechanical seal is mounted as a complete unit in
the casing cover [1221] (Cartridge design).
The lubrication of the sealing faces and the cooling is
done from top of the sealing chamber through a pipe
with an orifice back to the suction side (API Plan 11).
Next to the mechanical seal is a quenching chamber
with a throttle bushing the quenching chamber has to
be flushed with water or steam (API Plan 62).
Refer to the GA - drawing for the
required quench medium, pressure and flow.
Disassembly of the seal cartridge
is only allowed by authorized personal. Contact
Flowserve for any service of the mechanical seal. We
recommend to have a spare cartridge seal on stock
for easy replacement.
7.1.3 Dual Mechanical Seal pressurized with
API–Plan 02+53b
Refer to mechanical seal drawing and
auxiliary piping drawing.
The pump is equipped with a dual mechanical seal in
face to back configuration, back to back configuration
or face to face configuration.
Try to turn the rotor by hand.If the
rotor cannot be turned, the pump must be
disassembled, refer to section 6.6 Dismantling HWX.
The mechanical seal requires no adjustment
anymore. Check if the mounting plates are already
swung out.
Actions after start up:
Check all connections to the seal gland and the
mechanical seal itself against leakage. Check the
temperature of the seal gland. I slight increase of
temperature may be observed during the run in
period.
Page 33 of 40
HWX USER INSTRUCTIONS ENGLISH - 07/14
Plan 02 is a dead ended seal chamber with no flush
fluid circulation. Flushing is not necessary because
the seal is not exposed to the pumped liquid.
Plan 53 pressurized dual seal systems are used in
services where no leakage to atmosphere can be
tolerated. A Plan 53b system consists of dual
mechanical seals with a liquid barrier fluid between
them. The barrier fluid is contained in a seal pot and
is pressurized by using a bladder type accumulator.
Inner seal leakage will be barrier fluid leakage into
the product. There will always be some leakage
(max.5 ml/hour).
The leakage rate is monitored by monitoring the seal
pot level. The product must be able to accommodate
a small amount of contamination from the barrier
fluid. The seal pot pressure must be maintained at
the proper level. If the seal pot pressure drops, the
system will begin to operate like a Plan 52, or
unpressurized dual seal, which does not offer the
same level of sealing integrity. Specifically, the inner
seal leakage direction will be reversed and the barrier
fluid will, over time, become contaminated with the
process fluid with the problems that result, including
possible seal failure.
Fill the seal system with a suitable
barrier buffer fluid (refer to lubrication table).
temperature may be observed during the run in
period. The mechanical seal is flushed by an API
Plan 13 and the temperature at the seal gland should
be max. 10 °C (18 °F) above the pumped liquid
temperature, unless otherwise specified by
mechanical seal supplier.
In API Plan 13 product is routed from the seal
chamber back to the pump suction to provide cooling
for the seal and to vent air or vapors from the seal
chamber. The seal chamber is subjected to discharge
pressure.
API Plan 61 has tapped and plugged connections for
the purchaser´s use. Typically this plan is used when
the purchaser is to provide fluid (such as steam, gas, or
water) to an external sealing device.
Refer to the GA - drawing for the
required quench medium, pressure and flow.
Disassembly of the seal cartridge
is only allowed by authorized personal. Contact
Flowserve for any service of the mechanical seal. We
recommend to have a spare cartridge seal on stock
for easy replacement.
Open all necessary valves in the
cooling and auxiliary piping and check the flow.
Disassembly of the seal cartridge
is only allowed by authorized personal. Contact
Flowserve for any service of the mechanical seal. We
recommend to have a spare cartridge seal on stock
for easy replacement.
7.1.4 Single Mechanical Seal with API–Plan 13+61
Refer to mechanical seal drawing and
auxiliary piping drawing.
The pump is equipped with a single mechanical seal.
The cartridge design allows to change the
mechanical seal without taking it apart.
Try to turn the rotor by hand.If the
rotor cannot be turned, the pump must be
disassembled, refer to section 6.6 Dismantling HWX.
Actions after start up:
Check all connections to the seal gland and the
mechanical seal itself against leakage. It is usual that
at the seal faces a small leakage occurs after start
up, which decreases with the time of operation and
should stop after the seal is run in. Check the
temperature of the seal gland. I slight increase of
7.2 Changing of mechanical seal
1) Completely drain the pump by using the drain
connection. By pumping explosive or toxic media,
flush the system with Nitrogen.
2) Secure the mechanical seal by putting the
mounting plates into the groove of the shaft
sleeve [2450]. Loose the grub screws [6814.4],
and disconnect the seal piping.
Drain the seal system, if
applicable.
3) For disassembly refer to section 6.6, Dismantling of pump.
4) For assembly refer to section 6.8, Assembly of
pump.
Page 34 of 40
⇓⇓⇓⇓
PROBABLE CAUSES
POSSIBLE REMEDIES
B. MECHANICAL TROUBLES
8.0 FAULTS; CAUSES AND REMEDIES
FAULT SYMPTOM
Pump overheats and seizes
Bearings have short life
⇓⇓⇓⇓
⇓⇓⇓⇓
Pump vibrates or is noisy
⇓⇓⇓⇓
⇓⇓⇓⇓
Mechanical seal has short life
⇓⇓⇓⇓
⇓⇓⇓⇓
Mechanical seal leaks excessively
⇓⇓⇓⇓
⇓⇓⇓⇓
Pump requires excessive power
⇓⇓⇓⇓
⇓⇓⇓⇓
Pump loses prime after starting
⇓⇓⇓⇓
⇓⇓⇓⇓
Insufficient pressure developed
⇓⇓⇓⇓
⇓⇓⇓⇓
Insufficient capacity delivered
⇓⇓⇓⇓
⇓⇓⇓⇓
⇓⇓⇓⇓
⇓⇓⇓⇓
Pump does not deliver liquid
⇓⇓⇓⇓
A. SYSTEM TROUBLES
Pump not primed. Check complete filling
Pump or suction pipe not completely filled with
liquid.
Suction lift too high or level too low.
Excessive amount of air or gas in liquid. Check and purge from pipes
Air or vapour pocket in suction line. Check suction line design for pockets
Air leaks into suction line. Check airtight pipe then joints and gaskets
Air leaks into pump through mechanical seal,
sleeve joints, casing joint or pipe lugs.
Foot valve too small. Investigate replacing the foot valve
Foot valve partially clogged. Clean foot valve
Inlet of suction pipe insufficiently submerged. Check cut out system design
Total head of system higher than differential
head of pump.
Total head of system lower than pump design
head.
Specific gravity of liquid different from design. Consult Flowserve
Viscosity of liquid differs from that for which
designed.
Operation at very low capacity. Measure value and check minimum permitted
Operation at high capacity.
Misalignment due to pipe strain.
Improperly designed foundation.
Shaft bent. Check shaft runouts within acceptable values
Rotating part rubbing on stationary part
internally.
Bearings worn Replace bearings
Wear ring ring surfaces worn. Replace worn wear ring/ surfaces
Impeller damaged or eroded. Replace impeller and check reason
Leakage under sleeve due to joint failure. Replace joint and check for damage
Mechanical seal improperly installed.
HWX USER INSTRUCTIONS ENGLISH - 07/14
Check and complete filling
Check NPSHa>NPSHr, proper submergence,
losses at strainers / fittings
Check airtight assembly then joints and
gaskets
Check discharge head and head losses in
discharge pipe at the valve settings. Check
back pressure is not too high
Throttle at discharge valve or ask Flowserve if
the impeller can be trimmed
Consult Flowserve
Measure value and check maximum
permitted
Check the flange connections and eliminate
strains using elastic couplings or a method
permitted
Check setting of baseplate: tighten, adjust,
grout base as required
Check for signs of this and consult Flowserve
if necessary
Check alignment of faces or damaged parts
and assembly method used
Page 35 of 40
⇓⇓⇓⇓
PROBABLE CAUSES
POSSIBLE REMEDIES
C. ELECTRICAL TROUBLES
FAULT SYMPTOM
Pump overheats and seizes
Bearings have short life
⇓⇓⇓⇓
⇓⇓⇓⇓
Pump vibrates or is noisy
⇓⇓⇓⇓
⇓⇓⇓⇓
Mechanical seal has short life
⇓⇓⇓⇓
⇓⇓⇓⇓
Mechanical seal leaks excessively
⇓⇓⇓⇓
⇓⇓⇓⇓
Pump requires excessive power
⇓⇓⇓⇓
⇓⇓⇓⇓
Pump loses prime after starting
⇓⇓⇓⇓
⇓⇓⇓⇓
Insufficient pressure developed
⇓⇓⇓⇓
⇓⇓⇓⇓
⇓⇓⇓⇓
⇓⇓⇓⇓
HWX USER INSTRUCTIONS ENGLISH - 07/14
Insufficient capacity delivered
Pump does not deliver liquid
⇓⇓⇓⇓
⇓⇓⇓⇓
⇓⇓⇓⇓
Incorrect type of mechanical seal for operating
conditions.
Shaft running off center because of worn
bearings or misalignment.
Impeller out of balance resulting in vibration. Check and consult Flowserve
Abrasive solids in liquid pumped. Check and consult Flowserve
Mechanical seal was run dry.
Internal misalignment due to improper repairs
causing impeller to rub.
Excessive thrust caused by a mechanical
failure inside the pump.
Excessive grease in ball bearings. Check method of regreasing
Lack of lubrication for bearings.
Improper installation of bearings
Damaged bearings due to contamination.
Wrong direction of rotation. Reverse 2 phases on motor terminal box
Motor running too slow, Check motor terminal box connections
Consult Flowserve
Check misalignment and correct if necessary.
If alignment satisfactory check bearings for
excessive wear
Check mechanical seal condition and source
of dry running and repair
Check method of assembly, possible damage
or state of cleanliness during assembly
Check wear condition of Impeller, its
clearances and liquid passages
Check hours run since last change of
lubricant, the schedule and its basis
Check method of assembly, possible damage
or state of cleanliness during assembly and
type of bearing used
Check contamination source and replace
damaged bearings
Page 36 of 40
9.0 CERTIFICATION
Certificates determined from the contract
requirements are provided with these instructions
where applicable. Examples are certificates for CE
marking, ATEX marking etc. If required, copies of
other certificates sent separately to the Purchaser
should be obtained from the Purchaser for retention
with these User Instructions.
10.0 OTHER RELEVANT
DOCUMENTATION AND MANUALS
10.1 Supplementary user instructions
Supplementary instructions determined from the
contract requirements for inclusion into user
Instructions such as for a driver, instrumentation,
controller, sub-driver, seals, sealant system, mounting
component etc are included in the Data Book. If
further copies of these are required they should be
obtained from the supplier for retention with these
user instructions.
Where any pre-printed set of user instructions are
used, and satisfactory quality can be maintained only
by avoiding copying these, they are included at the
end of these user instructions such as within a
standard clear polymer software protection envelope.
HWX USER INSTRUCTIONS ENGLISH - 07/14
10.2 Change notes
If any changes, agreed with Flowserve, are made to
the product after its supply, a record of the details
should be maintained with these User Instructions.
10.3 Additional sources of information
Reference 1:
NPSH for Rotordynamic Pumps: a reference guide,
Europump Guide No. 1, Europump & World Pumps,
Elsevier Science, United Kingdom, 1999.
Reference 2:
Pump Handbook, 2nd edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.
Reference 3:
ANSI/HI 1.1-1.5
Centrifugal Pumps - Nomenclature, Definitions,
Application and Operation.