Flowserve IDP CPXV User Manual

USER INSTRUCTIONS

IDP ® CPXV and CPXRV

Installation

Operation

Maintenance

Centrifugal, modular design, vertical sump pumps, including high temperature configuration

PCN=71569193 09-14 (E). (Based on C942KH001, C942KH021, and C942KH017.) Original instructions.

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

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CPXV and CPXRV USER INSTRUCTIONS ENGLISH 71569193 09-14

CONTENTS

Page

1 INTRODUCTION AND SAFETY 4

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

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

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

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

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

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

1.7 Nameplate and safety labels ........................... 9

1.8 Specific machine performance ........................ 9

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

2 TRANSPORT AND STORAGE 10

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

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

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

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

2.5 Recycling and end of product life .................. 11

3 DESCRIPTION 11

3.1 Configurations ............................................... 11

3.2 Name nomenclature ...................................... 11

3.3 Design of major parts .................................... 11

3.4 Performance and operating limits.................. 12

4 INSTALLATION 13

4.1 Location ......................................................... 13

4.2 Part assemblies ............................................. 13

4.3 Foundation ..................................................... 13

4.4 Grouting ......................................................... 13

4.5 Piping ............................................................. 13

4.6 Electrical connections .................................... 15

4.7 Protection systems ........................................ 16

5 COMMISSIONING, START-UP, OPERATION

AND SHUTDOWN 16

5.1 Pre-commissioning procedure ....................... 16

5.2 Pump lubricantsError! Bookmark not defined.

5.3 Open impeller clearance ............................... 19

5.4 Direction of rotation ....................................... 19

5.5 Guarding ........................................................ 20

5.6 Priming and auxiliary supplies ....................... 20

5.7 Starting the pump .......................................... 20

5.8 Running the pump ......................................... 21

5.9 Stopping and shutdown ................................. 22

5.10 Hydraulic, mechanical and electrical duty .. 23

Page

6 MAINTENANCE 23

6.1 General .......................................................... 23

6.2 Maintenance schedule ................................... 24

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

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

6.5 Tools required ................................................ 25

6.6 Casing, seal housing and fastener torques ... 26

6.7 Setting impeller clearance .............................. 26

6.8 Renewal clearances ....................................... 27

6.9 Disassembly ................................................... 27

6.10 Examination of parts .................................... 29

6.11 Assembly ..................................................... 29

7 FAULTS; CAUSES AND REMEDIES 32 8 PARTS LISTS AND DRAWINGS 34

8.1 CPXV ............................................................. 34

8.2 CPXRV ........................................................... 35

8.3 CPXV jacketed ............................................... 36

8.4 CPXV molten salt version .............................. 37

8.5 CPXV and CPXRV bearing options ............... 39

8.6 CPXV and CPXRV sealing and drive

options…. ....................................................... 42

8.7 Parts interchangeability .................................. 45

8.8 General arrangement drawing ....................... 46

9 CERTIFICATION 46 10 OTHER RELEVANT DOCUMENTATION AND

MANUALS 46

10.1 Supplementary User Instruction manuals ... 46

10.2 Change notes .............................................. 46

10.3 Additional sources of information ................ 46

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INDEX

Page

Additional sources (10.3) ......................................... 46

Assembly (6.11) ....................................................... 29

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

Bearing sizes and capacities (5.2.2)........................ 18

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

Certification (9) ........................................................ 46

Change notes (10.2) ................................................ 46

Clearances, impeller (6.7) ....................................... 26

Commissioning and operation (5) ............................ 16

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

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

Design of major parts (3.3) ...................................... 11

Direction of rotation (5.4) ......................................... 19

Disassembly (6.9) .................................................... 27

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

Dismantling (6.9, Disassembly) ............................... 27

Drawings (8) ............................................................ 34

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

Electrical connections (4.6) ..................................... 15

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

Examination of parts (6.10) ..................................... 29

Fastener torques (6.6) ............................................. 26

Faults; causes and remedies (7) ............................. 32

Foundation (4.3) ...................................................... 13

General arrangement drawing (8.8) ........................ 46

General assembly drawings (see 8) ........................ 34

Grouting (4.4) ........................................................... 13

Guarding (5.5) .......................................................... 20

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

Hydraulic, mechanical and electrical duty (5.10) ..... 23

Impeller clearance (5.3 and 6.7)

Inspection (6.2.1 and 6.2.2) ..................................... 24

Installation (4) .......................................................... 13

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

Location (4.1) ........................................................... 13

Lubrication (5.1.1, 5.2 and 6.2.3)

Lubrication schedule (5.2.5) .................................... 18

Maintenance (6) ....................................................... 23

Maintenance schedule (6.2) .................................... 24

Name nomenclature (3.2) ........................................ 11

Nameplate (1.7.1) ...................................................... 9

Operating limits (3.4.1) ............................................ 12

Ordering spare parts (6.3.1) .................................... 25

Part assemblies (4.2) ............................................... 13

Parts lists (8) ............................................................ 34

Performance (3.4) .................................................... 12

Piping (4.5) .............................................................. 13

Pre-commissioning (5.1) .......................................... 16

Priming and auxiliary supplies (5.6) ......................... 20

Protection systems (4.7) .......................................... 16

Page

Reassembly (6.11, Assembly) .................................29

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

Recommended fill quantities (see 5.2.2) ..................18

Recommended grease lubricants (5.2.3) .................18

Recommended oil lubricants (5.2.1) ........................18

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

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

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

Running the pump (5.8) ...........................................21

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

Safety labels (1.7.2) ................................................... 9

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

Safety, protection systems (1.6 and 4.7)

Sectional drawings (see 8) .......................................34

Setting impeller clearance (6.7) ...............................26

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

Sources, additional information (10.3) .....................46

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

Specific machine performance (1.8) .......................... 9

Starting the pump (5.7).............................................20

Stop/start frequency (5.8.8) ......................................22

Stopping and shutdown (5.9) ...................................22

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

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

Supplementary manuals or information sources ......46

Supplementary User Instructions (10.1)...................46

Tools required (6.5) ..................................................25

Torques for fasteners (6.6) .......................................26

Trouble-shooting (see 7) ..........................................32

Vibration (5.8.6) ........................................................22

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1 INTRODUCTION AND SAFETY

1.1 General

These instructions must always be kept

close to the product's operating location or directly with the product.

Flowserve products are designed, developed and manufactured with state-of-the-art technologies in modern facilities. The unit is produced with great care and commitment to continuous quality control, utilising sophisticated quality techniques, and safety requirements.

Flowserve is committed to continuous quality improvement and being at service for any further information about the product in its installation and operation or about its support products, repair and diagnostic services.

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

These instructions must be read prior to installing, operating, using and maintaining the equipment in any region worldwide. The equipment must not be put into service until all the conditions relating to safety, noted in the instructions, have been met. Failure to follow and apply the present user instructions is considered to be misuse. Personal injury, product damage, delay or failure caused by misuse are not covered by the Flowserve warranty.

1.2 CE marking and approvals

It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and, where applicable, Low Voltage Equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED) and Equipment for Potentially Explosive Atmospheres (ATEX).

Where applicable, the Directives and any additional Approvals, cover important safety aspects relating to machinery and equipment and the satisfactory provision

of technical documents and safety instructions. Where applicable this document incorporates information relevant to these Directives and Approvals.

To confirm the Approvals applying and if the product is CE marked, check the serial number plate markings and the Certification. (See section 9, Certification.)

1.3 Disclaimer

Information in these User Instructions is believed to be complete and reliable. However, in spite of all of the efforts of Flowserve Corporation to provide comprehensive instructions, good engineering and safety practice should always be used.

Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance organisations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorised Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by the Flowserve 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

1.5 Duty conditions

This product has been selected to meet the specifications of your purchaser order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.

The product must not be operated beyond

the parameters specified for the application. If there is any doubt as to the suitability of the product for the application intended, contact Flowserve for advice, quoting the serial number.

If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty) it is requested that the user seeks the written agreement of Flowserve before start-up.

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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 and could result in loss of life.

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

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

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

involve a high risk to personal safety and could result in loss of life.

This symbol indicates safety instructions

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

This symbol is used in safety instructions to

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

This sign is not a safety symbol but indicates

an important instruction in the assembly process.

1.6.2 Personnel qualification and training

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

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

1.6.3 Safety action

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

also applies.

NEVER DO MAINTENANCE WORK

WHEN THE UNIT IS CONNECTED TO POWER

GUARDS MUST NOT BE REMOVED WHILE

THE PUMP IS OPERATIONAL

DRAIN THE 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 ºC (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this condition these are extremely dangerous and skin contact must be avoided.

HANDLING COMPONENTS

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

THERMAL SHOCK

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

NEVER APPLY HEAT TO REMOVE IMPELLER

Trapped lubricant or vapor could cause an explosion.

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

If the temperature is greater than 80 ºC (175 ºF) or

below -5 ºC (23 ºF) in a restricted zone, or exceeds local regulations, action as above shall be taken.

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HAZARDOUS LIQUIDS

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

Gland packing must not be used when pumping

hazardous liquids.

PREVENT EXCESSIVE EXTERNAL

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

NEVER RUN THE PUMP DRY

Liquid level controls are recommended to avoid the risk of dry running.

ENSURE CORRECT LUBRICATION (See section 5, Commissioning, start-up, operation and shutdown.)

ONLY CHECK DIRECTION OF

MOTOR ROTATION WITH COUPLING ELEMENT/ PINS REMOVED Starting in reverse direction of rotation will damage the pump.

START THE PUMP WITH OUTLET VALVE PART OPENED (Unless otherwise instructed at a specific point in the User Instructions.)

This is recommended to minimize the risk of overloading and damaging the pump or motor at full or zero flow. Pumps may be started with the valve further open only on installations where this situation cannot occur. The pump outlet control valve may need to be adjusted to comply with the duty following the run-up process. (See section 5, Commissioning start-up, operation and shutdown.)

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.

1.6.4 Products used in potentially explosive atmospheres

Measures are required to:

 Avoid excess temperature  Prevent build up of explosive mixtures  Prevent the generation of sparks  Prevent leakages  Maintain the pump to avoid hazard

The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection. For ATEX, both electrical and non-electrical equipment must meet the requirements of European Directive 2014/34/EU (previously 94/9/EC which remains valid until 20 April 2016 during the transition). Always observe the regional legal Ex requirements e.g. Ex electrical items outside the EU may be required certified to other than ATEX e.g. IECEx, UL.

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it is

appropriate. Always check that the driver, drive

coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed.

Where Flowserve has supplied only the bare shaft pump, the Ex rating applies only to the pump. The party responsible for assembling the ATEX 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 motor, coupling, pump thrust bearing and seal can be made compliant with ATEX Directive 2014/34/EU (previously 94/9/EC which remains valid until 20 April 2016 during the transition) for Equipment Categories 2 and 3 as required by the duty conditions.

See the pump nameplate and Declaration of Conformity for the pump classification. The pump column below sole plate will also generally be to the same category however in some applications the section of the pump below sole plate and above liquid will have been designed to Category 1, whereas above sole plate Category 2 or 3 will apply. (See section 1.6.4.2.)

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Temperature class

to EN 13463-1

Maximum surface

temperature permitted

Temperature limit of

liquid handled

T6 T5 T4 T3 T2 T1

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

65 °C (149 °F) *

80 °C (176 °F) * 115 °C (239 °F) * 180 °C (356 °F) * 275 °C (527 °F) * 400 °C (752 °F) *

The pump will then be supplied with a copy of the Certificate of Approval by a Notified Body and marked with both categories. Users must pay particular attention to pump operation and maintenance instructions because of the hazard of the explosive atmosphere.

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

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 or in the case of Category 1, below the sole plate on a special ATEX marking plate.

0518 II 1G/2GD cb IIC 135 ºC (T4)

External examination body *

Equipment Group I = Mining II = Non-mining

See also sections 5.8.2 to 5.8.6.

1.6.4.4 Preventing the build-up of explosive mixtures

ENSURE THE PUMP IS PROPERLY FILLED

AND VENTED AND DOES NOT RUN DRY

Ensure the pump and relevant suction and discharge pipeline system is totally filled with liquid at all times during the pump operation, so that an explosive atmosphere is prevented. In addition it is essential to

make sure that seal chambers, auxiliary shaft seal systems and any heating and cooling systems are properly filled.

If the operation of the system cannot avoid this condition, fit an appropriate dry run protection device (for example 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 for Category 2.

To avoid the potential hazard from random induced current generating a spark, the sole plate must be properly grounded.

Avoid electrostatic charge: do not rub non-metallic

surfaces with a dry cloth; ensure cloth is damp. For ATEX the coupling must be selected to comply with

the requirements of European Directive 2014/34/EU (previously 94/9/EC which remains valid until 20 April 2016 during the transition). Correct coupling alignment must be maintained.

1.6.4.6 Preventing leakage

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

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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.

If leakage of liquid to atmosphere can result in a hazard, install a liquid detection device.

1.6.4.7 Maintenance 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.)

1.7 Nameplate and safety labels

1.7.1 Nameplate

For details of nameplate, see the Declaration of Conformity. Where a unit is ATEX Group II Category

1 below the sole plate there is an additional ATEX marking plate. (See section 1.6.4.2, Marking.)

1.7.2 Safety labels

Oil lubricated units only:

1.8 Specific machine performance

For performance parameters see section 1.5, Duty conditions. Where performance data has been supplied

separately to the purchaser these should be obtained and retained with these User Instructions if required.

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”.

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Motor size and speed

kW (hp)

Typical sound pressure level LpA at 1 m reference 20 μPa, dBA

3 550 r/min

2 900 r/min

1 750 r/min

1 450 r/min

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

<0.55 (<0.75)

0.75 (1)

1.1 (1.5)

1.5 (2)

2.2 (3)

3 (4)

4 (5)

5.5 (7.5)

7.5 (10)

11 (15)

15 (20)

18.5 (25)

22 (30)

30 (40)

37 (50)

45 (60)

55 (75)

75 (100)

90 (120)

110 (150)

150 (200)

200 (270)



  

300 (400)

–

For estimating sound power level LWA (re 1 pW) then add 14 dBA to the sound pressure value.

 The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are inappropriate. Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be checked against the delivery/shipping documents for its completeness and that there has been no damage

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

in transportation. Any shortage and/or damage must be reported immediately to Flowserve and must be received in writing within one month of receipt of the equipment. Later claims cannot be accepted.

Check any crate, boxes or wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to side walls of the box or equipment.

A crane must be used for all pump sets in excess of 25 kg (55 lb). Fully trained personnel must carry out lifting, in accordance with local regulations.

Pumps with drivers over approximately 7.5 kW, are supplied with the pump packed as a separate item from the driver. These should be lifted separately into their installed position, using lifting points on the pump sole plate, and on the motor.

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.

the resulting center of gravity may be above the lifting points, and the method of slinging must prevent the machine tipping during the lift.

When lifting pumps with drivers fitted,

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For lifting the driver refer to the dimension drawing of the driver

Lift points for the pump or the pump and the driver

Slings, ropes and other lifting gear must be positioned where they cannot slip and where a balanced lift is obtained.

Most units are supplied with four lifting points on the pump sole plate [6140]. Attach D links onto all four lifting points. Lift the pump up to the vertical, suspending initially from only two of the D links on the sole plate while the pump casing foot remains resting on the floor, until almost vertical. Then use all four lifting points to lift completely off the floor.

For improved stability unbolt the driver and lift the driver and pump separately.

To avoid distortion, the pump unit

should be lifted as shown.

2.4 Storage

Store the pump in a clean, dry location

away from vibration. Leave piping connection covers in place to keep dirt and other foreign material out of pump casing. Turn pump at intervals to prevent brinelling of the bearings and the seal faces, if fitted, from sticking.

The pump may be stored as above for up to six months. Consult Flowserve for preservative actions when a longer storage period is needed.

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 requirements. If the product contains substances that 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 that may be used in the "seal system" or other utilities.

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

3 DESCRIPTION

3.1 Configurations

The pump is a modular designed centrifugal pump that can be built to achieve almost all chemical liquid pumping requirements. (See 3.2 and 3.3 below.)

3.2 Name nomenclature

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

80-50CPXV200

Nominal suction size in mm Nominal discharge size in mm Configuration – see 3.3.1 and 3.3.2 below Nominal ISO maximum impeller diameter in mm

The typical nomenclature above is the general guide to the CPXV configuration 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 pump casing is designed for operation when submerged in the sump liquid.

3.3.2 Impeller

An open impeller is fitted. (On the CPXRV the impeller is recessed within the back of the casing and the impeller setting is to the rear backvanes.)

3.3.3 Shaft

The shaft has a keyed drive coupling. It is supported by rolling bearing(s) above the sole plate and journal bearing(s) below.

3.3.4 Bearing housing

The bearing housing enables adjustment of impeller face clearance on the open impeller via the bearing carrier jacking screws.

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High temperature pumps have a cooling fan above the pump thrust bearing housing and a heat sink disk fan below the pump thrust bearing but above the sole plate shaft seal.

3.3.5 Pump bearings and lubrication

The pump is fitted with a thrust type ball bearing that may be configured differently dependent on use.

The thrust bearing(s) may be grease or oil lubricated depending upon the application.

The journal (line) bearings may be lubricated by product or from an external source depending upon the application.

3.3.6 Sole plate shaft seal

The modular design enables one of a number of sealing options to be fitted. The option of a rigid coupling below the thrust bearing and above a mechanical seal provides back-pull-out servicing of the mechanical seal; removing the motor extends the back-pull-out feature to the thrust bearing.

3.3.7 Driver

The pump is normally driven by a flange mounted electric motor. An air or hydraulic motor may be utilized.

The position of the terminal box can be changed by rotating the complete motor. To do this, remove the fasteners from the motor flange, rotate the motor and re-fit the fasteners.

3.3.8 Accessories

Accessories may be fitted when specified by the customer.

3.4 Performance and operating limits

This product has been selected to meet the specifications of the purchase order. See section 1.5.

The following data is included as additional information to help with your installation. It is typical, and factors such as temperature, materials, and seal type may influence this data. If required, a definitive statement for your particular application can be obtained from Flowserve.

3.4.1 Operating limits

Maximum pump ambient temperature: +55 ºC (131 ºF) where driver, flexible coupling and thrust bearing is also rated for this ambient. Check the nameplate.

Maximum pump speed: refer to the nameplate.

3.4.2 Energy efficiency operation of pumps

The pump supplied will have been selected from Flowserve’s extensive product line to have optimum efficiency for the application. If supplied with an electric motor then the motor will meet or exceed current legislation for motor efficiency. However it is the way the pump is operated which has the greatest impact on the amount and cost of energy used during the operating life of the pump. The following are key points in achieving minimum operating cost for the equipment:

 Design the pipe system for minimum friction losses  Ensure that the control system switches off the

pump when not required

 In a multi-pump system run the minimum number

of pumps

 Try to avoid systems which by-pass excess flow  As far as possible avoid controlling pump flow by

throttle valves

 When commissioned, check that the pump

operates at the duty specified to Flowserve

 If it has been found that the pump head and flow

exceed that required, trim the pump impeller diameter

 Ensure that the pump is operating with sufficient

NPSH available

 Use variable speed drives for systems that

require variable flow. A VFD for an induction motor is a particularly effective way of achieving speed variation and energy/cost reduction

 Notes for VFD usage:

o make sure that the motor is compatible with

VFD

o Do not over-speed the pump without

checking the power capability with Flowserve

o On systems with high static head, speed

reduction is limited. Avoid running the pump at a speed which gives low or zero flow

o Do not run a low speed and flow rate that lets

solids settle out of suspension in the pipework

o Do not use a VFD for a fixed flow

requirement; it will introduce power losses

 Select high efficiency motors  If replacing a standard motor with a high

efficiency motor it will run faster and the pump could take more power. Reduce the impeller diameter to achieve energy reduction

 If the pump system pipework or equipment is

changed or process duty is changed, check that the pump is still correctly sized

 Periodically check that the pipe system has not

become corroded or blocked

 Periodically check that the pump is operating at

the flow, head and power expected and that the efficiency has not reduced with erosion or corrosion damage

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CPXV and CPXRV USER INSTRUCTIONS ENGLISH 71569193 09-14

4 INSTALLATION

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

potentially explosive atmospheres.

4.1 Location

The pump should 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

On pump sets the coupling elements are supplied loose. It is the responsibility of the installer to ensure that the pump set is finally lined up and checked as detailed in section 4.5.5, Final checks.

4.3 Foundation

There are many methods of installing

pump units to their foundations. The correct method depends on the size of the pump unit, its location and noise and vibration limitations. Non-compliance with the provision of correct foundation and installation may lead to failure of the pump and, as such, would be outside the terms of the warranty.

The pump mounting should have concrete or metal to support it around its edges.

4.3.1 Levelling

The sole plate must be level so that the pump column hangs vertically; confirmed by inspection. With the motor removed check the top face of the machined motor pedestal [3160] is set level to 0.05 mm (0.002 in.) or 0.2 mm/m (0.0025 in./ft) maximum. The optional base plate should be levelled and grouted first.

Larger size motors are shipped unfitted. The motor will need to be fitted after completion of the pump foundation installation. Turn shaft clockwise by hand to ensure it is free to turn.

4.3.2 Packing pieces

Where the sole plate and its counter-face do not each have a machined face, packing pieces (metallic shims) will need to be placed evenly adjacent to the foundation (holding down) bolts to avoid “soft-foot” distortion. Turn shaft clockwise by hand to ensure it is free to turn.

Soft-foot distortion may significantly increase vibration and damage equipment by causing distortion and should normally be inspected. If high vibration occurs when pump is run (see section 5, Commissioning, start- up, operation and shutdown) place a vibration meter at the side of the motor as soft-foot is most effectively reduced when the vibration is reduced to a minimum.

Overall vibration measurement can be used - it is not necessary to use a vibration spectrum to pick up softfoot which occurs at 1x running speed and should be the first issue to check.

To adjust for soft-foot use a dial gauge on the sole plate top face near to the holding down bolt, zero it, record the soft-foot spring in the sole plate and undo one holding down bolt at a time.

Soft-foot is removed by inserting packing pieces (metallic shims) equal to or slightly less than the softfoot spring amount recorded at the individual holding down point locations. Re-torque the holding down bolt. Continue this procedure for each holding down bolt position in turn, one at a time. The thickness of packing pieces (metallic shims) adjacent to an individual holding down bolt should not exceed 3 mm (0.12 in.); ie soft-foot spring is not to exceed 3 mm (0.12 in.) at any individual location.

4.4 Grouting

Where applicable, grout in the foundation bolts.

Grouting provides solid contact between the pump unit and foundation, prevents lateral movement of vibrating equipment and dampens resonant vibrations.

4.5 Piping

Protective covers are fitted to the pipe

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

If sludge and debris can build up in the sump it is recommended to use a strainer with a maximum opening size of 6 mm (0.024 in.) and a free surface area greater than three times the pump suction area.

Category 1/2 and 1/3 pumps must be fitted with a strainer.

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CPXV and CPXRV USER INSTRUCTIONS ENGLISH 71569193 09-14

Discharge

flange size

mm (in.)

Maximum forces (F) in kN (lbf) and moments (M) in Nm (lbf•ft)

40 (1.5)

0.71 (160)

0.58 (130)

0.89 (200)

1.28 (290)

0.46 (340)

0.23 (170)

0.35 (260)

0.62 (460)

50 (2.0)

0.71 (160)

0.58 (130)

0.89 (200)

1.28 (290)

0.46 (340)

0.23 (170)

0.35 (260)

0.62 (460)

80 (3.0)

1.07 (240)

0.89 (200)

1.33 (300)

1.93 (430)

0.95 (700)

0.47 (350)

0.72 (530)

1.28 (950)

100 (4.0)

1.42 (320)

1.16 (260)

1.78 (400)

2.56 (570)

1.33 (980)

0.68 (500)

1.00 (740)

1.80 (1 330)

125 (5.0)

1.95 (440)

1.58 (355)

2.45 (550)

3.50 (790)

1.93 (1 420)

0.98 (720)

1.36 (1 000)

2.56 (1 880)

150 (6.0)

2.49 (560)

2.05 (460)

3.11 (700)

4.48 (1010)

2.30 (1 700)

1.18 (870)

1.76 (1 300)

3.13 (2 310)

200 (8.0)

3.78 (850)

3.11 (700)

4.89 (1 100)

6.92 (1560)

3.53 (2 600)

1.76 (1 300)

2.58 (1 900)

4.71 (3 500)

250 (10.0)

5.34 (1 200)

4.45 (1 000)

6.67 (1 500)

9.63 (2 200)

5.02 (3 700)

2.44 (1 800)

3.80 (2 800)

6.75 (5 000)

Maximum forces and moments allowed on the pump flanges vary with the pump size and type. To minimize these forces and moments that may, if excessive, cause misalignment, hot bearings, worn couplings, vibration and the possible failure of the pump casing, the following points should be strictly followed:

 Prevent excessive external pipe load  Never draw piping into place by applying force to

pump flange connections

 Do not mount expansion joints so that their force,

due to internal pressure, acts on the pump flange

4.5.1 Discharge pipework

In order to minimize friction losses and hydraulic noise in the pipework it is good practice to choose pipework that is one or two sizes larger than the pump discharge. Typically main pipework velocities should not exceed 3 m/s (9 ft/sec) on the discharge.

Never use the pump as a support for

piping.

Ensure piping and fittings are flushed

before use.

Ensure piping for hazardous liquids is arranged

to allow pump flushing before removal of the pump.

4.5.2 Discharge piping

A non-return valve should be located in the discharge pipework to protect the pump from excessive back pressure and hence reverse rotation when the unit is stopped.

Fitting an isolation valve will allow easier maintenance.

4.5.3 Maximum forces and moments allowed on the main sole plate discharge flange

The table below uses the sign convention shown for the pump sole plate discharge flange maximum forces and moments. These are valid for a pump end up to 100 ºC (212 ºF) and the sole plate on a rigid foundation.

4.5.4 Auxiliary piping

4.5.4.1 Pumps fitted with a sole plate packed gland

Ensure lubrication is supplied to the gland packing. High temperature molten salt builds require a Nitrogen gas injection at 3.4 m3/h (2 ft3/min) to the gland packing and this must be operating whenever adjusting the packing.

4.5.4.2 Pumps fitted with mechanical seals

Double seals require a barrier liquid between the seals, compatible with the pumped liquid.

With back-to-back double seals, the barrier liquid should be at a minimum pressure of 1 bar (15 psi) above the maximum pressure on the pump side of the inner seal. The barrier liquid pressure must not exceed limitations of the seal on the atmospheric side. For toxic service the barrier liquid supply and

discharge must be handled safely and in line with local legislation.

Special seals may require modification to auxiliary piping described above. Seal on pumps in potentially explosive atmospheres shall comply with section

1.6.4.3. Consult Flowserve if unsure of correct method or arrangement.

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CPXV and CPXRV USER INSTRUCTIONS ENGLISH 71569193 09-14

Pa ralle l

An gular

4.5.4.3 Pumps fitted with heating jacket

As the pump is constructed as a heated jacketed unit, steam must be connected to the steam inlet flange and removed via the steam outlet flange. These flanges are located on the upper side of the sole plate. A flanged steam valve should be provided at the steam inlet and outlet for control of the steam supply.

4.5.5 Final checks

Check the tightness of all bolts in the suction and discharge pipework. Check also the tightness of all foundation bolts.

After connecting piping to the pump, rotate the shaft several times by hand to ensure there is no binding and all parts are free.

Recheck the flexible element coupling is aligned with the permitted limits.

Where there is the option of an additional rigid coupling below the thrust bearing, above the mechanical seal: this has full metal-to-metal joints which do not permit its adjustment.

For couplings with narrow flanges use a dial indicator as shown. The alignment values are maximums for continuous service.

If alignment needs to be adjusted, a small amount of adjustment of the motor is available within the motor spigot but alignment is generally achieved automatically on assembly. Larger motors always require re-adjustment.

If it is not possible to achieve the alignment accuracy defined, it may be an indication that the pump has not been installed or handled correctly.

4.6 Electrical connections

Electrical connections must be made by

a qualified Electrician in accordance with relevant local national and international regulations.

It is important to be aware of the EUROPEAN

DIRECTIVE on potentially explosive 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.

Permissible misalignment limits at working temperature:  Parallel alignment

- 0.25 mm (0.010 in.) TIR maximum

 Angular alignment

- 0.3 mm (0.012 in.) TIR maximum for couplings not exceeding 100 mm (4 in.) flange diameter

- 0.5 mm (0.020 in.) TIR maximum for couplings over 100 mm (4 in.) diameter

 Use the lower of the above values and values

indicated in the coupling manual

When checking parallel alignment, the total indicator read-out (TIR) shown is twice the value of the actual shaft displacement.

The motor must be wired up in accordance with the motor manufacturer's instructions (normally supplied within the terminal box). Any temperature, earth leakage, current or other appropriate protective devices must be correctly installed and monitored. 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.

See section 0, Direction of rotation,

before connecting the motor to the electrical supply.

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