Page 1
USER INSTRUCTIONS
Worthington® LPNV centrifugal pumps
Installation
Operation
API 610 (BB1), Between Bearings, Axially Spit,
Single Stage, Double Suction Pumps, Vertically Mounted
PCN=87900031 - 06/14 (E) Original instructions
_________________________________________________________________________________
Maintenance
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
Page 2
INDEX
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
................................................................... PAGE
1.1 General…………… ........................................... 3
1.2 CE marking and approvals ............................... 3
1.3 Disclaimer…….. ............................................... 3
1.4 Copyright ……………………………………3
1.5 Duty conditions ................................................. 3
1.6 Safety……….. .................................................. 4
1.7 Nameplate and warning labels ......................... 7
1.8 Specific machine performance ......................... 7
1.9 Noise level 8
2 TRANSPORT AND STORAGE ............................... 9
2.1 Consignment receipt and unpacking ................ 9
2.2 Handling………. ............................................... 9
2.3 Lifting………. .................................................... 9
2.5 Recycling and end of product life ................... 13
3 PUMP DESCRIPTION .......................................... 14
3.1 Configurations ................................................ 14
3.2 Nomenclature ................................................. 14
3.3 Design of major parts ..................................... 14
3.4 Performance and operating limits ................... 15
4 INSTALLATION ..................................................... 17
4.1 Location……….. ............................................. 17
4.2 Foundation…… .............................................. 17
4.3 Installation and alignment ............................... 18
4.4 Piping……… .................................................. 20
4.5 Final shaft alignment check ............................ 22
4.6 Electrical connections ..................................... 22
4.7 Protection systems ......................................... 22
7 FAULTS; CAUSES AND REMEDIES ................... 39
8 GENERAL ARRANGEMENT, SECTIONAL
DRAWINGS AND PA RT LIST .......................... 41
9 CERTIFICATION ................................................... 46
10 OTHER RELEVANT DOCUMENTA TION AND
MANUALS ........................................................ 46
10.1 Supplementary User Instruction manuals .... 46
10.2 Change notes ............................................... 46
10.3 Additional sources of information ................. 46
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN ........................................... 23
5.1 Pre-commissioning procedure........................ 23
5.2 Pump Lubricants............................................. 25
5.3 Direction of rotation ....................................... 26
5.4 Guarding…….. .............................................. 26
5.6 Starting the pump .......................................... 27
5.7 Operating checks .......................................... 27
5.8 Normal Start Up .............................................. 29
5.9 Stopping the pump ......................................... 29
5.10 Hydraulic, mechanical and ........................... 29
electrical dut…….y ............................................... 29
6 MAINTENANCE .................................................... 30
6.1 General……. .................................................. 30
6.2 Maintenance schedule ................................... 30
6.3 Spare p arts …………………………………31
6.4 Recommended spares (according to API) ..... 32
6.5 Tools required ................................................. 32
6.6 Fastener torques ............................................ 33
6.7 Disassembly ................................................... 33
6.8 Examination of parts ....................................... 35
6.9 Reassembly …………………………………37
Page 2 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
1 INTRODUCTION AND SAFETY
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,
utilizing sophisticated quality techniques, and
safety requirements.
Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted
use. Operating the product in compliance with
these instructions is important to help ensure
reliability in service and avoid risks. The
instructions may not take into account local
regulations; ensure such regulations are observed
by all, including those installing the product.
Always coordinate repair activity with operations
personnel, and follow all plant safety requirements
and applicable safety and health laws/regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow
and apply the present user instructions is
considered to be misuse. Personal injury,
product damage, delay or 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 reliable. In spite of all the efforts
of Flowserve 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 organizations. Genuine parts
and accessories have been designed, tested and
incorporated into the products to help ensure
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 authorized Flowserve parts
and accessories is considered to be misuse.
Damage or failure caused by misuse is not
covered by Flowserve's warranty. In addition, any
modification of Flowserve products or removal of
original components may impair the safety of these
products in their use
1.4 Copyright
All rights reserved. No part of these instructions
may be reproduced, stored in a retrieval system or
transmitted in any form or by any means without
prior permission of Flowserve Corporation.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been
sent separately to the Purchaser. A copy should
be kept with these instructions.
The product must not be operated beyond the
parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial
number.
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.
Page 3 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction
would cause hazards. The specific safety markings
are:
This symbol indicates electrical
safety instructions where non-compliance will
involve a high risk to personal safety or the loss of
life.
This symbol indicates safety instructions
where non-compliance would affect personal
safety and could result in loss of life.
This symbol indicates “hazardous and toxic
fluid” safety instructions where non-compliance
would affect personal safety and could result in loss
of life.
This symbol indicates safety
instructions where non-compliance will involve
some risk to safe operation and personal safety and
would damage the equipment or property.
This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in
safety instructions where non-compliance in the
hazardous area would cause the risk of an
explosion.
This symbol indicates is used in safety
instructions to remind not to rub non-metallic
surfaces with a dry cloth; ensure cloth is damp. It
is used where 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 co-ordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicabl e s afe ty 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.
PREVENT EXCESSIVE
EXTERNAL PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by
Flowserve in writing, so that their force, due to
internal pressure, acts on the pump flange.
ENSURE CORRECT
LUBRICATION
(See section 5, Commissioning, startup, operation
and shutdown.)
START THE PUMP WITH OUTLET
VALVE PARTLY OPENED
(Unless otherwise instructed at a specific point in
the User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump motor at full
or zero flow. Pumps may be started with the valve
further open only on installations where this
situation cannot occur. The pump outlet control
valve may need to be adjusted to comply with the
duty following the run-up process. (See section 5,
Commissioning start-up, operation and shutdown.)
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY
OPEN WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will
cause damage to the seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a
flow rate with no backpressure on the pump may
overload the motor and cause cavitation. Low flow
rates may cause a reduction in pump/bearing life,
overheating of the pump, instability and
cavitation/vibration.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
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Page 5
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
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 p rocedures
must be applied.
Gland seal must not be used when pumping
hazardous liquids.
DRAIN THE PUMP AND ISOLATE
PIPEWORK BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be
taken where the pumped liquids are hazardo us.
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 sh arp corners and the
wearing of appropriate safety gloves and
equipment is required when handling these
components. To lift heavy pieces above 25 kg (55
lb) use a crane appropriate for the mass and in
accordance with current local regulations.
GUARDS MUST NOT BE REMOVED
WHILE THE PUMP IS OPERATIONAL
The unit must not be operated unless coupling guard
is in place. Failure to observe this warning could
result in injury to operating personnel.
THERMAL SHOCK
Rapid changes in the temperature of the liquid
within the pump can cause thermal shock, which
can result in damage or breakage of components
and should be avoided.
NEVER APPLY HEAT TO REMOVE
IMPELLER
Trapped lubricant or vapor could cause an
explosion.
must be limited to maintenance staff only, with
clear visual warnings and indicators to those
entering the immediate area. Note: bearing
housings must not be insulated and drive motors
and bearings may be hot.
If the temperature is greater than 80 °C (175 °F)
or below -5 °C (20 °F) in a restricted zone, or
exceeds local regulations, action as above
shall be taken.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
Avoid excess temperature.
Prevent build up of explosive mixtures.
Prevent the generation of sparks.
Prevent leakages.
Maintain the pump to avoid hazard.
The following instructions for pumps and pump units
when installed in 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
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of
the specific atmosphere in which they are to be
installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the pump set shall
select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable
for the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so,
for pumps sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
where electrical supply is from the VFD. This
particular requirement still applies even if the VFD is
in a safe area.
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
Page 5 of 48
Page 6
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
1.6.4.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D = Dust
C = Constructional safety
(in accordance with En13463-5)
Gas Group
(Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature
Class) (See section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface
temperatures
ENSURE THE EQUIPMENT
TEMPERATURE CLASS IS SUITABLE FOR THE
HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are
based on a maximum ambient of 40 °C (104 °F);
refer to Flowserve for higher ambient
temperatures.
The surface temperature on the pump is
influenced by the temperature of the liquid
handled. The maximum permissible liquid
temperature depends on the temperature class
and must not exceed the values in the table that
follows.
The temperature rise at the seals and bearings
and due to the minimum permitted flow rate is
taken into account in the temperatures stated.
Temperature
class to
EN 13463-1
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is
lower)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
The responsibility for compliance with the
specified maximum liquid temperature is with
the plant operator.
Temperature classification “Tx” is used when the
liquid temperature varies and the pump could be
installed in different hazardous atmospheres. In
this case the user is responsible for ensuring that
the pump surface temperature does not exceed
that permitted in its actual installed location.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting
from contact between rotating and stationary
components.
Where there is any risk of the pump being run
against a closed valve generating high liquid and
casing external surface temperatures it is
recommended that users fit an external surface
temperature protection device.
Avoid mechanical, hydraulic or electrical overload
by using motor overload trips, temperature monitor
or a power monitor and make routine vibration
monitoring checks.
In dirty or dusty environments, regular checks
must be made and dirt removed from areas around
close clearances, bearing housings and motors.
1.6.4.4 Preventing the build up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY
FILLED AND VENTED AND DOES NOT RUN
DRY.
Ensure the pump and relevant suction and
discharge pipeline system is totally filled with liquid
at all times during the pump operation, so that an
explosive atmosphere is prevented. In addition it is
essential to make sure that seal chambers,
auxiliary shaft seal systems and any heating and
cooling systems are properly filled.
If the operation of the system cannot avoid this
condition the fitting of an appropriate dry run
protection device is recommended (eg liquid
detection or a power monitor).
To avoid potential hazards from fugitive emissions
of vapor or gas to atmosphere the surrounding
area must be well ventilated.
Page 6 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
1.6.4.5 Preventing sparks
To prevent a potential hazard from
mechanical contact, the coupling guard must be
non-sparking and anti-static for Category 2.
To avoid the potential hazard from random
induced current generating a spark, the earth
contact on the base plate must be used.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth ensure cloth is damp.
The coupling must be selected to comply with
2006/42/EC and correct alignment must be
maintained.
1.6.4.6 Preventing leakage
The pump must only be used to handle
liquids for which it has been approved to have the
correct corrosion resistance.
Avoid entrapment of liquid in the pump and
associated piping due to closing of suction and
discharge valves, which could cause dangerous
excessive pressures to occur if there is heat input to
the liquid. This can occur if the pump is stationary or
running.
Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the
pump and ancillary systems.
Where there is the potential hazard of a loss of a
seal barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device
is recommended.
1.6.4.7 Maintenance to avoid the hazard
1.7 Nameplate and warning labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity, or separate documentation included
with these User Instructions.
1.7.2 Warning labels
CORRECT MAINTENANCE IS REQUIRED
TO AVOID POTENTIAL HAZARDS WHICH GIVE
A RISK OF EXPLOSION
The responsibility for compliance with
maintenance instructions is with the plant
operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where
there is a risk from such tools or materials;
maintenance must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted.
(See section 6, Maintenance.)
Page 7 of 48
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. Pump performance data are
summarized on pump data sheet which is included
in proper section of “Job User’s Instruction”.
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
1.9 Noise level
When pump noise level exceeds 85 dBA attention
must be given to prevailing Health and Safety
Legislation, to limit the exposure of plant operating
personnel to the noise. The usual approach is to
control exposure time to the noise or to enclose
the machine to reduce emitted sound. You may
have already specified a limiting noise level when
the equipment was ordered, however if no noise
requirements were defined then machines above a
certain power level will exceed 85 dBA. In such
situations consideration must be given to the fitting
of an acoustic enclosure to meet local regulations.
Pump noise level is dependent on a number of
The dBA values are based on the noisiest
ungeared electric motors that are likely to be
encountered. They are Sound Pressure levels at 1
m (3.3 ft) from the directly driven pump, for "free
field over a reflecting plane".
If a pump unit only has been purchased, for fitting
with your own driver, then the "pump only" noise
levels should be combined with the level for the
driver obtained from the supplier. If the motor is
driven by an inverter, it may show an increase in
noise level at some speeds. Consult a Noise
Specialist for the combined calculation.
factors - the type of motor fitted, the operating
conditions, pipework design and acoustic
characteristics of the building . The levels specified
in the table 1.1 are estimated and not guaranteed.
For units driven by equipment other than
electric motors or units contained within
enclosures, see the accompanying information
sheets and manuals.
Typical sound pressure level, dBA, LpA at 1 m reference 20 μPa (LwA sound power1 pW where LpA >85 dBA)
Motor size
and speed
kW (hp)
30 (40) 73 73 71 73
37 (50) 73 73 71 73
45 (60) 76 76 74 76
55 (75) 76 76 74 76
75 (100) 77 77 75 77
90 (120) 77 78 75 78
110 (150) 79 80 77 80
132 (175) 79 80 77 80
150 (200) 79 80 77 80
160 (215) 83 84 81 83
200 (270) 85 87 83 85
300 (400) 87 90 85 86
315 (422) 87 90 85 86
355 (475) 87 90 86 87
500 (670) 88
1000 (1300) 90 (1) 88 (1)
1500 (2000) 90 (1) 90 (1)
(1) Noise levels of machines in this range should be based on actual equipment selected
For 1180 and 960 r/min reduce the 1450 r/min values by 2dBA
For 880 and 720 r/min reduce the 1450 r/min values by 3dBA
1750 rpm 1450 rpm
Pump
only
dBA
Pump &
motor
dBA
(1)
Pump
only
dBA
86 (1)
Pump &
motor
dBA
Page 8 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and
unpacking
Immediately after receipt of the equipment it must
be checked against the delivery and shipping
documents for its completeness and that there has
been no damage in transportation.
Any shortage and or damage must be reported
immediately to Flowserve and received in writing
within one month of receipt of the equipment. Later
claims cannot be accepted.
Check any crates, boxes and wrappings for any
accessories or spare parts which may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check
that this number corresponds with that advised
and always quote this number in correspondence
as well as when ordering spare parts or further
accessories.
2.2 Handling
2.2.1 General instructions concerning handling
Boxes, crates, pallets or cartons may be unloaded
using forklift vehicles or slings dependent on their
size and construction.
To lift machines or pieces with one or several
suspension rings, only use hooks and chains in
compliance with the local regulations concerning
safety. Never put cables, chains or ropes directly
on or in the suspension rings. Cables, chains or
lifting ropes must never present excessive
bending.
Never bend the lifting hooks, suspension rings,
chains, etc., which should only be made to endure
stresses within, calculated limits. Remember that
the capacity of a lifting device decreases when the
direction of the lifting force direction makes an
angle with the device axis.
To increase the safety and the efficiency of the
lifting device, all the lifting elements must be as
perpendicular as possible. If necessary a lifting
beam can be placed between the winch and the
load.
When heavy pieces are lifted up, never stay or
work under the load or in the area, which could be
in the path of the load if it were to swing or fall
away.
Never leave a load hanging from a winch. The
acceleration or the slowing-down of lifting
equipment must stay in the safety limits for the
staff.
A winch must be positioned in such a way that the
load will be raised perpendicularly. Where
possible, necessary precautions must be taken to
avoid the swing of the load, using for example two
winches making approximately the same angle,
below 30°, with the vertical.
2.3 Lifting
Make sure that any equipment
used to lift the pump or any of its components is
capable of supporting the weights encountered.
Make sure that all parts are correctly rigged before
attempting to lift.
A crane must be used for all pump sets in
excess of 25 kg (55 lb). Fully trained personnel
must carry out lifting, in accordance with local
regulations. The driver and pump weights are
recorded on general arrangement drawing
included into the job user’s instruction.
2.3.1 To Lift unit
Pump, motor stand and soleplate can be lifted as a
unit. Sling from all lifting lugs provided on motor
stand (rif. Fig. 2.3).
Failure to do this may result in permanent
distortion of the motor stand.
2.3.2 To lift driver
Refer to Manufacturer’s Instructions.
2.3.3 To lift complete pump only
Rig lifting straps around the two nozzles on the
nozzle half casing, and around the two cast lifting
lugs on cover half casing (rif. Fig. 2.1 & 2.2).
Make sure straps are adjusted to obtain an even
lift.
2.3.4 To lift cover half casing
Carefully move away in a horizontal direction the
removable covert half casing to prevent damage to
casing rings and impeller, using dedicated tools to
allow pump casing opening (rif. Fig. 2.4).
2.3.5 To lift pump rotor
Using slings that will not damage shaft, rig around
shaft close to the bearings and to overhead hoist.
Carefully lift rotor from nozzle half casing
Page 9 of 48
Page 10
Figure 2.1
Lifting of complete pump only (side view)
Figure 2.2
Lifting of complete pump only (top view)
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
Page 10 of 48
Page 11
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
Figure 2.3
Lifting of complete unit
Figure 2.4
Lifting of cover half casing
STANDARD LPNV
ONLY FOR : 28 LPNV 32
Page 11 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
2.4 Storage
Store the pump in a clean, dry
location away from vibration. Leave piping
connection covers in place to keep dirt and other
foreign material out of pump casing. Turn pump at
intervals to prevent brinelling of the bearings and
the seal faces, if fitted, from sticking.
Electric Motors (Pump Driver) should not be stored
in damp places without special protection (Refer to
Motor manufacturers instructions).
The pump may be stored as above for up to 6
months.
2.4.1 Long term storage
During extended periods of storage prior to
installation, precautions must be taken to protect
the pump from deterioration. The various parts of
the pump are protected prior to shipment by
applying varying grades of preservative to the
parts. However, during shipment and handling the
preservatives are subjected to conditions that can
cause their removal. Also, during extended
periods of time the preservatives may deteriorate.
The listed procedures (2.4.1.1 to 2.4.1.5) should
be followed to prevent deterioration of the pump
during the extended storage period. These
procedures may also be supplemented by the
experience of the person(s) performing the tasks.
2.4.1.1 Inspection upon arrival
When the pump is received it should be inspected
for damage or other signs of rough handling. If any
damage is found it should be reported to the
carrier immediately. Inspect the preservative
coating on various parts. If necessary, renew
preservative in areas where it has been rubbed or
scraped.
Inspect all painted surfaces. If necessary, touch up
the areas where paint has been chipped or
scraped.
Inspect all covers over pump openings and piping
connections. If covers or seals for the covers are
damaged or loose, they are to be removed, and a
visual inspection made of the accessible interior
areas for accumulation of foreign materials or
water. If necessary, clean and preserve the interior
parts as noted above to restore the parts to the "as
shipped" condition. Install or replace covers and
fasten securely.
2.4.1.2 Storage
If at all possible, the pump and its
component parts should be stored indoors where
they will be protected from the elements. In no
case should any pump element be subjected to
extended periods of submergence or wetting prior
to start up. If it is not possible to store the pump
and its components indoors, precautions must be
taken to protect them from the elements.
Regardless of whether storage is indoors or
outside, the storage area should be vibration free.
All boxes marked for indoor storage should be
stored indoors. When stored outdoors the pump
and its components should be protected from dirt,
dust, rain, snow, or other unfavourable conditions
by heavy plastic sheets, canvas, waterproof burlap
or other suitable coverings.
All equipment must be placed upon skids or blocks
to prevent contact with the ground and surface
contaminants. Equipment must be adequately
supported to prevent distortion and bending.
The pump shaft should be rotated, in the direction
of rotation, at least 1 and 1/4 turns each week
during the storage period and any other periods of
standby.
When selecting a storage area the following
should be taken into consideration.
a) The deterioration of the equipment will be
proportionate to the class of storage provided.
b) The expenses involved in restoring the
equipment at time of installation will be
proportionate to the class of storage provided.
2.4.1.3 Inspection and maintenance
The stored equipment has to be placed on a
periodic inspection schedule by the purchaser.
The responsibility for setting up an inspection
schedule rests with the purchaser and will be
dependent upon the class of storage provided. It
would be expected initially, inspection would occur
weekly, then depending upon the inspection
reports being favorable or unfavorable, inspection
would continue weekly, monthly, or quarterly, as
may be determined.
Each inspection should consist of a general
surface inspection to assure that:
a) Pump supports are firmly in place.
b) Pump covers over openings are firmly in
place.
c) Pump coverings, plastic or tarps are firmly in
place. Any holes or tears must be repaired to
prevent entrance of dirt or water.
d) Pump covers are periodically removed from
openings and interior accessible areas
inspected. If surface rusting has occurred,
clean or coat with preservative.
e) If rusting occurs on exterior surfaces clean and
repaint or coat with preservative.
f) Check individually wrapped parts for signs of
deterioration. If necessary, renew preservative
and wrapping.
Page 12 of 48
Page 13
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
Six months prior to the scheduled installation date,
a FLOWSERVE representative is to be employed
to conduct an inspection. This inspection may
include, not necessarily in its entirety and not
limited to the following:
a) An inspection of all periodic inspection records
as kept on file by the purchaser, and all
inspection reports that have been compiled
during the storage period.
b) An inspection of the storage area to determine
the "as stored" condition of the equipment
prior to any protection covers being removed.
c) An inspection of the equipment with protective
covers and flange covers removed.
d) Depending upon the length of time the
equipment was stored, the type of storage
provided (i.e. Indoor: heated, unheated,
ground floor, concrete floor. Outdoors: under
roof, no roof, waterproof coverings, on
concrete, on ground) and as a result of the
inspection of (a),(b) & (c) above the
FLOWSERVE representative may require a
partial or complete dismantling of the
equipment.
e) Dismantling may necessitate restoration of
painted or preserved surfaces, and, or
replacement of gaskets, "O" rings, packing and
bearings.
f) All costs involved during inspection,
dismantling, restoration, replacement of parts
and reassembly will have to the accounted to
the purchaser. All necessary labor, tools and
cranes will be supplied by the purchaser.
Upon completion of the inspection the
FLOWSERVE representative shall submit a report
to the purchaser, and to the Manager of Customer
Service, stating in detail the results of the
inspection.
One month prior to installation of the equipment, a
FLOWSERVE representative is to be employed to
conduct a final inspection.
This inspection will be made to assure that the
requirements of the six months inspection report
were satisfactorily completed and that the
equipment is ready for installation.
Upon completion of this inspection the
FLOWSERVE representative shall submit a final
report to the purchaser, and to the Manager of
Customer Service, advising the results of the final
inspection.
All costs involved in conducting the final inspection
will have to the accounted to the purchaser.
Prior to and during start up, any requirements for
the services of an FLOWSERVE representative
will revert back to the original contract agreement
for equipment purchased, with revised costing
.
2.4.1.4 Painting and preservation
Paints and preservatives used are either
FLOWSERVE standard or 'special' as required by
the contract specification. Refer to FLOWSERVE
for the description of paints and preservatives
used on this order if needed.
2.4.1.5 Associated equipment
Motors, Turbines, Gears, etc., being supplied by
FLOWSERVE.
Generally rotors of associated equipment should
be blocked to relieve bearing loads. Storage
should be indoors and dry. See the specific
manufacturers storage requirements.
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 or toxic
fluids are disposed of safely and that the
correct personal protective equipment is used.
The safety specifications must be in
accordance with the current regulations at all
times.
Page 13 of 48
Page 14
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
3 PUMP DESCRIPTION
3.1 Configurations
The LPNV pumps are single stage, double suction
impeller, double volute vertically split casing,
vertically mounted on a bottom bracket integrally
casted with the stationary half-casing, with
side/side nozzles, medium pressure pumps,
preferred for water cooling, fluid transfer and
general services.
LPNV pumps are fully compliant with API 610/ISO
13709, latest edition.
The LPNV pumps provide both outstanding
performance and the highest reliability level as
required in the most arduous services of the
process industry.
The different sizes available, combined with the
choice of impellers, ensure optimum efficiency
throughout the range.
Various options of construction materials and
bearing types are available.
Standard Rotation of LPNV pumps is counter
clockwise (CCW) when viewed from the coupling
end. Clockwise (CW) rotation can be supplied on
request.
3.2 Nomenclature
The pump size will be engraved on the nameplate
typically as below:
6 LPNV 18
Nominal discharge branch size
Pump type
Nominal full size impeller diameter
The typical nomenclature above is the general
guide to the LPNV 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 vertically split with suction and
discharge nozzles cast integral with the stationary
half. The removable casing half permits inspection
and/or repair of the rotor without disturbing the
suction and discharge piping.
The double volute casing minimizes the radial
thrust on the pump rotor and gives longer life to
the seals, bearings and wear rings. The casing
halves are sealed by the use of a confined gasket
and are joined together by studs, which are
installed in the lower half casing and fastened with
cap nuts. Confined gasket design allows metal-tometal contact for proper gasket compression and
eliminates the risk of corrosion of bolts and nuts.
The casing is provided with vent, drain and seal
connections.
3.3.2 Impeller
The impeller, designed for maximum hydraulic
efficiency, is double suction, closed type.
The double suction design allows minimum NPSH
requirement and provides symmetric pressure
distribution acting on impeller shrouds, for a
complete axial balance of the rotor.
The impeller first, and then the complete rotor, are
dynamically balanced for vibration free operation.
The impeller is keyed to the shaft and secured
against axial movement by means of a threaded
shaft nut on one side, and by means of a split
locating ring and a shaft locking nut on the other
one.
3.3.3 Wearing Rings
Wear rings fitted both on casing and impellers are
smooth depth design.
The diameters of the wear rings are differentiated
to maintain a controlled axial load on the bearing
under all operating conditions.
Both rings are of the renewable type and are held
in place by a press-fit with threaded dowels on the
impellers and by grooves and pins on the casing.
Clearances between wear surfaces are in
compliance with API 610 Standard.
3.3.4 Rotors
Rotors are of the stiff shaft design, with the first dry
critical speed above the maximum rotational
speed.
Shafts are of ample diameter, combined with the
minimum bearing span to minimize shaft deflectors
especially when the pump is operating at off peak
conditions.
Shafts are machined and finished throughout their
length for positive location of the rotating parts
and to ensure minimum runouts. The whole shafts
are protected by sleeves and mounted-on parts
extending up to throat bushing area.
Shafts are designed to meet API 610 Latest
Edition deflection and vibration requirements. Fully
assembled rotors are dynamically balanced can
accommodate a wide variety of single or dual seal
arrangements as standard.
Page 14 of 48
Page 15
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
3.3.5 Stuffing Boxes
The stuffing boxes are cast integral with the
casing: of sturdy, extra deep design can receive
either gland or mechanical seals built fully in
accordance with API 682/ISO 21049. Mechanical
seals of any type can be fitted to meet special
requirements or customer preference.
3.3.6 Shaft seal
The mechanical seal, fitted on the pump shaft,
seals the pumped liquid from the environment.
Packing seal may be fitted as an option.
3.3.7 Bearing Assembly
Standard bearing design for LPNV pump foresees
the use of a combined line bearing at the shaft
bottom end and of a thrust bearing at the shaft top
end.
The thrust bearing is mounted in a fabricated steel
housing which is fixed directly to a bracket
integrally cast with the stationary half casing.
The thrust bearing is constituted by two different
ball-bearings, a top and a bottom one separated
one another by a shaft nut.
The bearings are oil bath lubricated, and a TRICO
constant level oiler, is provided as standard.
The line bearing is sleeve bearing product
lubricated, and externally flushed from the pump
discharge volute.
Cooling Systems is not standard and generally
neither required.
It can be provided as an option in case of
technical evaluation of particularly severe
condition of service (high power – high fluid
temperatures – high speed), in case of high
ambient temperature, or in case of Customer
request.
In these cases the thrust bearing housing can be
air-cooled through the provision of an external
fan, or alternatively it can be water-cooled through
the provision of an internal coil.
3.3.8 Driver
The driver is normally an electric motor. Different
drive configurations may be fitted such as internal
combustion engines, turbines, hydraulic motors etc
driving via couplings, belts, gearboxes etc.
3.3.9 Coupling
An all-metal-flexible coupling with a spacer (API
feature for easy mechanical seal dismantling) is
adopted.
The coupling can be provided in various makes
and models to suit customer preference.
3.3.10 Motor stand
Depending from Customer preference combined
with technical evaluation about the pump size, the
motor size, pump’s performances and the type of
application, there are two possible different types
of motor stand:
a) EXTERNAL MOTOR STAND
In this case the motor stand is a separated welded
steel construction that supports the motor weight
directly on the foundation (ref. Par. 8, Fig. 8.1).
b) INTEGRATED MOTOR STAND
In this case the motor stand is fixed directly on a
bracket integrally cast with the pump-casing, and
the motor weight is supported directly by the pump
itself (ref. Par. 8, Fig. 8.2).
3.4 Performance and operating limits
This product has been selected to meet the
specifications of your purchase order see section
1.5.
These pumps are furnished for a particular service
condition. Changes in the hydraulic system may
affect the pump's performance adversely.
This is especially true if the changes reduce the
pressure at the suction flange or if the liquid
temperature is increased. In case of doubt, contact
the nearest FLOWSERVE office.
3.4.1 Effect of specific gravity
Pump capacity and total head in meters (feet) do
not change with SG, however pressure displayed
on a pressure gauge is directly proportional to SG.
Power absorbed is also directly proportional to SG.
It is therefore important to check that any change
in SG will not overload the pump driver or over-
pressurize the pump
3.4.2 Effects of viscosity
The pump is designed to deliver rated capacity
and rated head for a liquid with a particular
viscosity.
For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity. Also for a given flow rate the power
absorbed increases with increased viscosity, and
reduces with reduced viscosity
When contemplating operation at some viscosity
other than the one for which the pump was
originally designed and/or applied, the changed
conditions should be referred to FLOWSERVE for
recommendations.
.
.
When pump is handling heavy
viscous liquid, the temperature of the liquid
must allow it to be pumped easily. Liquid may
have to be heated prior to pump start-up.
Page 15 of 48
Page 16
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
3.4.3 Changing the pump speed
The pump must be operated at the rated speed
defined in the contract, corresponding to the motor
speed or to the maximum speed specified in case
of VFD (variable frequency driver).
In case that it is needed to operate the pump at
increased speed, it is mandatory to refer to the
Pump Manufacturer.
Changing pump speed effects flow, total head,
power absorbed, NPSH
, noise and vibration.
R
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
refer to the Pump Manufacturer in order to ensure
that the maximum pump working pressure is not
exceeded, that the driver is not overloaded, that
NPSH
>NPSHR, and that noise and vibration are
A
within local requirements and regulations.
3.4.4 Net Positive Suction Head (NPSH)
Any liquid, hot or cold, must be pushed into the
impeller of the pump by absolute pressure, such
as the atmospheric or vessel pressure from which
the pump takes its suction.
The head in feet of liquid necessary to push the
required flow into the pump is called Net Positive
Suction Head.
This value, more commonly called NPSH, is
measured above the vapor pressure of the liquid at
the pumping temperature.
There are two kinds of NPSH: the NPSH
head required by the pump to cover the losses in
the pump suction - that is shown on the pump
characteristic curve.
The second, NPSH
, is the head available in the
A
system, taking into account friction loss in suction
piping, valves, fittings etc. In all cases the NPSH
measured above vapor pressure, must exceed the
NPSH
in order to push the liquid into the pump.
R
Failure to have this will result in both bad
performance and mechanical damage to the
pump, and in certain cases actual pump failure.
If any change in NPSHA is proposed, ensure its
margin over NPSH
is not significantly eroded.
R
Refer to the pump performance curve to determine
exact requirements particularly if flow has
changed. If in doubt please consult your nearest
Flowserve office for advice and details of the
minimum allowable margin for your application.
3.4.5 Minimum Continuous Stable Flow (MCSF)
The Minimum Continuous Stable Flow for the
pump is stated on the Data sheet.
3.4.6 Minimum flow control
In all cases, it is the customer's responsibility to
supply a system and/or control which assures that
is the
R
,
A
any pump within a system is not operated below its
minimum flow condition.
In many cases, this is not a problem because the
system is operating within its own flow range to
assure product delivery. A simple high pressure
alarm, shut down and/or bypass control can be
used. However, in systems where product demand
has high swings or where more than 100%
capacity units are desired to support a product
system, additional care must be taken.
3.4.7 Thermal control
A thermal control of the unit can be provided by
thermal sensors which read direct or "related to"
fluid temperatures and respond accordingly by
opening additional flow paths until the given unit
re-establishes the acceptable temperature rise,
and sets off alarms if not achieved within
reasonable/normal time periods. (High limit could
actually shut down unit).
3.4.8 Pressure and/or Flow Control
Pressure and/or flow sensors can be used to hold
the unit at higher flows by opening additional flow
paths once a "high pressure limit" or " low flow
limit" was indicated.
Upon system reaching increased flow a "low
pressure limit" or "high flow limit" setting would
close the bypass flow path. Care must be taken to
allow for signal spread to avoid cyclic conditions
.
3.4.9 Operating at Reduced Capacity
Damage to pump may result from
prolonged operations at capacities less than
MCSF as stated in Data Sheet.
Page 16 of 48
Page 17
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
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 always be located as near as
possible to the suction supply.
Install the unit close to the source of the liquid to
be pumped.
It is desired to simplify the suction and discharge
piping layout. When selecting the location, be sure
to allow adequate space for operation as well as
for maintenance operations involving dismantling
and inspections of parts.
Head room is an important consideration as an
overhead lift of some type is required.
There should be ample head room to allow the use
of an overhead crane or other lifting device with
sufficient capacity to handle the assembled pump
and the pump motor individually.
4.2 Foundation
The foundation may consist of any material that
will afford permanent, rigid support to the full area
of the pump supporting member and will absorb
expected stresses and shocks that may be
encountered in service. Concrete foundations
should be level and built on solid ground.
Foundation bolts of the specified size should be
located according to the pump template drawing.
When the pump unit is mounted directly on
structural steel framing, it should be located
directly over or as near as possible to the main
building members, beams, or walls. The soleplate
should be bolted to the steel supports to avoid
distortion, prevent vibration, and retain proper
alignment.
The General Arrangement Drawing (In Job’s User
Instruction) will furnish overall outline of pump
foundation plate, anchor bolt locations, size of
bolts, etc. in order to provide proper shape to the
primary concrete. Anchor bolts can be positioned
or by a special template (not supplied by
FLOWSERVE see figure 4.1 - 4.2) or by the
foundation itself if proper pockets have been
provided in primary concrete.
Figure 4.1
Template for Hanging Foundation Bolts
There are many methods of
installing pump units to their foundations. The
correct method depends on the size of the pump
unit, its location and noise vibration limitations.
Non-compliance with the provision of correct
foundation and installation may lead to failure of
the pump and, as such, would be outside the
terms of the warranty.
The foundation should be sufficiently rigid and
substantial to prevent any pump vibration and to
permanently support the baseplate at all points.
The most satisfactory foundations are made of
reinforced concrete. These should be poured well
in advance of the installation to allow sufficient
time for drying and curing.
Page 17 of 48
Figure 4.2
Page 18
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
4.3 Installation and alignment
Normally the pump and motor stand are shipped
mounted on the soleplate, whereas the motor is
sent separately.
4.3.1 Pump
- Clean all debris from pump and foundation
before making the installation
- Lift pump assembly using lifting lugs provided
on motor stand.
- Slowly lower pump onto foundation guiding
pump until discharge and suction nozzles face
proper direction to mate with discharge and
suction piping respectively, and soleplate
mounting holes align with foundation bolts.
- Seat pump on foundation and level, using
shims under pump soleplate at each foundation
bolt. The levelling tolerance is 0.4 mm/m (0.005
inch per foot), to be checked in both directions
on machined surfaces.
- Uniformly tighten foundation bolts.
- Connect suction and discharge piping to pump
flanges taking care that no excessive strains
are applied to pump nozzles.
- Recheck leveling tolerance. Any eventual
distortion affecting the alignment must be
corrected by varying shims between
soleplate and foundation.
- Ensure that shaft alignment per Section 4.3.3
can be achieved prior to grouting the soleplate.
4.3.2 Electric motor
- Fit half coupling on pump shaft, if not already
fitted.
- Install driver half of coupling on motor shaft.
- Lift motor and center over pump shaft.
- Slowly lower motor onto motor stand making
certain that mounting holes in motor flange and
motor stand are aligned.
Driver and driven shafts should
not be rotated unless bearings are prelubricated before aligning starts.
4.3.3 Alignment of spacer - couplings
- Check the gap between the coupling halves
against the dimensions shown on the elevation
drawing or as stamped on the coupling hub.
For any necessary adjustment move the driver
rather than the driven machine.
- Using the coupling nut or the draw holes, clamp
on the driven machine half-coupling a suitable
extension arm or bracket sufficiently long to
extend across the space between the driven
machine and driver coupling hubs.
Attach to the bracket as shown in Fig.4.3 a dial
indicator with the probe resting on the outer
diameter of the driver half-coupling to check
both parallel and angular alignment.
For angular alignment rotate both the driver
and driven shafts together making sure that the
indicator probe always rests on the same point.
Take readings at every quarter turn.
For parallel alignment rotate the driven shaft
with the probe resting on the O.D. of the driver
half-coupling. Take readings at every quarter
turn.
For detailed alignment procedure refer to API
RP686.
During pump assembly at
factory, the pump shaft is axially positioned by
the adjusting nut so that the impeller is
centered in respect of the casing volute, and
the space between coupling halves is as
specified on pump elevation drawing.
Make certain that above value is maintained. If
necessary, rotate the adjusting nut to lift or
lower the pump rotor.
When the pump is provided with
mechanical seal, the shaft collar drive screws
must be loosened prior to
screwing/unscrewing of the adjusting nut.
Page 18 of 48
Figure 4.3
Maximum permissible misalignment at working
temperature:
Parallel 0.05 mm (0.002 in.) TIR
Angular 0.05mm/100mm (0.0005In/In)
- Recheck alignment by reversing bracket and
repeating angular and parallel check readings
- Assemble coupling-spacer as per the
manufacturer's instructions.
Page 19
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
4.3.4 Shims
The shims under pump soleplate at each
foundation bolt should be clean and dry. This is
especially critical for pumps in service for
sometime and need to be realigned. Water, dirt
and rust may change the height of the shim pack
over a period of time. Do not use many thin shims
as this may result in a spongy mounting.
Recommended shim design
Figure 4.4
Move the soleplate vertically by adding or
removing the calculated thickness of shims.
Torque holding down bolts to required values.
4.3.5 Types of misalignment
There are two types of shaft misalignment: angular
and offset. Therefore, two sets of measurements
and corrections are required. Both types of
misalignment can occur in horizontal and vertical
planes and are present in most applications.
A) Angular misalignment
In angular misalignment, the center line of the
shafts intersect, but are not on the same axis.
Figure 4.7 – combination of offset and angular misalignment
4.3.6 Cases that require to check alignment
It is necessary to check alignment
a) Prior to fix the soleplate to foundation to ensure
soleplate is not twisted.
b) After securing the soleplate.
c) After securing suction and discharge piping.
d) While unit is at operating temperature:
On factory assembled units dowels are fitted
between motor stand and soleplate.
Do not attempt any maintenance,
inspection, repair or cleaning in the vicinity of
rotating equipment. Such action could result in
injury to operating personnel.
Before attempting any inspection or
repair on the pump the driver controls must be
in the "off" position, locked and tagged to
prevent restarting equipment and injury to
personnel performing service on the pump.
Figure 4.5
B) Offset misalignment
In offset misalignment, the shaft center lines are
parallel but do not intersect.
Figure 4.6 – offset misalignment
Page 19 of 48
Page 20
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
4.3.7 Hot alignment check
As both pump and driver may
rise when they reach operating temperature, it
is necessary to allow for this expansion when
aligning the shafts. Refer to elevation drawing
for approximate rise of pump and driver.
Consult driver manufacturer’s instructions. A
final alignment check (hot check) must be
made as soon as possible after both driver and
pump are heated to their normal operating
temperatures.
A hot check can only be made after the unit has
been in operation a sufficient length of time to
assume its normal operating temperature and
conditions. If the unit has been correctly cold set,
the parallel misalignment will be within the limits
stated on par 4.3.3 when in operation. If not make
adjustments.
4.4 Piping
Never use the pump as a support
for piping.
4.4.1 General
These units are furnished for a particular service
condition. Changes in the hydraulic system may
affect performance adversely. This is especially
true if the changes reduce the pressure at the
suction or if the liquid temperature is increased. In
case of doubt contact FLOWSERVE.
Suction and discharge piping should be of ample
size, be installed in direct runs, and have a
minimum of bends. Double bends must be avoided
in suction line and a straight run of pipe, equal 8 to
10 times the pipe diameter is desired directly
upstream of the suction nozzle.
In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose
pipework that is one or two sizes larger than the
pump suction and discharge. Typically main
pipework velocities should not exceed 2 m/s (6
ft/sec) suction and 3 m/s (9 ft/sec) on the
discharge.
Provision must be made to support
piping external to the pump to prevent excessive
nozzle loads, maintain pump/driver alignment and
avoid pipe induced vibrations.
Take into account the available NPSH which must
be higher than the required NPSH of the pump.
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.
Ensure piping and fittings are
flushed before use.
arranged to allow pump flushing before
removal of the pump.
Page 20 of 48
Ensure piping for hazardous liquids is
Page 21
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
4.4.2 Suction Piping
a) The inlet pipe should be one or two sizes
larger than the pump inlet bore and pipe bends
should be as large radius as possible.
b) Keep the suction pipe free of all air pockets.
(Vent is required).
c) Pipework reducers should have a maximum
total angle of divergence of 15 degrees.
d) Use only eccentric reducers with the straight
side on the top.
e) Flow should enter the pump suction with
uniform flow, to minimize noise and wear.
f) A gate valve is recommended in the suction
line.
g) Except if considerable foreign matter is
expected strainers are not recommended in
inlet piping. Inlet strainers, when used, should
have a net “free area” (see section 4.4.2.1)
4.4.2.1 Suction Strainer
It is recommended that a temporary strainer be
placed in the suction pipe to prevent lodging of
foreign material in the pump. A pipe spool of
sufficient size should be provided with gauge taps
to accommodate the suction strainer.
The strainer should be installed as close to the
pump as possible.
The open area of the strainer should have a
minimum of a 3 to 4 ratio to the area of the pump
inlet.
The strainer is usually conical and should be made
of 40x40 mesh screen (corresponding to an
aperture lower than 0.4 mm - 0.0157 in.), backed
up by 4x4 mesh hardware cloth (corresponding to
an aperture lower than 4.7 mm - 0.185 in).
Pressure gauges should be installed on both sides
of the strainer, so the pressure drop across the
strainer can be measured when the unit is
operated.
A spool piece should be installed in
suction line so that the suction strainer may be
installed and removed with a pressure gauge
between the strainer and pump.
4.4.2.2 Bypass Line
Operation at low flows results in
pump horsepower heating the liquid. A bypass
may be required to prevent vaporization and
subsequent pump damage. Refer to local
FLOWSERVE branch to determine if a bypass
is required. Mechanical damage may result
from continuous operation at flows less than
specified.
4.4.3 Discharge piping
a) Install a check valve and a gate valve in the
discharge pipe of the pump. When the pump
is stopped, the check valve will protect the
pump against excessive pressure and will
prevent the pump from running backward. The
check valve should be installed between the
gate valve and the pump nozzle in order to
permit its inspection. Never throttle pump on
suction side and never place a valve directly
on the pump inlet nozzle.
b) Pipework reducers should have a maximum
total angle of divergence of 15 degrees.
4.4.4 Drains and Vents
Pipe pump casing drains and vent to a convenient
disposal point.
4.4.5.1 Pumps fitted with gland seal
When suction pressure is below ambient pressure
it is necessary to feed the gland packing with liquid
to provide lubrication and prevent the ingress of
air. This is normally achieved with a supply from
the pump discharge volute to the stuffing box.
A control valve is fitted in the line to enable the
pressure to the gland to be controlled.
Figure 4.8 Typical temporary suction strainer
Pressure gauges should be installed on both sides
of the screen so that the pressure drop across the
screen can be measured.
When the unit is being started, the gauges on each
side of the screen should be carefully watched. An
increase in the differential pressure between the
two gauges indicates that the screen is becoming
clogged with dirt and scale. At this point, the pump
should be shut down, and the screen cleaned
and/or replaced.
Page 21 of 48
If the pumped liquid is dirty and cannot be used for
sealing, a separate clean compatible liquid supply
to the gland at 1 bar (15 psi) above suction
pressure is recommended.
Page 22
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
4.4.5.2 Pumps fitted with mechanical seals
Single seals requiring re-circulation will normally
be provided with auxiliary piping from pump casing
already fitted. Symbols which FLOWSERVE work
on seal connections are as follows:
Q - quench
F - flush
D - drain outlet
BI - barrier fluid in
BO - barrier fluid out
Single seals which require external flushing or
auxiliary quench must be connected to a specific
supply.
Double seals require a barrier liquid compatible
with the pumped liquid.
With back-to-back double seals, the barrier liquid
should be at a minimum pressure of 2 bar 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 in a safe area.
For specific information refer to the mechanical
seals manufacturer’s instructions.
4.4.6 Final checks
Check the tightness of all bolts in the suction and
discharge pipework. Check also the tightness of
all foundation bolts and auxiliary lines.
4.5 Final shaft alignment check
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 coupling alignment, as previously
described, to ensure no strain on coupling is due
to pipe. If pipe strain exists, correct piping.
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.
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.
See section 5.3, Direction of
rotation before connecting the motor to the
electrical supply
4.7 Protection systems
The following protection systems are
recommended particularly if the pump is installed
in a potentially explosive area or is handling a
hazardous liquid. If in doubt consult Flowserve.
If there is any possibility of the system allowing the
pump to run against a closed valve or below
minimum continuous safe flow a protection device
should be installed to ensure the temperature of
the liquid does not rise to an unsafe level.
If there are any circumstances in which the system
can allow the pump to run dry, or start up empty, a
power monitor should be fitted to stop the pump or
prevent it from being started. This is particularly
relevant if the pump is handling a flammable liquid.
If leakage of product from the pump or its
associated sealing system can cause a hazard it is
recommended that an appropriate leakage
detection system is installed.
To prevent excessive surface temperatures at
bearings it is recommended that temperature or
vibration monitoring are carried out. See sections
5.7.4 and 5.7.5.
Page 22 of 48
Page 23
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN
The following procedures are presented to outline
the most important steps involved in pump
operation. Any modification of these procedures
due to particular installation peculiarities should
conform to good engineering practices.
Never operate the pump with
suction valve closed.
Never operate the pump unless it is
filled with liquid and vented.
Never operate the pump unless a
liquid source is available.
Never operate the pump with
discharge valve closed or below the minimum
specified flow rate. If reduced capacity operation is
required on occasion, a recirculation line should be
installed according FLOWSERVE
recommendations.
5.1 Pre-commissioning 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
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) Install suction strainer if required. (See Section
4.4.2.1).
d) Activate lubrication; fill the bearing housings
with the appropriate oil to the correct level.
Bearing must receive a small amount of oil
prior to starting to ensure adequate lubrication
at start up. (Refer to Section 5.1.1).
e) Turn pump rotor by hand or with a strap
wrench to make sure it turns smoothly.
f) Assure that correct seal piping has been
installed and has not been damaged.
g) If the pump is fitted with mechanical seal,
ensure it is correctly assembled and tightened.
(slag,
Where possible avoid severe
thermal shocks due to sudden changes of liquid
temperature. Warm-up the pump at all times
before start-up if the pumped liquid is hot or
subject to crystallize
Lubricate the unit prior to starting.
Do not operate the unit unless coupling
guards are bolted in place.
Never operate the pump above the
name plate conditions.
During pump operation, keep the
vent and drain valves in closed position, to prevent
any liquid from a high pressure point flowing into a
low pressure point.
Do not wipe down in the vicinity of rotating
parts. If unusual noise or high vibrations occur,
secure the pump as soon as possible.
Most cartridge seals are
equipped with a spacer between the gland
plate and drive collar. This spacer must be
removed before starting unit.
h) 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
power prior to change).
i) Ensure coupling is correctly aligned and
lubricated, and pump and driver is
satisfactorily doweled. (Refer to Section 4.3).
change rotation (Shut down all
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.
j) Check torque of all bolting and the plugs for
tightness.
Page 23 of 48
Page 24
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
5.1.1 Lubrication of the thrust bearing
In LPNV pumps the thrust bearing is positioned on
the top of the shaft and it is oil lubricated.
The thrust bearing is constituted by two different
antifriction bearings, a bottom one separated
through a nut by a top one.
Before filling the bearing housing reservoir, flush
out the housing thoroughly with safety solvent and
a leading grade of flushing oil, compatible with the
lubrication oil that will be used.
The oil level must be maintained at the correct
level: oil lack may cause overheating and failure of
the bearings, while exceeding the correct level can
result in leakage from the labyrinth seals.
The constant level oiler can be adjusted by
changing the height of the cross arms which
support the glass reservoir, as illustrated for
TRICO oiler in Figure 5.1.
The oil circulation inside the bearing housing is
ensured by the rotation of the bottom ball bearing,
according to the description as follow.
The oil level inside the bearing housing is
designed to bath half of the ball’s elements
of the bottom antifriction bearing.
With the rotation of the pump, the wet part
of the ball’s elements is splashing oil to the
bearing housing walls.
The dropping of oil from the bearing
housing walls is reaching and lubricating
also the top antifriction bearing.
5.1.2 TRICO oiler setting (standard)
Constant level oil control inside the bearing
housing is ensured adopting a TRICO oiler as
standard:
a) Initial fill via top of housing, using overflow
b) Release thumb screw and remove bottle.
c) Fill bottle with recommended oil and install on
d) Remove bottle and ascertain that the oil level
plug to establish correct level.
Establish a measurement from the center line
of the oiler connection in bearing housing to
the upper cross arm of 6 mm (0.24 in.); this
can be obtained by completely screwing down
the lower arm as illustrated on figure 5.6.
holder. Remove and fill bottle as many times
as is required to fill the bearing housing up to
the cross arm level and no air bubbles appear
in the bottle.
is 6 mm (0.24 in.) from the center line of oiler
connection. Adjust upper cross arm as
required and lock in place with lower arm.
Never fill reservoir through the air
vent opening.
Figure 5.1
The constant level oil control maintains a constant
level of oil in the reservoir. The control feeds only
enough oil to maintain the required level. It
operates on the liquid seal principle, feeding only
when the level in the reservoir is low enough to
break the liquid seal at the end of the shank, thus
permitting air to enter the bottle. It will cease to
feed when there is sufficient oil in the reservoir to
cover the hole in the end of the shank.
5.1.3 Inspection
Inspect the oil level in the bearing housing at least
once a day. Inspect the condition of the oil at least
weekly. Oil is always subject to gradual
deterioration from use and contamination from dirt
and moisture which is the cause of premature
bearing wear.
For oil lubricated pumps, fill the
bearing housing with correct grade of oil to the
correct level, i.e. constant level oiler bottle
(standard configuration).
5.1.4 Replenishment
Replenish the oil in the oiler as required. More
frequent replenishment at high temperatures may
be required.
5.1.5 Oil change
Frequency of oil change is dependent on pump
service and environmental conditions. As a general
guide, oil in the bearing housing should be
changed every 4000 operating hours or every six
months, after the initial change.
5.1.6 Lubrication Specification
The ideal bearing lubricant is a straight well
refined, neutral mineral, preferably of the turbine
type. It should not contain free acid, chlorine
sulphur or more than a trace of free alkali. It is
suggested that the oil conform to the following
physical characteristics.
Page 24 of 48
Page 25
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
5.2 Pump Lubricants
5.2.1 Recommended oil lubricants
Oil Oil Ring or Slinger Lubrication Pure Oil Mist Lubrication
Lubrication service Ball Bearing
Type
Viscosity
mm ²/s 40 ºC [cSt]
Oil temperature
range * ºC (ºF)
Approx. Consumption
continuous operation
Running in Period 500 hours 500 hours 500 hours
First Oil Charge 500 hours 500 hours 500 hours
Centrifugal Pump Lubrication
Further Oil Changes 4000 hours 4000 hours 4000 hours
One Year
Consumption
Designation
according to
DIN51502 ISO VG
BP
CASTROL Perfecto T46 Perfecto T68 -
1.44 liters approx. max 1.44 liters approx. max 1.44 liters approx. max
46 68 100
-5 to 75 up to 85 -30 and above
(up to 167) (up to 185) (59 and above)
0.12 liters 0.12 liters 0.12 liters
¼ pint per month ¼ pint per month ¼ pint per month
46 68 100
BP Energol HL46 BP Energol HL68
BP Energol HLP46 BP Energol HLP68
Elf
Esso
Mobil
Q8
Oil Companies and Lubricants
Shell
Texaco
Total Azolla ZS46 Azolla ZS68 -
(*) Note that it normally takes 2 hours for bearing temperature stabilize and the final temperature will depend on the ambient, r/m in,
pumpage temperature and pump size. Also some oils have a greater Viscosity Index than the minimum acceptable of 95 (e.g. Mobil
DTE13M) which may extend the minimum temperature capability of the oil. Always check the grade capability where the ambient is less
than -5 ºC (-23 ºF).
TURBELF SA46 TURBELF SA68
ELFOLNA DS46 ELFOLNA DS68
TERESSO 46 TERESSO 68
NUTO H46 NUTO H68
Mobil DTE oil medium Mobil DTE oil heavy medium
Mobil DTE15M Mobil DTE26
Mobil DTE25
Q8 Verdi 46 Q8 Verdi 68
Q8 Haydn 46 Q8 Haydn 68
Shell Tellus 01 C 46 Shell Tellus 01 C68
Shell Tellus 01 46 Shell Tellus 01 68
Shell Turbo T46 Shell Turbo T68
Rando Oil 46 Rando Oil 68
Rando Oil HD B-46 Rando Oil HD C-68
Mineral Oil Mineral Oil
(Petroleum Based) (Petroleum Based)
-
-
-
-
-
-
-
Page 25 of 48
Page 26
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
If a synthetic lubricant (fire resistant fluid) is to be
used instead of the normal type oil for the lubrication
of bearings, gears etc., the material of all gaskets
and "O" rings in contact with the lubricant must be
compatible with the lubricant. Normal gasket
materials will usually swell and deteriorate when
immersed in synthetic lubricants: also normal paints
will peel from internal walls of reservoirs and bearing
chambers.
5.2.2 Bearing housing oil limitations
Recommended Oil Temperature At Start Up 15.6 °C
Desirable Operating Temperature 60-71 °C
Oil Level Above Oil Connection Centre line 6 mm
60 °F
140-160 °F
When the starting temperature is below -10 °C (14
°F) for long time it’s suggested to use a synthetic oil.
Other drivers and gearboxes, if appropriate, should
be lubricated in accordance with their manuals.
In the case of product lubricated bearings
the source of product supply should
the order. There may be requirements for an
external clean supply, particular supply pressure or
the commencement of lubrication supply before
pump start-up.
5.2.3 Lubrication schedule
Normal oil change intervals are 4000 operating hours
or at least every 6 months. For pumps on hot service
or in severely damp or corrosive atmosphere, the oil
will require changing more frequently. Lubricant and
bearing temperature analysis can be useful in
optimizing lubricant change intervals.
The lubricating oil should be a high quality mineral oil
having foam inhibitors. Synthetic oils may also be
used if checks show that the rubber oil seals will not
be adversely affected.
Based on the specified operating conditions and an
ambient temperature of 43°C (110 F) for ring-oiled or
splash systems, oil sump temperature below 82 C
(180°F) is expected.
be checked against
5.3 Direction of rotation
Ensure the pump is given the same
rotation as the pump direction arrow fit on bearing
housing. In any case the direction of rotation must
be checked with the pump disconnected.
To avoid dry running, the pump must either be filled
with liquid or have the flexible coupling disconnected
before driver is switched on.
If maintenance work has been carried
out to the site's electricity supply, the direction of
rotation should be re-checked as above in case the
supply phasing has been altered.
5.4 Guarding
Guarding is supplied fitted to the pump set.
If this has been removed or disturbed ensure
that all the protective guards around the pump
coupling and exposed parts of the shaft are
securely fixed.
5.5 Priming and auxiliary supplies
Ensure all electrical, hydraulic,
pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.
Ensure the inlet pipe and pump
casing are completely full of liquid before starting
continuous duty operation.
Before starting or while operating
the pump, the casing and suction line must be
completely filled with the liquid being pumped.
The rotating parts depend on this liquid for
lubrication and the pump may seize if operated
without liquid.
A continuously rising temperature, or
an abrupt rise, indicate a fault.
Page 26 of 48
Page 27
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
5.6 Starting the pump
a) Close discharge valve if valve is not already
closed, and then crack open to assure minimal
flow. (Do not start unit with fully closed valve).
On first starts care must be taken not to cause a
system water hammer .
b) Prepare the driver for start up in accordance with
the driver manufacturer's instructions.
c) Warm up pump (if applicable).
Avoid severe thermal shocks to the pump as the
result of sudden liquid temperature changes.
The pump must be preheated prior to start up.
Unless otherwise specified the thermal
temperature of the casing must be within 55 °C
(100 °F) of the temperature of the liquid to be
pumped at time of start up. Due to the heavy
metal sections, the casing will lag the liquid
temperature during such changes, and severe
temperature stresses and subsequent
misalignment of machined fits may result.
Preheating is accomplished by circulating a
small amount of hot fluid through the casing by
utilizing vents, drains or bypass from discharge.
Preheat pump slowly at a rate not to exceed 55
°C per hour (100 °F per hour).
d) Prime pump and ensure suction valve is open.
Ensure flushing and/or cooling/
heating liquid supplies (if required) are turned
ON before starting the pump.
Before starting or while operating
the pump, the casing and suction line must be
completely filled with the liquid being pumped.
The rotating parts depend on this liquid for
lubrication and the pump may seize if operated
without liquid.
e) Ensure pump re circulation line (if required) is
open, clear and free of obstructions.
f) Check that pump is vented by observing leakage
from casing vent (when fitted) and
vent. Close vent (if fitted) when liquid is emitted.
g) If the pump is equipped with mechanical seal,
make sure seal piping is turned on.
h) Turn on cooling liquid and assure correct flow
exists as specified (to cooler, bearing coil etc. if
provided.).
i) Prepare the driver for start-up in accordance
with the driver manufacturer’s instructions.
j) Double check pump rotation by starting unit
momentarily. The direction of input shaft
rotation is counter clockwise when facing
pump shaft from coupling end. Ensure that
the pump coasts down to a gradual stop.
seal piping
If pump stops abruptly when driver
is shut down, investigate for pump binding. Take
necessary remedial action before resuming
operation.
k) Start the driver and bring it up to speed quickly.
l) As soon as the pump is up to rated speed slowly
open discharge valve. This will avoid abrupt
changes in velocity and prevent surging in the
suction line.
m) Perform the operating checks.
5.7 Operating checks
In the interest of operator safety the unit
must not be operated above the nameplate
conditions. Such operations could result in unit
failure causing injury to operating personnel.
Consult user instruction book for correct
operation and maintenance of the pump and its
supporting components.
Operation at low flows results in
pump heating the liquid. A bypass may be
required to prevent vaporization and subsequent
pump damage. Refer to local FLOWSERVE
branch to determine if a bypass is required.
Mechanical damage may result from continuous
operation at flows less than the specified
minimum continuous stable flow.
Immediately after start up, and frequently during
running check the following:
a) Check suction and discharge pressure gauges.
b) Check pressure gauges on each side of suction
strainer.
c) Regulate the amount of fluid circulated to
mechanical seal, if applicable
d) Check for excessive leakage at seal areas.
e) Check for unusual noises.
f) Verify lubrication: check oil level in bearing
housing. (Refer to Section 5).
Operation of the unit without correct
lubrication can result in overheating of the
bearings, bearing failures, pump seizures and
actual break-up of the equipment exposing
operating personnel to physical injury.
g) Check for vibrations.
h) Check for adequate flow of cooling water, if
applicable.
i) Check for hot alignment: for services 55 °C ( 100
°F) and more above ambient, after unit has been
operated a sufficient period of time to reach
normal operating temperature and condition, the
unit is to be shut down and
a "HOT" coupling
Page 27 of 48
Page 28
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
alignment check must be made (Refer to
Section 4.3).
5.7.1 Venting the pump
Vent the pump to enable all trapped air to
escape taking due care with hot or hazardous
liquids.
Under normal operating conditions, after the pump
has been fully primed and vented, it should be
unnecessary to re-vent the pump.
5.7.2 Pumps fitted with Gland seal
Care must be taken when adjusting the gland
on an operating pump. Safety gloves are essential.
Loose clothing must not be worn to avoid being
caught up by the pump shaft. Shaft guards must be
replaced after the gland adjustment is complete.
Never run gland packing dry, even for
a short time.
5.7.3 Pumps fitted with mechanical seal
Mechanical seals require no adjustment. Any slight
initial leakage will stop when the seal is run in.
Before pumping dirty liquids it is advisable, if
possible, to run in the pump mechanical seal using
clean liquid to safeguard the seal face.
External flush or quench should be
started before the pump is run and allowed to flow
for a period after the pump has stopped.
If the pump has a packed gland there must be some
leakage from the gland. Gland nuts should initially
be finger-tight only. Leakage should take place soon
after the stuffing box is pressurized.
The gland must be adjusted evenly to give
visible leakage and concentric alignment of the
gland ring to avoid excess temperature.
If no leakage takes place the packing will begin to
overheat. If overheating takes place the pump
should be stopped and allowed to cool before being
re-started. When the pump is re-started, chec k to
ensure leakage is taking place at the packed gla nd.
If hot liquids are being pumped it may be necessary
to slacken the gland nuts to achieve leakage.
The pump should be run for 30 minutes with steady
leakage and the gland nuts tightened by 10 degrees
at a time until leakage is reduced to an acceptable
level, normally a minimum of 120 drops per minute is
required. Bedding in of the packing may take
another 30 minutes.
Never run a mechanical seal dry,
even for a short time.
5.7.4 Bearings
If the pumps are working in a potentially
explosive atmosphere temperature or vibration
monitoring at the bearings is recommended
If bearing temperatures are to be monitored it is
essential that a benchmark temperature is recorded
at the commissioning stage and after the bearing
temperature has stabilized (see 5.2.2 for
temperature limits).
When a oil temperature sensor is provided:
set the alarm at 82 °C (180 °F) and the trip at 90
°C (194 °F) for high ambient temperature and/or
hot service
When the bearing temperature sensor is provided:
set the alarm at 93 °C (200 °F) and the trip at
105 °C (220 °F).
It is important, to keep a check on bearing
temperatures. After start up the temperature rise
should be gradual, reaching a maximum after
approximately 1.5 to 2 hours. This temperature rise
should then remain constant or marginally reduce
with time.
Page 28 of 48
Page 29
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
5.7.5 Normal vibration levels, alarm and trip
For guidance, pumps generally fall under a
classification for rigid support machines within the
International rotating machinery standards and the
recommended maximum levels below are based on
those standards.
Alarm and trip values for installed
pumps should be based on the actual
measurements (N) taken on the pump in the fully
commissioned as new condition. Measuring
vibration at regular intervals will then show any
deterioration in pump or system operating
conditions.
Vibration velocity – unfiltered
mm/s (in./s) r.m.s.
Normal N
Alarm N x 1.25
Shutdown trip N x 2.0
LPNV
mm/s (in./s) r.m.s.
5 (0.2)
6.2 (0.25)
10 (0.4)
5.7.6 Stop/start frequency
Pump sets are normally suitable for the number of
equally spaced stop/starts per hour shown in the
table below. Check actual capability of the driver and
control/starting system before commi ssioning
Motor rating kW (hp) Maximum stop/starts
per hour
Up to 15 (20) 15
Between 15 (20) and 90 (120) 10
Above 90 (120) 6
.
Where duty and standby pumps are installed it is
recommended that they are run alternately every
week
.
5.8 Normal Start Up
The starting procedure to be followed for normal
start up is the same as that for initial starting with the
exception that Step (J) section 5.6 "CHECK
ROTATION" does not have to be repeated as long
as driver systems have not been changed since last
pump operation.
5.9 Stopping the pump
a) Shut down driver.
The pump should be shut down
rapidly to protect the internal wearing parts
which are lubricated by the liquid being pumped.
If pump stops abruptly when driver is shut
down, investigate for pump binding. Take necessary
remedial action before restarting pump.
b) Close the pump discharge valve, while the
suction valve normally remains open.
c) Close valve in bypass line and closed whenever
possible, switch off flushing and/or cooling liquid
supplies.
If pump is subjected to freezing
temperatures the pump must be drained of liquid
to prevent damage to the pump.
For pumping hot liquid or fluid
subject to crystallize, the flush supply must be
maintained on completion of pumping, to avoid
seals damage.
In some installations the use of a check
valve is not feasible due to the creation of pressure
surges or water hammer as a result of the sudden
closing of the valve under high discharge pressure.
In such cases the discharge valve should be closed
slowly prior to stopping the driver to eliminate the
possibility of water hammer
.
5.10 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 notes on section
3.4 may help the user decide how to evaluate the
implications of any change. If in doubt contact your
nearest Flowserve office.
Page 29 of 48
Page 30
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
6 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)
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".
Before attempting any inspection or
repair on the pump, the driver controls must be in
the "off" position, locked and tagged to prevent injury
to personnel performing service on the pump.
Before attempting to disassemble pump, pump
must be isolated from system, by closing suction and
discharge system valves, drained of liquid and
cooled, if pump is handling hot liquid.
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 seal 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.
FLOWSERVE 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 7, Faults; causes and remedies,
for fault diagnosis.
.
b) Ensure equipment complies with the
recommendations in this manual.
c) Contact Flowserve if the problem persist s.
6.2.1 Routine inspection (daily/weekly)
The following checks should be made
and the appropriate action taken to remedy any
deviations:
a) Check suction and discharge gauges.
b) Check for abnormal operating conditions
(High/Low Temperature, Flows, Vibration,
Pressures Etc.)
c) Check motor current/driver power.
d) Check that there are no abnormal fluid or
lubricant leaks (static and dynamic seals) and
that any sealant systems (if fitted) is full and
operating normally.
e) Check for leakage from seals, joints or packing.
f) Check all lubricant levels i.e. bearing housing
oilers, seal Plan 52/53, seal supply systems as
applicable.
Page 30 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
g) Check any auxiliary supplies as heating/cooling
(if fitted) are functioning correctly.
h) Check stand by pump is at applicable
temperature and available to start as required.
Refer to the manuals of any associated
equipment for routine checks needed.
6.2.2 Periodic inspection (monthly)
a) Check for lubricant contamination whether
bearing oil, or seal oil (if applicable) by sample
analysis.
b) Check all paint or protective coatings.
c) Check all power/instrument cable glands for
tightness.
Refer to the manuals of any associated
equipment for periodic checks needed.
6.2.3 Periodic inspection (six monthly)
a)
security of attachment, corrosion. Check
grouting for looseness, cracking or general
distress.
b) Change lubricants.
c) Check unit alignment
d) Check calibration of instruments.
e) The coupling should be checked for correct
alignment and worn driving elements.
Check foundation bolts for
Refer to the manuals of any associated
equipment for periodic checks needed.
6.2.4 Inspection (after 3 years)
a) Check internal condition of pump and all
ancillary pipework for corrosion/erosion.
b) Check internal pump components for wear .
c) Change bearings
d) Check calibration of instruments.
e) Check coupling teeth or discs for wear.
6.2.5 Re-lubrication
Lubricant and bearing temperature analysis can be
useful in optimizing lubricant change intervals.
In general however, the following is recommended.
6.2.5.1 Oil lubrication (if provided)
Maintaining the correct oil level is
very important.
If the pump is supplied with a constant level oiler the
oil level will be automatically maintained and as long
as oil is visible in the glass bottle there is no need to
refill. If however a sight glass has been fitted, then
regular checks should be made to ensure the level is
maintained at the center of the glass window.
Refer to the instructions of this manual for methods
of oil fill, for oil grade recommendations and for the
schedule and temperature limits.
6.2.6 Mechanical seals (for pumps with
mechanical seal)
No adjustment is possible. When leakage reaches
an unacceptable level the seal will need
replacement.
6.2.7 Gland packing (for pumps with gland seal)
The stuffing box split gland can be completely
removed for re-packing or to enable the addition of
extra rings of packing.
The stuffing box is normally supplied with a lantern
ring to enable a clean or pressurized flush to the
center of the packing. If not required, this can be
replaced by an extra 2 rings of packing.
There must always be a small leakage, normally a
minimum of 120 drops per minute to atmosphere to
lubricate and cool the packing is required.
6.3 Spare parts
6.3.1 Ordering of spares
Flowserve keep records of all pumps that have been
supplied. When ordering spares the following
information should be quoted:
1) Pump serial number
2) Pump size
3) Part name (a)
4) Part number (a)
5) Number of parts required
(a) Taken from the cross section drawing stored into
the job user instruction book and only in case not
available see at section 8.
The pump size and serial number are shown on the
pump nameplate.
To ensure continued satisfactory operation,
replacement parts to the original design specification
should be obtained from Flowserve.
Any change to the original design specification
(modification or use of a non-genuine part) will
invalidate the pump’s safety certification.
If rings are ordered as repair parts after
the pump has been put into service:
- Fully machined stationary rings
- Oversized im peller rings
will be furnished as standard unless differently
requested by the customer.
Page 31 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
If undersize or oversize rings are desired, the
amount of undersize or oversize required on the I.D.
or the O.D. must be stated by the customer in the
repair order.
It is recommended as insurance against delays that
spare parts be purchased at the time the order for
the complete unit is placed or as soon after receiving
the pump as possible.
6.3.2 Storage of spares
Spares should be stored in a clean dry area away
from vibration. Inspection and re-treatment of
metallic surfaces (if necessary) with preservative is
recommended at 6 monthly intervals
6.4 Recommended spares (according to
API)
The severity of the conditions of service, the extent
to which repairs can be carried out in the field, and
the number of units installed will determine to a great
extent the minimum number of spare parts which
should be carried in stock at the site of the
installation.
The minimum spare parts for a pump of the LPNV
line should include the following:
For start up purposes:
1 – set of bearings
2 – sets of gaskets and o-ring
2 – set of wear rings (2 rotating + 2 stationary)
According to pump provision:
1 - set of mechanical seal or gland packing
For normal maintenance:
1 – set of bearings
2 – sets of gaskets and o-ring
2 – wear rings set (2 rotating + 2 stationary)
According to pump provision:
1 - set of mechanical seals or gland packing
1 – set of shaft sleeves
1 – set of bushings
1 – shaft
1 – impeller
6.5 Tools required
A typical range of tools that will be required to
maintain these pumps is listed below
Readily available in standard tool kits, and
dependent on pump size:
Open ended spanners (wrenches) to suit up to
2” (M 50) screws/nuts
Socket spanners (wrenches), up to 2” (M 50)
screws
Allen keys, up to 10 mm (A/F)
Range of screwdrivers
Soft mallet
Page 32 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
6.6 Fastener torques
Main Flange Studs/Nuts (Top Casing to Bottom Casing)
Stud Size
3/8” 16UNC
1/2”13UNC
5/8” 11UNC
3/4” 10UNC
7/8” 9UNC
1” 8UNC
1 1/8” 8UN
1 1/4” 8UN
1 3/8” 8UN
1 1/2” 8UN
1 5/8” 8UN
1 3/4” 8UN
1 7/8” 8UN
2” 8UN
2 ¼” 8UN
2 ½” 8UN
Main Flange Studs/Nuts (Top Casing to Bottom Casing)
Stud Size
3/8” 16UNC
1/2”13UNC
5/8” 11UNC
3/4” 10UNC
7/8” 9UNC
1” 8UNC
1 1/8” 8UN
1 1/4” 8UN
1 3/8” 8UN
1 1/2” 8UN
1 5/8” 8UN
1 3/4” 8UN
1 7/8” 8UN
2” 8UN
2 ¼” 8UN
2 ½” 8UN
Mechanical Seal to Casing Cover
Stud/Nut Size
1/2”
5/8”
3/4”
Torque Values listed above are selected to achieve
the correct amount of pre-stress in the threaded
fastener. Maintenance personnel must ensure that
threads are in good condition (free of burrs, galling,
dirt, etc.) and that commercial thread lubricant NILS
Wega 2 containing molybdenum disulphide is used.
Torque should be periodically checked to ensure that
it is at the recommended value.
Torque Value Materials:
A193Gr.B7(AISI4140), 17-4PH,
Monel K 500
Nm (lbft)
29
78
147
245
392
638
883
1226
1668
2060
2943
3728
4905
5396
7848
10497
Torque Value Materials:
A193Gr.B8M(AISI316),
S31803(duplex), S32760(superduplex)
Nm (lbft)
25
59
118
196
294
491
687
981
1275
1570
2256
2943
3787
4415
5886
7848
Torque Value (A193Gr.B8M material)
Nm (lbft)
35-41
58-68
130-150
(22)
(58)
(108)
(181)
(289)
(470)
(651)
(904)
(1230)
(1519)
(2170)
(2749)
(3617)
(3978)
(5786)
(7739)
(18)
(43)
(87)
(145)
(217)
(362)
(506)
(723)
(940)
(1157)
(1664)
(2170)
(2792)
(3255)
(4340)
(5786)
(26-30)
(45-50)
(95-110)
6.7 Disassembly
Frequency of a complete overhaul depends upon
the hours of operation of the pump, the severity of
the condition and the care the pump receive in
operation. It is not necessary to open your pump for
inspection unless there is definite evidence that the
capacity has fallen off excessively or unless there is
indication of trouble inside the pump or in the
bearings.
Before performing any disassembly, maintenance
and/or inspection on the unit, the following steps
should be taken and warnings observed.
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.
Tag driver control in the “off” position.
Before attempting any inspection or repair on
the pump the driver controls must be in the "off"
position, locked and tagged to prevent restarting
equipment and injury to personnel performing
service on the pump.
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.
When the pump is handling “hot” liquid,
extreme care must be taken to ensure the safety
of personnel when attempting to drain pump. Hot
pumps must be allowed to cool before draining.
When the pump is handling “caustic”
liquid, extreme care must be taken to ensure the
safety of personnel when attempting to drain
pump. Protective devices of suitable protective
materials must be worn when draining pump.
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.
Page 33 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
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.
6.7.1 Disassembly procedure
Care must be exercised in the dismantling operation
to prevent damages to internal parts of the pump.
Lay out all parts in the same order in which they are
removed for convenience at reassembly.
Protect all machined faces against metal-to-metal
contact and corrosion.
6.7.1.1 Disassembly procedure for inspection of
thrust bearing and mechanical seal
a) Switch off, lock and tag the motor circuit
breakers. Disconnect and tag electrical leads at
motor. This operation must be done by a
qualified electrician.
b) Switch off, isolate and tag all instrumentation
and monitoring equipment.
c) Close the pump suction valve. If discharge valve
has not already been closed this must be done
prior to dismantling.
d) Drain the pump casing. This can be done by first
opening the vent connections and then opening
the drains.
e) Drain bearing housing of oil by removing the
drain plug. Remove oilers.
Use caution when draining hot oil from
bearing housing to prevent burns/injury to
personnel.
f) Disconnect and remove all vents and seal flush
pipework and allow to drain.
g) It is advisable to thoroughly drain and dry off the
foundation and soleplate before attempting any
maintenance work on the pump.
This could eliminate the risk of slipping on a
wet surface causing personal injury or
mechanical damage.
h) Remove pump monitoring equipment, auxiliary
services or any other plant or equipment that
may interfere with safe dismantling of the pump.
i) Remove pump coupling guard.
j) Disconnect coupling spacer (Refer to coupling
instructions).
k) Loosen set screw securing pump coupling nut
and remove nut.
l) Remove pump coupling hub, using a puller.
Remove coupling key.
m) In case the pump is provided with mechanical
seal (no gland seal option): loose mechanical
seal and insert setting tab or spacer, according
to manufacturer’s instructions
n) Unscrew lock screw and remove adjusting nut
from upper end of pump shaft.
o) Unscrew grub screws and remove protecting
shield from thrust bearing assembly.
p) Remove shaft guide bushing key.
q) Remove bolts and dowels that secure thrust
bearing assembly to bracket on stationary half
casing.
r) Slip off complete thrust bearing assembly from
shaft top, or dismantle the same according to
Chapter 6.7.2)
s) According to pump provision:
- Remove gland packing (ref. 6.7.3)
- Remove mechanical seal assembly (ref. 6.7.4)
t) Unscrew bolts and remove bottom bearing
cover. Pay attention to falling of bearing bushing
onto soleplate.
Bearing bushing is pinned to end
cover, to prevent its rotation.
6.7.1.2 Disassembly procedure in case of overall
dismantling
In case of overall dismantling of the pump, continue
dismantling procedure of the chapter 6.7.1.1 with the
following steps:
u) Remove bolts and dowels that secure motor to
motor stand.
v) Lift motor vertically. Provide a suitable support
and lower motor on it.
w) Remove bolts and dowels that secure motor
stand to pump-bracket (integrated stand option)
or to soleplate (external stand option).
x) Lift vertically and clear away motor stand.
y) Sling and suspend vertically and independently
rotor shaft and removable casing half. Use
appropriate lifting eyes.
z) Remove dowel pins and casing stud nuts, then
break casing joint using forcing-off bolts
provided on removable casing half.
aa) Carefully move away in a horizontal direction the
removable casing half to prevent damage to
casing rings and impeller, using dedicated tools
to allow pump casing opening (rif. Chapter 6.5
and Chapter 2.3 Figure n° 2.4)
bb) Secure bottom casing ring to the impeller with
tape or wire to prevent its falling.
cc) Carefully move away in a horizontal direction the
rotor assembly to prevent damage to casing
rings, bushings and impeller.
Casing rings and throttle bushing are
pinned to stationary casing half, to prevent their
rotation.
dd) Place rotor on “V” blocks for further
disassembly.
Page 34 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
6.7.2 Thrust bearing disassembly
Disassemble the thrust bearing as follows:
a) Unbolt and remove cover from thrust bearing
housing.
b) Remove springs and shaft guide bushing
complete with line bearing, locking nut and thrust
bearing.
c) Unscrew locking nut and pull out the upper thrust
bearing.
d) Remove the shaft nut and pull out the bottom
thrust bearing.
6.7.3 Shaft seal - gland packing
a) Remove gland nuts and gland.
b) Lever out gland ring using its grip groove.
c) Remove glan d packing rings and lantern rings
using a bent wire.
6.7.4 Shaft seal - mechanical seal
d) Remove seal cover screws and pull off seal
cover complete with the stationary seal ring
which is held in place by the O-ring seal.
e) The mechanical seal cover can also be removed
by placing a wedge into the gland chamfer, as
below:
Refer to any special instructions supplied
with the mechanical seal.
6.7.5 Rotor disassembly
Disassemble the rotor as follows:
a) Remove throttle bushing and casing rings.
b) Unscrew locking nut and remove impeller and
impeller key.
c) Slide out shaft sleeve and remove locating ring in
two halves.
6.8 Examination of parts
As the pump and rotor are dismantled, all individual
parts, all important joints and all wearing surfaces
should be carefully examined. As a general rule,
regardless of the performance of the unit, parts
appreciably worn should be renewed if it is not
intended to examine the pump until the next
overhaul period. It should be remembered that when
parts in new or good condition with metal seats are
assembled in contact with dirty or worn parts, the
new parts are very likely to wear out rapidly.
Used parts must be inspected before
assembly to ensure the pump will subsequently run
properly.
In particular, fault diagnosis is essential to enhance
pump and plant reliability.
6.8.1 Half casings
a) Inspect for excessive wear, pitting, corrosion,
erosion or damage and any sealing surface
irregularities. New casing gasket should be
installed whenever the pump is disassembled.
Remove all traces of all gasket material. When
using any tool to remove gasket material, take
great care not to damage the machined
surfaces.
b) Replace as necessary.
6.8.2 Impeller
a) Remove worn impeller rings by mechanical
turning.
Slightly eroded parts can be repaired by welding.
Dynamically balance impellers after any machine
work. To balance remove metal from the front or
back shroud of the impeller at the point of
unbalance.
6.8.3 Mechanical seal (if fitted)
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.
6.8.4 Bearing housing
Thoroughly flush and clean the oil passages, then
coat the inner surfaces with a thin film of lubricating
oil.
Cover the bearing body to keep it clean until ready
for installation.
Page 35 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
6.8.5 Shaft
When the pump is dismantled, examine the shaft
carefully. Its condition should be checked at the
impeller hub fit, under the shaft sleeve and at the
bearings.
The shaft may become damaged by rusting or pitting
because of leakage along the shaft at the impeller or
shaft sleeve.
Check the shaft keyway for distortion.
Excessive thermal stresses or corrosion may loosen
the impeller on the shaft and subject the keyway to
excessive shock. Replace a shaft that is bent or
distorted. Check a shaft that has been repaired for
possible runout (maximum 0.050 mm).
The shaft sleeve is subject to wear and may require
replacement, depending on the severity of service.
Replace it if grooved, pitted or worn.
6.8.6 Gaskets and O-rings
After dismantling, discard and replace.
The gasket must be of the same material and of the
same thickness as the original gasket
6.8.7 Bearings
6.8.7.1 Bearing bushing
If the bearing bushing shows wear upon inspection it
should be replaced. Worn bearings can cause pump
vibration and can result in damage to the wearing
rings and mechanical seal.
The bearing bushing is pinned to bearing cover to
prevent its rotation.
6.8.7.2 Antifriction bearings
Anti-friction bearings are shrunk on the shaft guide
bushing and a pulling device must be used to
remove them. The pulling jaws or fingers must be
located behind the shoulder of the inner race.
Place bearings on a shelf in a temperature
controlled oven. A temperature of 80° for one half
hour should be sufficient.
Care must be taken to keep the bearing clean and
uncontaminated.
Check the position of the bearing on the bushing
with a feeler gage to make sure it is pressing firmly
against the shoulder.
6.8.8 Wear rings
Impeller wearing rings are pressed into place and
held by set screws. To remove these rings for
replacement it is necessary to remove the recessed
screws and pry off the rings using wedges of some
other suitable device. Care must be exercised to
make sure the impeller is not damaged during this
operation. Preferably remove rings by mechanical
turning.
Unless extreme care is used when
removing an anti-friction bearing, the bearing
may be damaged to the extent that is no longer
useable.
Always check the bearing immediately after
removal for any imperfections or any play
between the races. It is recommended that new
bearings be used for replacement of removed
bearings since very often damage caused by
removal cannot be detected until the pump is put
into operation.
When mounting anti-friction bearings on the pump
shaft guide bushing remember that the satisfactory
operation of anti-friction bearings requires that the
inner be firmly held on the bushing so that it cannot
turn on the bushing.
Heat the bearing to expand the inner race and shrink
it on the bushing.
Page 36 of 48
Page 37
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
6.9 Reassembly
To reassemble the pump consult the sectional
drawings, see section 8, parts list and drawings.
Ensure threads, gasket and O-ring mating faces are
clean.
6.9.1 Wear rings
The impeller is fitted with both front and rear wear
rings.
The impeller rings 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 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 rings.
6.9.1.1 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.
HAND
GRI ND ER
Figure 6.3
IMPELLE
IMPELLER
RING
b) To fit new weaqr rings:
Make sure ring fits on impeller are free of nicks
or burrs. Heat new ring to 107 °C (225 °F) and
install on impeller. Drill and tap new holes in
impeller spaced half the circular distance from
the previously used holes in the impeller. See
sketch below.
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 Sectional drawing for the requested
running clearance.
The impeller wear ring bore is relieved
at one edge. Ensure that the ring is installed on
the impeller so that the chamfered edge is sitting
against the impeller.
Do not tighten set screws
excessively, as this will distort the wearing ring.
Lock set screws by prick punching.
6.9.1.2 Casing wear rings
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 -20°C (-4°F) when installing in casing
cover. 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.
Page 37 of 48
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LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
6.9.2 Rotor Assembly
To reassemble the pump, reverse the dismantling
procedure previously described.
The torque table value in Chapter 6.6 provides a
guide for properly assembling the equipment.
Proceed as follows:
a) Place split locating ring in relevant shaft groove.
b) Install shaft sleeve against locating ring.
c) Place impeller key in relevant shaft key-way.
d) Install impeller against shaft sleeve.
Direction of impeller rotation
Figure 6.5
Take care to mount the impeller so that
the vane tips point away from the apparent flow
direction (See figure 6.5).
e) Install impeller locking nut. Screw nut until it butt
against the impeller hub.
f) Locate casing rings on impeller. Secure bottom
casing ring to the impeller with tape or wire.
g) Place in position stuffing box throat bushing.
6.9.3 Pump completion
a) Sling and suspend rotating element vertically
against the stationary casing half, taking care that
the impeller is centered as closely as possible in
its volute and throttling bushing, shaft guide
bushing and casing rings are inserted in their
respective seats.
e) Stuffing box assembly
- Gland packing: Insert inner two rings of packing,
then lantern ring halves and finally 2 or 3 more
rings of packing. Loosely fit the gland and
connect flush line.
- Mechanical seal: Fasten seal covers complete
with O-ring and connect flush line. Connect any
auxiliary piping.
At this tag don’t lock mechanical
seal sleeve to pump shaft and don’t remove
setting tab or spacer.
f) Assemble and install complete thrust bearing
assembly. Adjust bearing housing until dowel pins
can be driven into place on bearing bracket.
g) Centralize impeller in its volute, acting on
adjusting nut. Lift rotor against upper stop in the
casing and measure total axial clearance. Lower
rotor an amount equal to half of above
measurement.
h) Screw adjusting nut lock screws.
i) Lock mechanical seal sleeve (if fitted) to pump
shaft and remove setting tab or spacer.
j) Install coupling key and pump half coupling (if
fitted), coupling nut and coupling nut set screws.
k) Turn rotor by hand to ensure there are no rubs or
binding.
6.9.4 Unit reinstallation
a) Install motor stand on soleplate and set electric
motor as described under Section 6.7.1.
b) Check driver/driven shafts alignment and
assemble flexible coupling.
c) Replace all auxiliary piping, instrumentation and
pipe plugs.
d) Install oiler and fill thrust bearing housing to
correct oil level (refer to Section 5.1.1
“Lubrication”).
e) Install coupling guards.
f) Refer to section 5.6 “Operation” for starting
procedure.
Bottom bearing bushing is pinned to
end cover. Bolt (snug up) end cover to stationary
casing half.
b) Install removable casing half against the
stationary one. Close up pump, applying the
torque values recommended on in Chapter 6.6,
tightening first of all the central studs and then
proceeding towards the periphery and outer
ends.
c) Fix end cover to the casing.
d) Lower pump rotor until rotor weight is borne by
the casing.
Page 38 of 48
Page 39
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
7 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
PROBABLE CAUSES POSSIBLE REMEDIES
Pump not primed.
Pump or suction pipe not completely filled with
liquid.
Suction lift too high or level too low.
Insufficient margin between suction pressure and
vapor pressure.
Excessive amount of air or gas in liquid. Check and purge pipes and s ystem.
Air or vapor pocket in suction line. Check suction line design for vapor pockets.
Air leaks into suction line. Check suction pipe is airtight.
Air leaks into pump through mechanical seal,
sleeve joints, casing joint or pipe plugs.
Foot valve too small. Investigate replacing the foot valve.
Foot valve partially clogged. Clean foot valve.
Inlet of suction pipe insufficiently submerged. Check out system design.
Speed too low. CONSULT FLOWSERVE.
Speed too high. CONSULT FLOWSERVE.
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.
Viscosity of liquid differs from that for which
designed.
Operation at very low capacity. Measure value and check minimum permitted.
Operation at high capacity. Measure value and check maximum permitted.
A. System troubles
Check complete filling. Vent and/or prime.
Check NPSHa>NPSHr, proper submergence,
losses at strainers/fittings.
Check and replace faulty parts.
CONSULT FLOWSERVE.
Check system losses.
Remedy or CONSULT FLOWSERVE.
Check and CONSULT FLOWSERVE.
Remedy or CONSULT FLOWSERVE.
Remedy or CONSULT FLOWSERVE.
B. Mechanical troubles
Misalignment due to pipe strain. Check the flange connections and eliminate strains
using elastic couplings or a method permitted.
Improperly designed foundation. Check setting of baseplate: tighten, adjust, grout
base as required.
Shaft bent. Check shaft runouts are within acceptable values.
CONSULT FLOWSERVE.
Rotating part rubbing on stationary part internally. Check and CONSULT FLOWSERVE, if necessary.
Page 39 of 48
Page 40
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
PROBABLE CAUSES POSSIBLE REMEDIES
Bearings worn Replace bearings .
Wearing ring surfaces worn. Replace worn wear ring/surfaces.
Impeller damaged or eroded. Replace or CONSULT FLOWSERVE for improved
Leakage under sleeve due to joint failure. Replace joint and check for damage.
Mechanical seal improperly installed. Check alignment of faces or damaged parts and
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.
Abrasive solids in liquid pumped.
Internal misalignment of parts preventing seal ring
and seat from mating properly.
Mechanical seal was run dry. Check mechanical seal condition and source of dry
Internal misalignment due to improper repairs
causing impeller to rub.
Excessive thrust caused by a mechanical failure
inside the pump.
Lack of lubrication for bearings. Check hours run since last change of lubricant, the
Improper installation of bearings (damage during
assembly, incorrect assembly, wrong type of
bearing etc.).
Damaged bearings due to contamination. Check contamination source and replace damaged
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
material selection.
assembly method used.
CONSULT FLOWSERVE.
Check misalignment and correct if necessary. If
alignment satisfactory check bearings for excessive
wear.
Check and CONSULT FLOWSERVE.
running and repair.
Check method of assembly, possible damage or
state of cleanliness during assembly.
Remedy or CONSULT FLOWSERVE, if necessary.
Check wear condition of impeller, its clearances and
liquid passages.
schedule and its basis.
Check method of assembly, possible damage or
state of cleanliness during assembly and type of
bearing used. Remedy or CONSULT
FLOWSERVE, if necessary.
bearings.
C. MOTOR ELECTRICAL PROBLEMS
Wrong direction of rotation. Reverse 2 phases at motor terminal box.
Motor running on 2 phases only. Check supply and fuses.
Motor running too slow. Check motor terminal box connections and voltage.
Page 40 of 48
Page 41
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
8 GENERAL ARRANGEMENT, SECTIONAL DRAWINGS AND PART LIST
The specific sectional drawing, the specific general arrangement drawing and any specific drawings required
by the contract will be sent to the Purchaser separately unless the contract specifically calls for these to be
included into the User Instructions.
8.1 Motor Stand layout
Figure 8.1 – External motor stand layout Figure 8. 2 – Integrated motor stand layout
Page 41 of 48
Page 42
8.2 Sectional Drawing and Part List
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
8.3.1 Parts list
Ref no Description
2910.2 LOCKING NUT
2910.1 SHAFT NUT
2909 ADJUSTING NUT
2905 WASHER
2531 SPLIT RETAINING RING
2470 BEARING HOUSING
2450 SLEEVE
2300.2 IMPELLER WEAR RING
2300.1 IMPELLER WEAR RING
2200 IMPELLER
2100 SHAFT
1500.2 CASING WEAR RING
1500.1 CASING WEAR RING
1214 UPPER PUMP CASING
1100 CASING
Figure 8.3 – LPNV Sectional Drawing
4300 BEARING ISOLATOR
(INPROSEAL VBXX)
4260 SPRING
4200 MECHANICAL SEAL
4132 THROAT BUSHING
3860 OIL CONTAINING BUSHING
3855 CONSTANT LEVEL OILER
3854 BREATHER PLUG
3400 CASING BUSHING
3260.2 CASING COVER
3260.1 BEARING COVER
3230 THRUST BEARING HOUSING
3160 MOTOR STAND
3013 THRUST BALL BEARING
3010 ANTI-FRICTION BEARING
2912 IMPELLER NUT
6700.3 KEY
6700.2 KEY
6700.1 KEY
6581.2 NUT
6581.1 NUT
6572.2 STUD
6572.1 STUD
6130 FOUNDATION PLATE
4610.1 O-RING
4590.2 FLAT GASKET
4590.1 FLAT GASKET
Page 42 of 48
Page 43
8.3 Thrust bearing details
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
Figure 8.4 – Thrust Bearing with ball bearings and without cooling
8.4.1 Parts list
Ref no Description
6700 KEY
6517 DRAIN PIPE
4610 O-RING
4260 SPRING
3860 OIL RETAINING TUBE
3858 OIL LEVEL SIGHT GLASS
3855 COSTANT LEVEL OILER
3854 OIL FILTER PLUG
3260 BEARING COVER
3200 BEARING HOUSING
3013.2 THRUST BALL BEARING
3013.1 THRUST BALL BEARING
2910 SHAFT NUT
2909 ADJUSTING NUT
2905 WASHER
2540 DEFLECTOR
2471 INNER RACE CENTRING SLEEVE
Page 43 of 48
Page 44
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
Figure 8.5 – Thrust Bearing with ball bearings and fan cooling
8.5.1 Parts list
Ref no Description
8162 COVER
8161 FAN
6700 KEY
6517 DRAIN PIPE
4610 O-RING
4260 SPRING
3860 OIL RETAINING TUBE
3858 OIL LEVEL SIGHT GLASS
3855 COSTANT LEVEL OILER
3854 OIL FILTER PLUG
3260 BEARING COVER
3200 BEARING HOUSING
3013.2 THRUST BALL BEARING
3013.1 THRUST BALL BEARING
2910 SHAFT NUT
2909 ADJUSTING NUT
2905 WASHER
2540 DEFLECTOR
2471 INNER RACE CENTRING SLEEVE
Page 44 of 48
Page 45
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
Figure 8.6 – Thrust Bearing with ball bearings and liquid cooling
8.6.1 Parts list
Ref no Description
6700 KEY
6580 NUT
6551 COOLING COIL
6517 DRAIN PIPE
4610.2 O-RING
4610.1 O-RING
4260 SPRING
3860 OIL RETAINING TUBE
3858 OIL LEVEL SIGHT GLASS
3855 COSTANT LEVEL OILER
3854 OIL FILTER PLUG
3260 BEARING COVER
3200 BEARING HOUSING
3013.2 THRUST BALL BEARING
3013.1 THRUST BALL BEARING
2910 SHAFT NUT
2909 ADJUSTING NUT
2905 WASHER
2540 DEFLECTOR
2471 INNER RACE CENTRING SLEEVE
Page 45 of 48
Page 46
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
9 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 OTHER RELEVANT
DOCUMENTATION AND MANUALS
10.1 Supplementary User Instruction
manuals
Supplementary instruction 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 under this
section. If further copies of these are required they
should be obtained from the purchaser for
retention with these User Instructions.
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:
Pumping Manual, 9
Elsevier Advanced Technology, United Kingdom,
1995.
Reference 3:
Pump Handbook, 2nd edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.
Reference 4:
ANSI/HI 1.1-1.5
Centrifugal Pumps - Nomenclature, Definitions,
Application and Operation
Reference 5:
ANSI B 31 3- Process Piping.
th
edition, T.C. Dickenson,
.
Page 46 of 48
Page 47
NOTES:
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
Page 47 of 48
Page 48
Your Flowserve factory contact:
Service & Warranty
Flowserve – Italy
Worthington S.r.l,
Via Rossini, 90/92
20832 Desio (MB)
Italy
Telephone (24 hours) +39 0362 6121
Fax +39 0362 628882
+39 0362 620750
Spare Parts & Repair
Flowserve – Italy
Worthington S.r.l,
S.S.Sannitica, 87 – km 19
81025 Marcianise (Caserta)
Italy
Telephone (24 hours) +39 0823 634111
Fax +39 0823 821747
+39 0823 634218
Your local Flowserve representative:
To find your local Flowserve representative,
please use the Sales Support Locator System
found at www.flowserve.com
LPNV USER INSTRUCTIONS ENGLISH 87900031 – 06/14
FLOWSERVE REGIONAL
SALES OFFICES:
USA and Canada
Flowserve Corporation
5215 North O’Connor Blvd.,
Suite 2300
Irving, Texas 75039-5421 USA
Telephone 1 972 443 6500
Fax 1 972 443 6800
Europe, Middle
East, Africa
Worthing S.r.l.
Flowserve Corporation
Via Rossini 90/92
20832 Desio (MB) Italy
Telephone 39 0362 6121
Fax 39 0362 303396
Latin America
and Caribbean
Flowserve Corporation
6840 Wynnwood Lane
Houston, Texas 77008 USA
Telephone 1 713 803 4434
Fax 1 713 803 4497
Asia Pacific
Flowserve Pte. Ltd
10 Tuas Loop
Singapore 637345
Telephone +65 6771 0600
Fax +65 6779 4607
Page 48 of 48
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