Flowserve LPNV Worthington User Manual
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.
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
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
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
Page 4 of 48
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
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
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”.
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
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
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
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
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.
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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
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
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
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