Flowserve LR Worthington User Manual
USER INSTRUCTIONS
WORTHINGTON®
LR, LRV, LLR and LR-S
Horizontal, split case, volute type centrifugal pumps for
water and general service
PCN=71569088 08-10 (E) (Based on C953KH013)
Original instructions
Installation
Operation
Maintenance
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
CONTENTS
PAGE
1 INTRODUCTION AND SAFETY ............................ 4
1.1 General ........................................................... 4
1.2 CE marking and approvals .............................. 4
1.3 Disclaimer ....................................................... 4
1.4 Copyright ......................................................... 4
1.5 Duty conditions................................................ 4
1.6 Safety .............................................................. 5
1.7 Safety labels summary .................................... 8
1.8 Specific machine performance ........................ 8
1.9 Noise level ....................................................... 9
2 TRANSPORT AND STORAGE ............................ 10
2.1 Consignment receipt and unpacking............. 10
2.2 Handling ........................................................ 10
2.3 Lifting ............................................................. 10
2.4 Storage .......................................................... 10
2.5 Recycling and end of product life .................. 10
3 PUMP DESCRIPTION .......................................... 11
3.1 Configurations ............................................... 11
3.2 Name nomenclature ...................................... 11
3.3 Design of major parts .................................... 11
3.4 Performance and operating limits ................. 12
4 INSTALLATION .................................................... 12
4.1 Location ......................................................... 12
4.2 Part assemblies............................................. 12
4.3 Foundation .................................................... 12
4.4 Grouting ........................................................ 13
4.5 Initial alignment ............................................. 13
4.6 Piping ............................................................ 14
4.7 Final shaft alignment check .......................... 17
4.8 Electrical connections ................................... 17
4.9 Protection systems ........................................ 17
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN ........................................... 18
5.1 Pre-commissioning procedure ...................... 18
5.2 Pump lubricants ............................................ 19
5.3 Direction of rotation ....................................... 20
5.4 Guarding ....................................................... 20
5.5 Priming and auxiliary supplies ...................... 20
5.6 Starting the pump .......................................... 20
5.7 Running the pump ......................................... 21
5.8 Stopping and shutdown ................................. 22
5.9 Hydraulic, mechanical and electrical duty ..... 22
PAGE
6 MAINTENANCE ................................................... 22
6.1 General ......................................................... 22
6.2 Maintenance schedule .................................. 23
6.3 Spare parts.................................................... 25
6.4 Recommended spares
7 FAULTS; CAUSES AND REMEDIES .................... 34
8 PARTS LISTS AND DRAWINGS ......................... 36
9 CERTIFICATION .................................................. 47
10 OTHER RELEVANT DOCUMENTATION
and consumable items ................................. 25
6.5 Tools required ............................................... 26
6.6 Fastener torques........................................... 26
6.7 Renewal clearances ..................................... 26
6.8 Disassembly ................................................. 26
6.9 Examination of parts ..................................... 29
6.10 Assembly .................................................... 29
8.1 Sectional drawings – LR single entry
impeller, grease lubricated, gland packed .... 36
8.2 Sectional drawings – LR double entry
impeller, grease lubricated, gland packed .... 38
8.3 Sectional drawings – LLR grease
lubricated, gland packed .............................. 40
8.4 Sectional drawings – LR-S double entry
impeller, grease lubricated, gland packed .... 42
8.5 Sectional drawings – LRV double entry
impeller, grease lubricated thrust bearing,
component mechanical seal, silicon
carbide bearing ............................................. 44
8.6 General arrangement drawing ...................... 46
8.7 Interchangeability charts ............................... 46
AND MANUALS ................................................ 47
10.1 Supplementary User Instructions ............... 47
10.2 Change notes ............................................. 47
10.3 Additional sources of information................ 47
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LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
INDEX
PAGE
Additional sources (10.3) ......................................... 47
Alignment of shafting (4.3, 4.5 and 4.7)
Assembly (6.10) ....................................................... 29
ATEX marking (1.6.4.2) ............................................. 7
CE marking and approvals (1.2) ................................ 4
Certification (9) ........................................................ 47
Change notes (10.2) ................................................ 47
Clearances (6.7, Renewal clearances).................... 26
Commissioning and operation (5) ............................ 18
Compliance, ATEX (1.6.4.1) ...................................... 6
Configurations (3.1) ................................................. 11
Consumable items (6.4) .......................................... 25
Copyright (1.4) ........................................................... 4
Design of major parts (3.3) ...................................... 11
Direction of rotation (5.3) ......................................... 20
Disassembly (6.8) .................................................... 26
Disclaimer (1.3) .......................................................... 4
Dismantling (6.8, Disassembly) ............................... 26
Drawings (8) ............................................................ 36
Duty conditions (1.5) .................................................. 4
Electrical connections (4.8) ..................................... 17
End of product life (2.5) ........................................... 10
Examination of parts (6.9) ....................................... 28
Fastener torques (6.6) ............................................. 26
Faults; causes and remedies (7) ............................. 34
Forces and moments (4.6.3) ................................... 15
Foundation (4.3) ...................................................... 12
General arrangement drawing (8.6) ........................ 46
General assembly drawings (8) ............................... 36
Grouting (4.4) ........................................................... 13
Guarding (5.4) .......................................................... 20
Handling (2.2) .......................................................... 10
Hydraulic, mechanical and electrical duty (5.9) ....... 22
Inspection (6.2.1 and 6.2.2) ..................................... 23
Installation (4) .......................................................... 12
Interchangeability charts (8.7) ................................. 46
Lifting (2.3) ............................................................... 10
Location (4.1) ........................................................... 12
Lubrication (5.1.1, 5.2 and 6.2.3)
Lubrication schedule (5.2.4) .................................... 19
Maintenance (6) ....................................................... 22
Maintenance schedule (6.2) .................................... 23
Name nomenclature (3.2) ........................................ 11
Nameplate (1.7.1) ...................................................... 8
Operating limits (3.4.1) ............................................ 12
Options (8) ............................................................... 36
Ordering spare parts (6.3.1) .................................... 25
Part assemblies (4.2) ............................................... 12
Parts lists (8) ............................................................ 36
Performance (3.4) .................................................... 12
Piping (4.6) .............................................................. 14
PAGE
Pre-commissioning (5.1) ..........................................18
Priming and auxiliary supplies (5.5) .........................20
Protection systems (4.9) ..........................................17
Reassembly (6.10, Assembly) .................................29
Receipt and unpacking (2.1) ....................................10
Recommended fill quantities (see 3.4.2) ..................12
Recommended grease lubricants (5.2.2) .................19
Recommended oil lubricants (5.2.1) ........................19
Recommended spares (6.4) .....................................25
Recycling (2.5) .........................................................10
Renewal clearances (6.7) ........................................26
Replacement parts (6.3 and 6.4) ..............................25
Running the pump (5.7) ...........................................21
Safety action (1.6.3) ................................................... 5
Safety labels (1.7.2) ................................................... 8
Safety markings (1.6.1) .............................................. 5
Safety, protection systems (1.6 and 4.9)
Sectional drawings (8) ..............................................36
Sound pressure level (1.9, Noise level) ..................... 9
Sources, additional information (10.3) .....................47
Spare parts (6.3) ......................................................25
Specific machine performance (1.8) .......................... 8
Starting the pump (5.6).............................................20
Stop/start frequency (5.7.6) ......................................22
Stopping and shutdown (5.8) ...................................22
Storage, pump (2.4) .................................................10
Storage, spare parts (6.3.2) .....................................25
Supplementary manuals or information sources ......47
Supplementary User Instructions (10.1)...................47
Tools required (6.5) ..................................................25
Torques for fasteners (6.6) .......................................26
Trouble-shooting (see 7) ..........................................34
Vibration (5.7.5) ........................................................21
Page 3 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
1 INTRODUCTION AND SAFETY
1.1 General
These Instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilising sophisticated quality techniques and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow and
apply the present user instructions is considered
to be misuse. Personal injury, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and
equipment put into service within certain regions of
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED) and Equipment for Potentially Explosive
Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory provision
of technical documents and safety instructions. Where
applicable this document incorporates information
relevant to these Directives and Approvals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certification.)
1.3 Disclaimer
Information in these User Instructions is believed
to be complete and reliable. However, in spite of
all of the efforts of Flowserve Corporation to
provide comprehensive instructions, good
engineering and safety practice should always be
used.
Flowserve manufactures products to exacting
International Quality Management System Standards as
certified and audited by external Quality Assurance
organisations. Genuine parts and accessories have
been designed, tested and incorporated into the
products to help ensure their continued product quality
and performance in use. As Flowserve cannot test
parts and accessories sourced from other vendors the
incorrect incorporation of such parts and accessories
may adversely affect the performance and safety
features of the products. The failure to properly select,
install or use authorised Flowserve parts and
accessories is considered to be misuse. Damage or
failure caused by misuse is not covered by the
Flowserve warranty. In addition, any modification of
Flowserve products or removal of original components
may impair the safety of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
Page 4 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user seeks
the written agreement of Flowserve before start up.
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 is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but indicates
an important instruction in the assembly process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
help prevent injury to personnel and damage to
the environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
contact must be avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.
APPLYING HEAT TO REMOVE IMPELLER
There may be occasions when the impeller has either
been shrunk fit on to the pump shaft or has become
difficult to remove due to products of corrosion.
If you elect to use heat to remove the impeller, it must
be applied quickly to the impeller boss. TAKE
GREAT CARE!
Before applying heat ensure any residual hazardous
liquid trapped between the impeller and pump shaft is
thoroughly drained out through the impeller keyway to
prevent an explosion or emission of toxic vapour.
This must be carried out with the shaft in the vertical
position. On some pump sizes a cavity exists in the
impeller bore so on occasions a significant volume of
liquid may drain out.
Page 5 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
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.
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
If the temperature is greater than 80 ºC (175 ºF) or
below -5 ºC (20 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care must
be taken to avoid exposure to the liquid by appropriate
siting of the pump, limiting personnel access and by
operator training. If the liquid is flammable and/or
explosive, strict safety procedures must be applied.
Gland packing must not be used when pumping
hazardous liquids.
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
in writing, so that their force, due to internal pressure,
acts on the pump flange.
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 pump and mechanical seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow
rate with no back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/vibration.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
• Avoid excess temperature
• Prevent build up of explosive mixtures
• Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
For ATEX, both electrical and non-electrical equipment
must meet the requirements of European Directive
94/9/EC. Always observe the regional legal Ex
requirements eg Ex electrical items outside the EU may
be required certified to other than ATEX eg IECEx, UL.
1.6.4.1 Scope of compliance
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of the
specific atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the ATEX pump set
shall select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
The 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.
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LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
Temperature class
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 ºC (104 ºF); 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.
to EN13463-1
T6
T5
T4
T3
T2
T1
* The table only takes the ATEX temperature class into consideration.
Pump design or material, as well as component design or material,
may further limit the maximum working temperature of the liquid.
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 *
Consult Flowserve
Consult Flowserve
115 °C (239 °F)
180 °C (356 °F)
275 °C (527 °F)
400 °C (752 °F)
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
Temperature classification “Tx” is used when the
liquid temperature varies and the pump could be
installed in different hazarous atmospheres. In this
case the user is responsible for ensuring that the
pump surface temperature does not exceed that
permitted in the particular hazardous atmosphere.
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, 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, make regular checks
and remove dirt 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 fit an appropriate dry run protection device
(for example liquid detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
Page 7 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking.
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
For ATEX application sthe coupling must be selected
to comply with 94/9/EC. Correct coupling alignment
must be maintained.
Additional requirement for metallic pumps on
non-metallic baseplates
When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.
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, install a liquid detection device.
1.6.4.7 Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with maintenance
instructions is with the plant operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
1.7 Safety labels summary
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity, or separate documentation included with
these User Instructions.
1.7.2 Safety labels
Oil lubricated units only:
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. Where performance data has
been supplied separately to the purchaser these
should be obtained and retained with these User
Instructions if required.
Page 8 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
1 1 85
1.9 Noise level
Attention must be given to the exposure of personnel
to the noise, and local legislation will define when
guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA.
The usual approach is to control the exposure time to
the noise or to enclose the machine to reduce emitted
sound. You may have already specified a limiting
noise level when the equipment was ordered,
however if no noise requirements were defined, then
attention is drawn to the following table to give an
indication of equipment noise level so that you can
take the appropriate action in your plant.
Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.
Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected from standard
and high efficiency motors when on load directly driving
the pump. Note that a motor driven by an inverter may
show an increased noise at some speeds.
If a pump unit only has been purchased for fitting with
your own driver then the “pump only” noise levels in the
table should be combined with the level for the driver
obtained from the supplier. Consult Flowserve or a
noise specialist if assistance is required in combining
the values.
It is recommended that where exposure approaches
the prescribed limit, then site noise measurements
should be made.
The values are in sound pressure level LpA at 1 m
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.
For estimating sound power level LWA (re 1pW) then
add 17 dBA to the sound pressure value.
Motor size
and speed
kW (hp)
<0.55(<0.75) 72 72 64 65 62 64 62 64
0.75 (1) 72 72 64 66 62 64 62 64
1.1 (1.5) 74 74 66 67 64 64 62 63
1.5 (2) 74 74 66 71 64 64 62 63
2.2 (3) 75 76 68 72 65 66 63 64
3 (4) 75 76 70 73 65 66 63 64
4 (5) 75 76 71 73 65 66 63 64
5.5 (7.5) 76 77 72 75 66 67 64 65
7.5 (10) 76 77 72 75 66 67 64 65
11(15) 80 81 76 78 70 71 68 69
15 (20) 80 81 76 78 70 71 68 69
18.5 (25) 81 81 77 78 71 71 69 71
22 (30) 81 81 77 79 71 71 69 71
30 (40) 83 83 79 81 73 73 71 73
37 (50) 83 83 79 81 73 73 71 73
45 (60) 86 86 82 84 76 76 74 76
55 (75) 86 86 82 84 76 76 74 76
75 (100) 87 87 83 85 77 77 75 77
90 (120) 87 88 83 85 77 78 75 78
110 (150) 89 90 85 87 79 80 77 80
150 (200) 89 90 85 87 79 80 77 80
200 (270)
300 (400) 87
1
The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are inappropriate.
Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.
3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min
Pump
only
1 1
Pump and
Typical sound pressure level LpA at 1 m reference 20 µPa, dBA
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
87 83
90 85
Pump
only
Pump and
motor
85
86
Page 9 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
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 that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check
that this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
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.
To avoid distortion, the pump unit
should be lifted as shown.
When there are no specific lifting points on the baseplate
Before lifting the driver alone, refer to the
manufacturer’s instructions.
2.4 Storage
Store the pump in a clean, dry location
away from vibration. Leave piping connection covers
in place to keep dirt and other foreign material out of
pump casing. Turn pump at intervals to prevent
brinelling of the bearings and the seal faces, if fitted,
from sticking.
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and local regulations. If the
product contains substances that are harmful to the
environment, these should be removed and disposed
of in accordance with current regulations. This also
includes the liquids and or gases that may be used in
the "seal system" or other utilities.
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the current
regulations at all times.
Page 10 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
3 PUMP DESCRIPTION
3.1 Configurations
The LR range of pumps are horizontal split casing
volute type centrifugal pumps designed for water
works, drainage, general service and circulating
applications. They can be used with motor, steam
turbine and gasoline or diesel engine drives.
The range can have the following configurations:
LR single-stage horizontal suction and discharge nozzles.
LLR two-stage horizontal suction and discharge nozzles.
LR-S single stage horizontal suction and discharge nozzles.
LRV single-stage LR horizontal suction/discharge nozzles,
with vertical pump shaft.
3.2 Name nomenclature
The pump size will be engraved on the nameplate
typically as below:
6LR-18S
Nominal discharge branch size
Configuration – see 3.1 above
Nominal maximum impeller diameter
Tongue and groove casing rings fitted
The typical nomenclature above is the general guide
to the LR configuration description. Identify the
actual pump size and serial number from the pump
nameplate. Check that this agrees with the
applicable certification provided.
3.3 Design of major parts
3.3.1 Pump casing
The pump has its main casing gasket axial to the
shaft allowing maintenance to the rotating element by
removing the top half casing. Suction and discharge
branches are in the bottom half and therefore remain
undisturbed.
3.3.2 Impeller
The impeller is fully shrouded and may be fitted with
optional hub rings.
3.3.3 Shaft
The large diameter stiff shaft, mounted on bearings,
has a keyed drive end.
3.3.4 Pump bearings and lubrication
Ball bearings are fitted as standard and may be either
oil or grease lubricated.
Oil lubrication is only available where the pump shaft
is horizontal.
Bearing isolators or stationary labyrinths may be fitted
as an option in the bearing covers to protect the
bearings.
The LRV as standard has a liquid lubricated journal
bearing fitted at the non-drive end. This bearing is
lubricated by pumped product or from an external
clean source.
3.3.5 Bearing housing
Two grease nipples enable grease lubricated bearings
to be replenished between major service intervals.
LR-S pumps have sealed for life bearings and cannot
be re-greased.
For oil lubricated bearings, a constant level oiler is fitted.
3.3.6 Seal housing
The design enables one of a number of sealing
options to be fitted.
3.3.7 Shaft seal
The mechanical seal(s), attached to the pump shaft, seals
the pumped liquid from the environment. Gland packing
may be fitted as an option on the LR, LR-S, and LLR.
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, drive shafts etc.
Page 11 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
3.3.9 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operating limits
This product has been selected to meet the
specifications of your purchase order, see section 1.5.
The following data is included as additional information to
help with your installation. It is typical, and factors such
as temperature, materials, and seal type may influence
this data. If required, a definitive statement for your
particular application can be obtained from Flowserve.
3.4.1 Operating limits
Pumped liquid temperature limits *
Maximum ambient temperature *
Maximum soft solids in suspension *
Maximum pump speed refer to the nameplate
* Subject to written agreement from Flowserve.
-20 to +150 ºC
(-4 to +302 ºF)
-20 to +40 ºC
(-4 to +104 ºF)
up to 3 % by volume
(refer for size limits)
4 INSTALLATION
Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
4.1 Location
The pump should be located to allow room for
access, ventilation, maintenance and inspection with
ample headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped.
Refer to the general arrangement drawing for the
pump set.
4.2 Part assemblies
Motors may be supplied loose on LRV pumps,
typically on frame sizes 250 and above. It is the
responsibility of the installer to ensure that the motor
is assembled to the pump and lined up as detailed in
section 4.5.2.
4.3 Foundation
lead to failure of the pump and, as such, would be
outside the terms of the warranty.
3.4.2 Pump and impeller data
Impeller
Pump
size
1.5LLR-7 6 (0.24)
2LLR-9
2LLR-11 124.0 (4.88)
4LLR-11 17 (0.67) 157.3 (6.19)
2.5LR10 9 (0.35) 95.25 (3.75) 0.19 (0.007) 0.16 (5.4)
2.5LR-13 13 (0.51) 123.8 (4.88)
3LR-9 8 (0.31) 103.2 (4.06)
3LR-12 14.5 (0.57)
4LR-10 16.5 (0.65)
4LR-11 18 (0.71)
4LR-12 12 (0.47)
4LR-14 16 (0.63)
5LR-10 16.5 (0.65)
5LR-15
5LR-19 168.4 (6.63)
6LR-10 21 (0.83) 157.2 (6.19)
6LR-13
6LR-16
6LR-18 23.5 (0.93)
8LR-12
8LR-14
8LR-20 27 (1.06)
10LR-16 39 (1.54)
10LR-17 41 (1.61)
10LR-18 22 (0.87)
6LR-18S 26.5 (1.04) 215.9 (8.5)
8LR-18S 38 (1.50) 247.7 (9.75)
8LR-23S 23 (0.91) 235 (9.25)
10LR-14S 42.5 (1.67) 247.7 (9.75)
10LR-18S 57.5 (2.26)
12LR-14S 58.5 (2.30)
* May be up to 0.13 mm (0.005 in.) larger if casing ring and
impeller have a tendency to gall.
minimum
passage size
mm (in.)
7.5 (0.29)
17 (0.67) 0.19 (6.4)
17.5 (0.69) 157.2 (6.19)
22 (0.87) 0.19 (6.4)
Nominal
wear ring
diameter
mm (in.)
95.25 (3.75) 0.19 (0.007)
103.2 (4.06)
123.8 (4.88)
139.7 (5.5) 5LR-13 15 (0.59) 0.17 (5.8)
190.5 (7.5)
228.6 (9.0) 0.21 (7.1) 10LR-14 44.5 (1.75)
278 (10.95) 0.28 (9.46)
273.1 (10.75)
Mean radial
wear ring
clearance
mm (in.) *
0.22 (0.009)
0.22 (0.009)
0.13 (0.005) 0.47 (15.9)
Approx. oil
capacity, both
bearings
litres (fl. oz.)
0.16 (5.4) 1.5LLR-10 9 (0.35)
0.19 (6.4) 3LLR-11 10.5 (0.41) 139.9 (5.51)
0.17 (5.8)
0.16 (5.4)
0.17 (5.8)
0.16 (5.4)
0.16 (5.4)
0.19 (6.4)
0.21 (7.1)
Clearances for non-metallic wear rings are
smaller, typically 50 - 65% of those for the standard
metallic rings shown above.
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
Page 12 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
Ensure the following are met:
a) The baseplate should be mounted onto a firm
foundation, either an appropriate thickness of
quality concrete or sturdy steel framework.
(It should NOT be distorted or pulled down onto
the surface of the foundation, but should be
supported to maintain the original alignment.)
b) Install the baseplate onto packing pieces evenly
spaced and adjacent to foundation bolts.
c) Level with shims between baseplate and packing
pieces.
d) The pump and driver have been aligned before
dispatch however the alignment of pump and motor
half coupling must be checked. If this is incorrect, it
indicates that the baseplate has become twisted
and should be corrected by re-shimming.
e) Vertical pumps should be mounted following the
practices outlined for baseplate mounted pumps.
(Larger sizes may need the motor fitting after
installing the pump - refer to section 4.5.2.)
f) If the pump is driven via a universal joint drive
shaft there may be a requirement to offset the
pump shaft with respect to the driver to optimize
the universal joint drive shaft bearing life. This
offset will typically be in the range 0 to 4 degrees
depending on shaft design. Please consult the
separate User Instructions before installation.
g) Any support for the universal joint drive shaft
plummer blocks must not exhibit resonant
frequencies in the range 0.8 to 1.2 N where
N = pump running speed.
h) If not supplied, guarding shall be fitted as necessary
to meet the requirements of ISO 12100 and EN953
and or any applicable local safety regulations.
4.4 Grouting
Where applicable, grout in the foundation bolts.
After adding pipework connections and rechecking the
coupling alignment, the baseplate should then be
grouted in accordance with good engineering practice.
Fabricated steel, cast iron and epoxy baseplates can be
filled with grout. Folded steel baseplates should be
grouted to locate their packing pieces. If in any doubt,
please contact your nearest service centre for advice.
Grouting provides solid contact between the pump
unit and foundation, prevents lateral movement of
running equipment and dampens resonant vibrations.
Foundation bolts should only be fully tightened when
the grout has cured.
4.5 Initial alignment
4.5.1 Thermal expansion
The pump and motor will normally
have to be aligned at ambient temperature and
should be corrected to allow for thermal expansion at
operating temperature. In pump installations
involving high liquid temperatures, the unit should be
run at the actual operating temperature, shut down
and the alignment checked immediately.
4.5.2 Alignment methods
Ensure pump and driver are isolated
electrically and the half couplings are disconnected.
The alignment MUST be checked.
Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.
Horizontal pumps – LR, LLR and LR-S
Alignment is achieved by adding or removing shims
under the motor feet and also moving the motor
horizontally as required. In some cases where the
alignment cannot be achieved it will be necessary to
move the pump before recommencing the above
procedure.
Vertical pumps – LRV
Adding or removing shims between the motor stool
and the pump casing achieves alignment. The
motor/motor stool assembly may also have to be
moved horizontally at the interface with the pump
casing, as required.
It should be noted that the motor has a spigot
(rabbet) fit into the motor stool and it is therefore not
possible to achieve any horizontal movement at this
interface.
For couplings with narrow flanges use a dial indicator
as shown below to check both parallel and angular
alignment.
Page 13 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
Angular
4.5.3 Check for soft foot
Parallel
Maximum permissible misalignment at working
temperature:
Parallel 0.2 mm (0.008 in.) TIR
Angular 0.1 mm (0.004 in.) TIR
When checking parallel alignment, the total indicator
read-out (TIR) shown is twice the value of the actual
shaft displacement.
Align in the vertical plane first, then horizontally by
moving motor. When performing final alignment, check
for soft-foot under the driver. A TIR indicator placed on
the coupling, reading in the vertical direction, should not
indicate more than 0.05 mm (0.002 in.) movement when
any driver foot fastener is loosened.
While the pump is capable of operating with the
maximum misalignment shown above, maximum pump
reliability is obtained by near perfect alignment of 0.05
to 0.10 mm (0.002 to 0.004 in.) TIR parallel and 0.05
mm (0.002 in.) per 100 mm (4 in.) of coupling flange
diameter as TIR angular misalignment. This covers the
full series of couplings available.
Pumps with thick flanged non-spacer couplings can
be aligned by using a straight-edge across the
outside diameters of the coupling hubs and
measuring the gap between the machined faces
using feeler gauges, measuring wedge or callipers.
When the electric motor has sleeve bearings it is
necessary to ensure that the motor is aligned to run
on its magnetic centreline.
Refer to the motor manual for details.
A button (screwed into one of the shaft ends) is
normally fitted between the motor and pump shaft
ends to fix the axial position.
If the motor does not run in its
magnetic centre the resultant additional axial force
may overload the pump thrust bearing.
This is a check to ensure that there is no undue
stress on the driver holding down bolts; due to nonlevel baseplate or twisting. To check, remove all
shims and clean surfaces and tighten down driver to
the baseplate. Set a dial indicator as shown in sketch
and loosen off the holding down bolt while noting any
deflection reading on the dial test indicator - a
maximum of 0.05 mm (0.002 in.) is considered
acceptable but any more will have to be corrected by
adding shims, for example, if the dial test indicator
shows the foot lifting 0.15 mm (0.006 in.) then this is
the thickness of shim to be placed under that foot.
Tighten down and repeat the same procedure on all
other feet until all are within tolerance
Complete piping as below and see sections 4.7,
Final shaft alignment check, up to and including
section 5, Commissioning, startup, operation and
shutdown, before connecting driver and checking
actual rotation.
4.6 Piping
Protective covers are fitted to the pipe
connections to prevent foreign bodies entering during
transportation and installation. Ensure that these
covers are removed from the pump before connecting
any pipes.
4.6.1 Suction and discharge pipework
In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose
pipework that is one or two sizes larger than the
pump 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.
Take into account the available NPSH which must be
higher than the required NPSH of the pump.
Page 14 of 48 flowserve.com
LR, LRV, LLR and LR-S USER INSTRUCTIONS ENGLISH 71569088 08-10
axis
Never use the pump as a support for
piping.
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
The table in 4.6.3 summarizes the maximum forces
and moments allowed on horizontal shaft pump
casings. Refer to Flowserve when the pump shaft is
vertical.
Ensure piping and fittings are flushed
before use.
Ensure piping for hazardous liquids is arranged
to allow pump flushing before removal of the pump.
4.6.2 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 a radius as possible.
b) Pipework reducers should be conical and have a
maximum total angle of divergence of 15 degrees.
c) On suction lift the piping should be inclined up
towards the pump inlet with eccentric reducers
incorporated to prevent air locks.
d) On positive suction, the inlet piping must have a
constant fall towards the pump.
e) Flow should enter the pump suction with uniform
flow, to minimize noise and wear. This is
particularly important on large or high-speed
pumps which should have a minimum of five
diameters of straight pipe on the pump suction
between the elbow and inlet flange. See section
10.3, Reference 1, for more detail.
f) Inlet strainers, when used, should have a net `free
area' of at least three times the inlet pipe area.
g) Do not install elbows at an angle other than
perpendicular to the shaft axis. Elbows parallel
to the shaft axis will cause uneven flow.
h) Except in unusual circumstances strainers are
not recommended in inlet piping. If considerable
foreign matter is expected a screen installed at
the entrance to the wet well is preferable.
i) Fitting an isolation valve will allow easier
maintenance.
j) Never throttle pump on suction side and never
place a valve directly on the pump inlet nozzle.
Typical design – flooded suction
Discharge
isolating
valve
Note:
Ideally reducers should be limited to one pipe diameter change,
ie 150 mm (6 in.) to 200 mm (8 in.). Must have a maximum total
angle of divergence of 15 degrees.
Non
return
valve
Concentric
conical
reducer
Eccentric
conical
reducer
Suction
isolating
valve
Slope up from
pump suction
Typical design – suction lift
Discharge
isolating
valve
Notes:
1. S = Minimum submergence >3E.
2. Ideally reducers to be limited to one pipe diameter change,
ie 150 mm (6 in.) to 200 mm (8 in.). Must have a maximum
total angle of divergence of 15 degrees.
Non
return
valve
Concentric
conical
reducer
Eccentric
conical
reducer
Slope down
from pump
suction
4.6.3 Maximum forces and moments allowed on
the pump suction and discharge flanges of
horizontal shaft pumps
Pump
Discharge
Suction
See table overleaf.
Long
radius
bend
Page 15 of 48 flowserve.com
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