USER INSTRUCTIONS
WORTHINGTON SIMPSON® L and U
Installation
Operation
Horizontal, split case, volute type centrifugal pumps for
water and general service
PCN=85392721 07-12 (Based on C953KH025)
Maintenance
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
CONTENTS
PAGE
1. INTRODUCTION AND SAFETY ........................ 4
1.1 General ........................................................... 4
1.2 CE marking and approvals ............................. 4
1.3 Disclaimer ....................................................... 4
1.4 Copyright ......................................................... 4
1.5 Duty conditions ............................................... 4
1.6 Safety .............................................................. 5
1.7 Nameplate and safety labels .......................... 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 .......................... 16
4.8 Electrical connections ................................... 16
4.9 Protection systems ........................................ 17
6 MAINTENANCE ............................................... 21
6.1 General ......................................................... 22
6.2 Maintenance schedule.................................. 22
6.3 Spare parts ................................................... 24
6.4 Recommended spares and consumable items
24
6.5 Tools required ............................................... 25
6.6 Fastener torques .......................................... 25
6.7 Renewal clearances ..................................... 25
6.8 Disassembly ................................................. 25
6.9 Examination of parts ..................................... 26
6.10 Assembly ...................................................... 26
7 FAULTS; CAUSES AND REMEDIES ............... 28
8 PARTS LISTS AND DRAWINGS ...................... 30
8.1 Sectional drawing – L, double entry impeller,
grease lubricated, gland packed .................. 30
8.2 Sectional drawing – U Pump horizontal,
grease lubricated, cartridge seal .................. 31
8.3 Sectional drawing – U Pump vertival, grease
lubricated, cartridge seal .............................. 32
8.4 General arrangement drawing ...................... 33
9 CERTIFICATION .............................................. 33
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ........................................................ 33
10.1 Supplementary User Instructions ................. 33
10.2 Change notes ............................................... 33
10.3 Additional sources of information ................. 33
PAGE
5 COMMISSIONING, STARTUP, OPERATION
AND SHUTDOWN ........................................... 17
5.1 Pre-commissioning procedure ...................... 17
5.2 Pump lubricants ............................................ 18
5.3 Direction of rotation ....................................... 18
5.4 Guarding ....................................................... 19
5.5 Priming and auxiliary supplies ...................... 19
5.6 Starting the pump .......................................... 19
5.7 Running the pump ......................................... 19
5.8 Stopping and shutdown ................................ 21
5.9 Hydraulic, mechanical and electrical duty .... 21
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L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
INDEX
PAGE
Additional sources (10.3) ......................................... 33
Alignment of shafting (4.5) ....................................... 13
ATEX marking (1.6.4.2) ............................................. 7
CE marking and approvals (1.2) ................................ 4
Certification (9) ........................................................ 33
Clearances (6.7, Renewal clearances).................... 25
Commissioning and operation (5) ............................ 17
Compliance, ATEX (1.6.4.1) ...................................... 6
Configurations (3.1) ................................................. 11
Consumable items (6.4) .......................................... 24
Copyright (1.4) ........................................................... 4
Design of major parts (3.3) ...................................... 11
Direction of rotation (5.3) ......................................... 18
Disassembly (6.8) .................................................... 25
Disclaimer (1.3) .......................................................... 4
Dismantling (6.8, Disassembly) ............................... 25
Drawings (8) ............................................................ 30
Duty conditions (1.5) .................................................. 4
Electrical connections (4.8) ..................................... 16
End of product life (2.5) ........................................... 10
Examination of parts (6.9) ....................................... 26
Fastener torques (6.6) ............................................. 25
Faults; causes and remedies (7) ............................. 28
Forces and moments (4.6.2) ................................... 14
Foundation (4.3) ...................................................... 12
General arrangement drawing (8.4) ........................ 33
General assembly drawings (8) ............................... 30
Grouting (4.4) ........................................................... 13
Guarding (5.4) .......................................................... 19
Handling (2.2) .......................................................... 10
Hydraulic; mechanical and electrical duty (5.9) ....... 21
Inspection (6.2.1 and 6.2.2) ..................................... 23
Installation (4) .......................................................... 12
Lifting (2.3) ............................................................... 10
Location (4.1) ........................................................... 12
Lubrication (5.1.1) .................................................... 17
Maintenance (6) ....................................................... 21
Maintenance schedule (6.2) .................................... 22
Name nomenclature (3.2) ........................................ 11
Nameplate (1.7.1) ...................................................... 8
Operating limits (3.4.1) ............................................ 12
Ordering spare parts (6.3.1) .................................... 24
Parts lists (8) ............................................................ 30
Performance (3.4) .................................................... 12
Piping (4.6) .............................................................. 14
PAGE
Priming and auxiliary supplies (5.5) .........................19
Protection systems (4.9) ..........................................17
Reassembly (6.10 Assembly) ..................................26
Receipt and unpacking (2.1) ....................................10
Recommended grease lubricants (5.2.2) .................18
Recommended oil lubricants (5.2.1) ........................18
Recommended spares (6.4) .....................................24
Re-lubrication (6.2.3) ................................................23
Renewal clearances (6.7) ........................................25
Replacement parts (6.3 and 6.4) ..............................24
Running the pump (5.7) ...........................................19
Safety (1.6) ................................................................. 5
Safety action (1.6.3) ................................................... 5
Safety labels (1.7.2) ................................................... 8
Safety markings (1.6.1) .............................................. 5
Safety, protection systems (4.9) ...............................17
Sectional drawings (8) ..............................................30
Sound pressure level (1.9, Noise level) ..................... 9
Sources, additional information (10.3) .....................33
Spare parts (6.3) ......................................................24
Specific machine performance (1.8) .......................... 8
Starting the pump (5.6).............................................19
Start/stop frequency (5.7.6) ......................................21
Stopping and shutdown (5.8) ...................................21
Storage, pump (2.4) .................................................10
Storage, spare parts (6.3.2) .....................................24
Supplementary manuals or info sources (10) ..........33
Supplementary User Instructions (10.1)...................33
Tools required (6.5) ..................................................25
Torques for fasteners (6.6) .......................................25
Trouble-shooting (see 7) ..........................................28
Vibration (5.7.5) ........................................................20
Page 3 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
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 purchase order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user seeks
the written agreement of Flowserve before start up.
Page 4 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
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
prevent injury to personnel and damage to the
environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
contact must be avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
in damage or breakage of components and should be
avoided.
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.
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L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
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 °C (175 °F) o r
below -5 °C (23 °F) in a restricted zone, or exceed
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, start-up, 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 excessive surface 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 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 effects 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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L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
s
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
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 temperature
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 ATEX temperature class and must not exceed the
values in the table that follows.
Temperature clas
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
65 °C (149 °F) *
80 °C (176 °F) *
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
The operator is responsible to ensure that the
specified maximum liquid temperature is not
exceeded.
Temperature classification “Tx” is used when the
liquid temperature varies and when the pump is
required to be used in differently classified potentially
explosive atmospheres. In this case the user is
responsible for ensuring that the pump surface
temperature does not exceed that permitted in its
actual installed location.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitors 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.
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.
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.
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
is (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 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
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, the 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 of a liquid detection device.
1.6.4.7 Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with maintenance
instructions is with the plant operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
1.7 Nameplate and safety labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity, 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 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
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 1 pW) 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 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
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:
Do not use the driver, bare-shaft
pump or component lifting points to lift the complete
machine. 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.
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L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
3 PUMP DESCRIPTION
3.1 Configurations
The L and U 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:
L single-stage horizontal suction and discharge nozzles.
U two-stage horizontal suction and discharge nozzles.
LV single-stage horizontal suction/discharge, vertical shaft.
UV two-stage horizontal suction/discharge, vertical shaft.
3.2 Name nomenclature
The pump size will be engraved on the nameplate
typically as below:
6 L-13
Nominal discharge branch size (inch)
Configuration – see 3.1 above
Nominal maximum impeller diameter (inch)
The typical nomenclature above is the general guide
to the 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 and are grease lubricated as
standard. There is an option of oil lubrication when
the pump is intended for horizontal mounting.
Bearing isolators or stationary labyrinths may be fitted
as an option in the bearing covers to protect the
bearings.
Vertically built pumps have 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.
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 L and U.
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.
3.3.9 Accessories
Accessories may be fitted when specified by the
customer.
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L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
Impeller
Mean radial
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)
3.4.2 Pump and impeller data
Pump
size
3L2 15 (0.59) 112.88 (4.44) 0.09 (0.003)
3L13 19 (0.75) 112.34 (4.42) 0.22 (0.009)
4L13 28.5 (1.13) 152.00 (5.98) 0.22 (0.009)
6L3 20 (0.78) 157.00 (6.18) 0.22 (0.009)
6L11 33 (1.31) 161.52 (6.36) 0.22 (0.009)
6L13 33 (1.31) 177.39 (6.98) 0.22 (0.009)
2U13 14 (0.55) 110 .00 (4.33) 0.16 (0.006)
3U15 14 (0.55) 152.00 (5.98) 0.23 (0.009)
4U13 16 (0.63) 190.00 (7.48) 0.20 (0.008)
4U18 20 (0.79) 190.00 (7.48) 0.20 (0.008)
6U18H 41 (1.61) 248.00 (9.76) 0.28 (0.011)
* 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)
Nominal wear
ring diameter
mm (in)
wear ring
clearance
mm (in)
Clearances for non-metallic wear rings are
smaller, typically 50 - 65% of those for the standard
metallic rings shown above.
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 vertically mounted
pumps, typically on motor frame sizes 315 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, Alignment methods.
4.3 Foundation
There are many methods of installing
pump units to their foundations. The correct method
depends on the size of the pump unit, its location and
noise vibration limitations. Non-compliance with the
provision of correct foundation and installation may
lead to failure of the pump and, as such, would be
outside the terms of the warranty.
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.
Page 12 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
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
Pump and driver must be isolated
electrically and the half couplings 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 – L and U pumps
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 – LV and UV
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. The alignment values are maximums for
continuous service.
Parallel
Angular
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.
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 calipers.
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.
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L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
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.
4.5.3 Check for soft foot
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 the
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, start-up, operation and
shutdown before connecting driver and checking
actual rotation.
4.6 Piping
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.
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. It is recommended that expansion joints
use threaded rod to limit any forces of this type
The table in 4.6.2 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 Maximum forces and moments allowed on
the pump suction and discharge flanges
of horizontal shaft pumps
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
See table overleaf.
piping.
Never use the pump as a support for
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L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
Type and
size
3L2
3L13
4L13
6L3
6L11
6L13
2U13
3U15
4U13
4U18
6U18H
Notes:
1. F= External force, tensile or compression
M=External moment, cw or ccw
2. Forces and Moments may be applied simultaneously in any
direction.
3. Values apply to all materials.
4. Higher loads may be acceptable, if direction and magnitude of
individual loads are known, but these need written approval
from Flowserve.
5. Pumps must be on rigid foundations and baseplates fully
grouted.
Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz
3680
(826)
2940
(661)
4410
(991)
5880
(1322)
5880
(1322)
5880
(1322)
2350
(529)
3680
(826)
4410
(991)
4410
(991)
5880
(1322)
2880
(648)
2310
(519)
3470
(779)
4620
(1039)
4620
(1039)
4620
(1039)
1850
(415)
2880
(648)
3470
(779)
3470
(779)
4620
(1039)
Maximum forces (F) in N (lbf) and maximum moments (M) in Nm (lbf•ft)
Suction Discharge
2100
(472)
1680
(378)
2520
(566)
3.36
(755)
3.36
(755)
3.36
(755)
1340
(302)
2100
(472)
2520
(566)
2520
(566)
3.36
(755)
2120
(1563)
1700
(1254)
2550
(1880)
3400
(2507)
3400
(2507)
3400
(2507)
1360
(1003)
2120
(1563)
2550
(1880)
2550
(1880)
3400
(2507)
1120
(826)
900
(664)
1350
(996)
1800
(1327)
1800
(1327)
1800
(1327)
720
(531)
1120
(826)
1350
(996)
1350
(996)
1800
(1327)
4.6.3 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.
1500
(1106)
120
(885)
1800
(1327)
2400
(1770)
2400
(1770)
2400
(1770)
960
(708)
1500
(1106)
1800
(1327)
1800
(1327)
2400
(1770)
1540
(346)
1540
(346)
1920
(432)
2880
(648)
2880
(648)
2880
(648)
1030
(230)
1540
(346)
1920
(432)
1920
(432)
2880
(648)
6. .Pump/baseplate should not be used as pipe anchor. Suction
and discharge piping should be anchored as close as possible
to the pump flanges to reduce vibration and prevent strain on
the pump casing. Expansion joints are recommended. They
must be properly tied and located on the side of the pipe anchor
away from the pump.
7. The pump mounting bolt torques specified must be used to prevent
relative movement between the pump casing and baseplate. (See
section 6.6 Fastener Torques.) The bolt material must have a
minimum yield strength of 600 N/mm² (87 000 lb/in²).
1760
(396)
1760
(396)
2200
(495)
3300
(742)
3300
(742)
3300
(742)
1170
(263)
1760
(396)
2200
(495)
2200
(495)
3300
(742)
1280
(288)
1280
(288)
160
(360)
2400
(540)
2400
(540)
2400
(540)
850
(192)
1280
(288)
160
(360)
160
(360)
2400
(540)
880
(649)
880
(649)
1100
(811)
1650
(1217)
1650
(1217)
1650
(1217)
590
(431)
880
(649)
1100
(811)
1100
(811)
1650
(1217)
480
(354)
480
(354)
600
(442)
900
(664)
900
(664)
900
(664)
320
(235)
480
(354)
600
(442)
600
(442)
900
(664)
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,
i.e. 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
640
(472)
640
(472)
800
(590)
1200
(885)
1200
(885)
1200
(885)
430
(314)
640
(472)
800
(590)
800
(590)
1200
(885)
Suction
isolating
valve
Slope up from
pump suction
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L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
Typical design – suction lift
Discharge
isolating
valve
Notes:
1. S = Minimum submergence >3E.
2. Ideally reducers to be limited to one pipe diameter change,
i.e. 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
Long
radius
bend
4.6.4 Discharge piping
See section 4.6.3 for typical pipework design.
A non-return valve should be located in the discharge
pipework to protect the pump from excessive back
pressure and hence reverse rotation when the unit is
stopped.
Pipework reducers should have a maximum total
angle of divergence of 9 degrees.
Fitting an isolation valve will allow easier maintenance.
4.6.5 Auxiliary piping
4.6.5.1 Drains
Pipe pump casing drains and gland leakage to a
convenient disposal point.
4.6.5.2 Pumps fitted with packed gland
When suction pressure is below ambient pressure it
is necessary to feed the gland packing with liquid to
provide lubrication and prevent the ingress of air.
This is normally achieved with a supply from the
pump discharge volute to the stuffing box. A control
valve or orifice plate may have been fitted into the
supply line to control the pressure to the
gland/stuffing box.
the gland at 1 bar (15 psi) above suction pressure is
recommended.
4.6.5.3 Pumps fitted with mechanical seals
Single seals requiring re-circulation will normally be
provided with the auxiliary piping from pump casing
already fitted.
If the seal requires an auxiliary quench then a
connection must be made to a suitable source of
liquid flow, low pressure steam or static pressure from
a header tank. Recommended pressure is 0.35 bar
(5 psi) or less. Check General arrangement drawing.
Special seals may require different auxiliary piping to
that described above. Consult separate User
Instructions and or Flowserve if unsure of correct
method or arrangement.
For pumping hot liquids, to avoid seal damage, it is
recommended that any external flush/cooling supply
be continued after stopping the pump.
4.6.6 Final checks
Check the tightness of all bolts in the suction and
discharge pipework. Check also the tightness of all
foundation bolts.
4.7 Final shaft alignment check
After connecting piping to the pump, rotate the shaft
several times by hand to ensure there is no binding
and all parts are free.
Recheck the coupling alignment, as previously
described, to ensure no pipe strain. If pipe strain
exists, correct piping.
4.8 Electrical connections
Electrical connections must be made
by a qualified Electrician in accordance with relevant
local, national and international regulations.
It is important to be aware of the EUROPEAN
DIRECTIVE on potentially explosive areas where
compliance with IEC60079-14 is an additional
requirement for making electrical connections.
It is important to be aware of the EUROPEAN
DIRECTIVE on electromagnetic compatibility when
wiring up and installing equipment on site. Attention
must be paid to ensure that the techniques used during
If the pumped liquid is dirty and cannot be used for
sealing, a separate clean compatible liquid supply to
wiring/installation do not increase electromagnetic
emissions or decrease the electromagnetic immunity of
the equipment, wiring or any connected devices. If in
any doubt contact Flowserve for advice.
Page 16 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
The motor must be wired up in
accordance with the motor manufacturer's instructions
(normally supplied within the terminal box) including
any temperature, earth leakage, current and other
protective devices as appropriate. The identification
nameplate should be checked to ensure the power
supply is appropriate.
A device to provide emergency stopping must be
fitted.
If not supplied pre-wired to the pump unit, the
controller/starter electrical details will also be supplied
within the controller/starter.
For electrical details on pump sets with controllers
see the separate wiring diagram.
See section 5.3, Direction of rotation
before connecting the motor to the electrical supply.
4.9 Protection systems
The following protection systems are
recommended particularly if the pump is installed in a
potentially explosive area or is handling a hazardous
liquid. If in doubt consult Flowserve.
If there is any possibility of the system allowing the
pump to run against a closed valve or below
minimum continuous safe flow a protection device
should be installed to ensure the temperature of the
liquid does not rise to an unsafe level.
If there are any circumstances in which the system
can allow the pump to run dry, or start up empty, a
power monitor should be fitted to stop the pump or
prevent it from being started. This is particularly
relevant if the pump is handling a flammable liquid.
If leakage of product from the pump or its associated
sealing system can cause a hazard it is
recommended that an appropriate leakage detection
system is installed.
To prevent excessive surface temperatures at
bearings it is recommended that temperature or
vibration monitoring are carried out. (See sections
5.6.4 and 5.6.5.)
If a defect of cooling can lead to temperature higher
than those acceptable a system of cooling
surveillance must be installed.
Except when explicitly required by the customer in
the specifications, when a possibility of reverse
rotation exists the customer must install a reverse
rotation protection device.
The customer must install all equipment required to
avoid water hammer.
5 COMMISSIONING, STARTUP,
OPERATION AND SHUTDOWN
These operations must be carried
out by fully qualified personnel.
5.1 Pre-commissioning procedure
5.1.1 Lubrication
Determine the mode of lubrication of the pump set,
eg grease, oil, product lubrication etc.
For oil lubricated pumps, fill the bearing
housing with correct grade of oil to the correct level, ie
sight glass or constant level oiler bottle.
When fitted with a constant level oiler, the bearing
housing should be filled by unscrewing or hinging back
the transparent bottle and filling the bottle with oil.
Where an adjustable body Denco oiler is fitted this should
be set to the height shown in the following diagram:
The oil filled bottle should then be refitted so as to
return it to the upright position. Filling should be
repeated until oil remains visible within the bottle.
Page 17 of 36 flowserve.com
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Grease
g
rade
NLGI 2*
-
20 to 100 ºC
BP
Elf
Fuchs
Esso
Mobil
Q8
Shell
Texaco
SKF
5.2 Pump lubricants
5.2.1 Recommended oil lubricants
Oil Splash / force feed / purge and pure**oil mist lubrication
Viscosity cSt @ 40 ºC 32
Oil temperature range *
Centrifugal
Oil companies and
* Note that it normally takes 2 hours for bearing temperature to stabilize and the final temperature will depend on the ambient, r/min, pumpage
temperature and pump size. Also some oils have a very low pour point and good viscosity index which extend the minimum temperature
capability of the oil. Always check the grade capability where the ambient is less than -5 ºC (23 ºF).
** If preheated pure oil mist lubrication LCS LSO 68 or LSO 100 synthetic oils are permitted.
†
Use LSC for oil mist. Oil parameters provide flash point > 166 ºC (331 ºF), density >0.87@15 ºC (59 ºF), pour point of -10 ºC (14 ºF) or lower.
Designation to ISO 3448
pump lubrication
lubricants
and DIN51524 part 2
BP Castrol †
ESSO †
ELF/Total †
LSC (for oil mist)
ExxonMobil †
Q8 †
Shell †
Chevron Texaco †
Wintershall (BASF Group) †
Fuchs †
5.2.2 Recommended grease lubricants
Temperature
range
Designation
acc. to DIN
* NLGI 2 is an alternative grease and is not to be mixed with other grades
** Standard pre-packed grease for fitted antifriction bearings. NLGI 3
greases are preferred for pumps with vertically mounted shaft.
NLGI 3**
(-4 to 212 ºF)
KP3K-20
Energrease LS-EP3
Multis EP3
RENOLIT EP3
Beacon EP3
Mobilux EP3
Rembrandt EP3
Alvania EP2
Multifak EP3
Energrease LS-EP2
RENOLIT EP2
Rembrandt EP2
5.2.3 Lubrication schedule
5.2.3.1 Oil lubricated bearings
Normal oil change intervals are 4 000 operating hours
or at least every 6 months. For pumps on hot service
or in severely damp or corrosive atmosphere, the oil
will require changing more frequently. Lubricant and
bearing temperature analysis can be useful in
optimizing lubricant change intervals.
-5 to 65 ºC
(23 to 149 ºF)
ISO VG 32
32 HLP
Energol HLP-HM 32
NUTO HP 32
ELFOLNA DS 32
Azolla ZS 32
LSO 32 (Synthetic oil)
Mobil DTE 24
Q8 Haydn 32
Shell Tellus 32
Rando HD 32
Wiolan HS32
Renolin CL 32
-20 to 100 ºC
(-4 to 212 ºF)
KP2K-25
Multis EP2
Beacon EP2
Mobilux EP2
Alvania EP2
Multifak EP2
LGEP 2
Energol HLP-HM 46
LSO 46 (Synthetic oil)
used if checks show that the rubber oil seals will not be
adversely affected.
The bearing outer ring temperature may be allowed to
rise to 50 ºC (90 ºF).above ambient, but should not
exceed 93 ºC (200 ºF). If the oil temperature is
monitored then it shall not exceed 82 °C (180 °F). A
continuously rising temperature, or an abrupt rise,
indicates a fault.
5.2.3.2 Grease lubricated bearings
When grease nipples are fitted, one charge between
grease changes is advisable for most operating
conditions, ie 2 000 hours interval.
Normal intervals between grease changes are 4 000
hours or at least every 6 months.
The characteristics of the installation and severity of
service will determine the frequency of lubrication.
Lubricant and bearing temperature analysis can be
useful in optimising lubricant change intervals.
The bearing temperature may be allowed to rise to
55 °C (99 °F) above ambient but should not exceed
95 °C (204 °F). For most operating conditions a quality
grease having a lithium soap base and NLGI
consistency of No 2 or No 3 is recommended. The
drop point should exceed 175 °C (350 °F).
The lubricating oil should be a high quality mineral oil
having foam inhibitors. Synthetic oils may also be
bases, thickeners or additives.
46
-5 to 78 ºC
(23 to 172 ºF)
ISO VG 46
46 HLP
Energol HLP-HM 68
NUTO HP 46
ELFOLNA DS 46
Azolla ZS 46
LSO 68 (Synthetic oil)
Mobil DTE 25
Q8 Haydn 46
Shell Tellus 46
Rando HD 46
Wiolan HS46
Renolin CL 46
68
-5 to 80 ºC
(23 to 176 ºF)
ISO VG 68
68 HLP
NUTO HP 68
ELFOLNA DS 68
Azolla ZS 68
Mobil DTE 26
Q8 Haydn 68
Shell Tellus 68
Rando HD 68
Wiolan HS68
Renolin CL 68
Never mix greases containing different
Page 18 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
(1) Possible
priming
points
5.3 Direction of rotation
Ensure the pump is given the same
rotation as the pump direction arrow cast on the
pump casing.
To avoid dry running the pump must either be filled
with liquid or have the flexible coupling disconnected
before driver is switched on.
If maintenance work has been carried
out to the site's electricity supply, the direction of
rotation should be re-checked as above in case the
supply phasing has been altered.
5.4 Guarding
Guarding is supplied fitted to the pump set.
In member countries of the EU and EFTA, it is a legal
requirement that fasteners for guards must remain
captive in the guard to comply with the Machinery
Directive 2006/42/EC. When releasing such guards,
the fasteners must be unscrewed in an appropriate
way to ensure that the fasteners remain captive.
Whenever guarding is removed or disturbed ensure
that all the protective guards are securely refitted prior
to start-up.
5.5 Priming and auxiliary supplies
5.5.2 Suction lift with foot valve fitted
Fill suction pipe and casing with liquid at a pressure
of 1 to 2 bar from an external source. Vent as
described in section 5.5.1.
5.5.3 Suction lift without foot valve
Pump casing vents on the suction volute must be
connected to an external vacuum pump priming
system. If in doubt please consult Flowserve.
Possible
priming
points
To vacuum
pump
Ensure all electrical, hydraulic,
pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.
Ensure the inlet pipe and pump casing
are completely full of liquid before starting continuous
duty operation.
5.5.1 Suction pressure above atmospheric
pressure
Horizontal pumps: Open vent connection (1) on top of
the pump upper casing to allow the trapped air to
escape. Let liquid run out until free from air bubbles.
Vertical pumps: open vent connection (1) at the front
of the upper half casing and disconnect the seal flush
line at the mechanical seal/stuffing box to allow the
trapped air to escape. Let liquid run out until free
from air bubbles.
5.6 Starting the pump
a) Ensure flushing and/or cooling/
heating liquid supplies are turned ON before
starting the pump.
b) CLOSE the outlet valve.
c) OPEN all inlet valves.
d) Prime the pump.
e) Ensure all vent connections are closed
before starting.
f) Start motor and check outlet pressure.
g) If the pressure is satisfactory, SLOWLY open
outlet control valve.
h) Do not run the pump with the
outlet valve closed for a period longer than 10
seconds.
i) If NO pressure, or LOW pressure, STOP the
pump. Refer to section 7, Faults; causes and
remedies, for fault diagnosis.
Page 19 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
5.7 Running the pump
5.7.1 Venting the pump
Vent the pump to enable all trapped air to
escape taking due care with hot or hazardous liquids.
Under normal operating conditions, after the pump
has been fully primed and vented, it should be
unnecessary to re-vent the pump.
5.7.2 Pumps fitted with packed gland
- P
If the pump has a packed gland there must be some
leakage from the gland. Gland nuts should initially be
finger-tight only. Leakage should take place soon
after the stuffing box is pressurised.
The gland must be adjusted evenly to give
visible leakage and concentric alignment of the gland
to avoid excess temperature. If no leakage takes
place the packing will begin to overheat. If
overheating takes place the pump should be stopped
and allowed to cool before being re-started. When
the pump is re-started, check to ensure leakage is
taking place at the packed gland.
If hot liquids are being pumped it may be necessary
to slacken the gland nuts to achieve leakage.
The pump should be run for 30 minutes with steady
leakage and the gland nuts then tightened by 10
degrees at a time until leakage is reduced to an
acceptable level, normally a minimum of 120 drops
per minute is required. Bedding in of the packing
may take another 30 minutes.
Care must be taken when adjusting the gland
on an operating pump. Safety gloves are essential.
Loose clothing must not be worn to avoid being
caught up by the pump shaft. Shaft guards must be
replaced after the gland adjustment is complete.
Never run gland packing dry, even for
a short time.
+ P
5.7.3 Pumps fitted with mechanical seal
Mechanical seals require no adjustment. Any slight
initial leakage will stop when the seal is run in.
Before pumping dirty liquids it is advisable, if
possible, to run in the pump mechanical seal using
clean liquid to safeguard the seal face.
External flush or quench should be
started before the pump is run and allowed to flow for
a period after the pump has stopped.
Never run a mechanical seal dry,
even for a short time.
5.7.4 Bearings
If the pumps are working in a potentially
explosive atmosphere, temperature or vibration
monitoring at the pump bearings is recommended.
If bearing temperatures are to be monitored it is
essential that a benchmark temperature is recorded
at the commissioning stage and after the bearing
temperature has stabilized.
• Record the bearing temperature (t) adjacent to
the bearing and the ambient temperature (ta)
• Estimate the likely maximum ambient
temperature (tb)
• Set the alarm at (t+tb-ta+5) °C [(t+tb-ta+10) °F]
and the trip at 100 °C (212 °F) for oil lubrication
and 105 °C (220 °F) for grease lubrication
It is important, particularly with grease lubrication, to
keep a check on bearing temperatures. After start up
the temperature rise should be gradual, reaching a
maximum after approximately 1.5 to 2 hours. This
temperature should then remain constant or
marginally reduce with time. (Refer to section 6.2.3.2
for further information.)
5.7.5 Normal vibration levels, alarm and trip
For guidance, pumps generally fall under a classification
for rigid support machines within the International
rotating machinery standards and the recommended
maximum levels below are based on those standards.
Alarm and trip values for installed
pumps should be based on the actual measurements
(N) taken on site on the bearing housings of the
pump in the fully commissioned as new condition.
The example (N) value is given for the preferred
operating flow region (typically this may extend to 70
to 120% of the pump best efficiency point); outside
Page 20 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
the preferred flow region the actual vibration
experienced may be multiplied by up to two.
These standard values can vary with the rotational
speed and the power absorbed by the pump. For any
special case, contact your nearest Flowserve office.
Measuring vibration at regular intervals will show any
deterioration in pump or system operating conditions.
Vibration velocity –
unfiltered
Normal N
Alarm N x 1.25
Shutdown trip N x 2.0
Horizontal pumps
mm/s (in./s) r.m.s.
≤ 5.6 (0.22)
≤ 7.1 (0.28)
≤ 11.2 (0.44)
5.7.6 Stop/start frequency
Pump sets are normally suitable for the number of
equally spaced stop/starts per hour shown in the
table below. Check actual capability of the driver and
control/starting system before commissioning.
Motor rating kW (hp)
Up to 15 (20) 15
Between 15 (20) and 90 (120)
Above 90 (120) 6
Maximum stop/starts per hour
10
Where duty and standby pumps are installed it is
recommended that they are run alternately every week.
5.8 Stopping and shutdown
a) Close the outlet valve, but ensure
that the pump runs in this condition for no more
than a few seconds.
b) Stop the pump.
c) Switch off flushing and/or cooling/heating liquid
supplies at a time appropriate to the process.
d) For prolonged shut-downs and
especially when ambient temperatures are likely
to drop below freezing point, the pump and any
cooling and flushing arrangements must be
drained or otherwise protected.
5.9 Hydraulic, mechanical and electrical
duty
This product has been supplied to meet the
performance specifications of your purchase order,
however it is understood that during the life of the
product these may change. The following notes may
help the user decide how to evaluate the implications
of any change. If in doubt contact your nearest
Flowserve office.
5.9.1 Specific gravity (SG)
Pump capacity and total head in meters (ft.) 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.
5.9.2 Viscosity
For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity. Also for a given flow rate the power
absorbed increases with increased viscosity, and
reduces with reduced viscosity. It is important that
checks are made with your nearest Flowserve office if
changes in viscosity are planned.
5.9.3 Pump speed
Changing pump speed effects flow, total head, power
absorbed, NPSHR, noise and vibration. Flow varies in
direct proportion to pump speed, head varies as speed
ratio squared and power varies as speed ratio cubed.
The new duty, however, will also be dependent on the
system curve. If increasing the speed, it is important
therefore to ensure the maximum pump working
pressure is not exceeded, the driver is not overloaded,
NPSHA > NPSHR, and that noise and vibration are
within local requirements and regulations.
5.9.4 Net positive suction head (NPSHA)
NPSH available (NPSHA) is a measure of the head
available in the pumped liquid, above its vapor
pressure, at the pump suction branch.
NPSH required (NPSHR) is a measure of the head
required in the pumped liquid, above its vapor pressure,
to prevent the pump from cavitating. It is important that
NPSHA > NPSHR. The margin between NPSHA >
NPSHR should be as large as possible.
If any change in NPSHA is proposed, ensure these
margins are not significantly eroded. Refer to the
pump performance curve to determine exact
requirements particularly if flow has changed. If in
doubt please consult your nearest Flowserve office
for advice and details of the minimum allowable
margin for your application.
5.9.5 Pumped flow
Flow must not fall outside the minimum and
maximum continuous safe flow shown on the pump
performance curve and or data sheet.
Page 21 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
6 MAINTENANCE
6.1 General
It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work
is carried out by authorized and qualified personnel
who have adequately familiarized themselves with
the subject matter by studying this manual in detail.
(See also section 1.6.)
Any work on the machine must be performed when it
is at a standstill. It is imperative that the procedure
for shutting down the machine is followed, as
described in section 5.8.
Guard fasteners must remain captive during
dismantling of guards as described in section 5.4.
On completion of work all guards and safety devices
must be re-installed and made operative again.
Before restarting the machine, the relevant
instructions listed in section 5 Commissioning, start
up, operation and shut down must be observed.
Oil and grease leaks may make the ground
slippery. Machine maintenance must always
begin and finish by cleaning the ground and the
exterior of the machine.
If platforms, stairs and guard rails are required for
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
carried out. The positioning of these accessories
must not limit access or hinder the lifting of the part to
be serviced.
When air or compressed inert gas is used in the
maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
protection.
Do not spray air or compressed inert gas on skin.
Do not direct an air or gas jet towards other people.
Never use air or compressed inert gas to clean clothes.
Before working on the pump, take measures to
prevent an uncontrolled start. Put a warning board
on the starting device with the words:
"Machine under repair: do not start".
With electric drive equipment, lock the main switch
open and withdraw any fuses. Put a warning board
on the fuse box or main switch with the words:
"Machine under repair: do not connect".
Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
6.2 Maintenance schedule
It is recommended that a maintenance plan
and schedule is adopted, in line with these User
Instructions. It should include the following:
a) The pump must be completely vented and
drained and rendered inert before any
disassembly operation.
b) Any auxiliary systems installed must be monitored,
if necessary, to ensure they function correctly.
c) During cleaning of the pump ensure the
compatibility between the cleaning products and
the gaskets.
d) Verify the condition of the gaskets.
e) Gland packings must be adjusted correctly to
give visible leakage and concentric alignment of
the gland follower to prevent excessive
temperature of the packing or follower.
Mechanical seals should present no leakage
f) Check for any leaks from gaskets and seals. The
correct functioning of the shaft seal must be
checked regularly.
g) Check bearing lubricant level and condition, and
if the hours run show a lubricant change is
required.
h) Check that the duty condition is in the safe
operating range for the pump.
i) Check vibration, noise level and surface
temperature at the bearings to confirm
satisfactory operation.
j) Check the tightness of the connections.
k) Check dirt and dust is removed from areas around
close clearances, bearing housings and motors.
l) Check coupling alignment and re-align if necessary.
m) Verify the correct operation of the system.
The equipment used for maintenance and
disassembly in an ATEX zone must be in conformity
with the requirements zone.
Our specialist service personnel can help with
preventative maintenance records and provide
condition monitoring for temperature and vibration to
identify the onset of potential problems.
Page 22 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
If any problems are found the following sequence of
actions should take place:
a) Refer to section 7, Faults; causes and remedies,
for fault diagnosis.
b) Ensure equipment complies with the
recommendations in this manual.
c) Contact Flowserve if the problem persists.
6.2.1 Routine inspection (daily/weekly)
The following checks should be made
and the appropriate action taken to remedy any
deviations:
a) Check operating behaviour. Ensure noise,
vibration and bearing temperatures are normal.
b) Check that there are no abnormal fluid or
lubricant leaks (static and dynamic seals) and
that any sealant systems (if fitted) are full and
operating normally.
c) Check that shaft seal leaks are within acceptable
limits.
d) d) Check the level and condition of oil lubricant.
On grease lubricated pumps, check running hours
since last recharge of grease or complete grease
change.
e) Check any auxiliary supplies e.g. heating/cooling,
if fitted, are functioning correctly.
Refer to the manuals of any associated
equipment for routine checks needed.
6.2.2 Periodic inspection (six monthly)
If however a sight glass has been fitted then regular
checks should be made to ensure the level is
maintained at the centre of the glass window.
Refer to section 5.1.1 for methods of oil fill, section
5.2.1 for oil grade recommendations and 5.2.4 for the
schedule and temperature limits.
6.2.3.2 Grease lubrication
See section 5.1.1 for grease
recommendations.
Regrease - via grease nipples every 2 000 hours or
sooner depending on the severity of the application.
a) It is important not to under or over grease the
bearings as this will lead to overheating and
premature failure. Grease lubricated bearing
housings have grease nipples fitted in the
bearing housings.
b) The maximum allowable operating temperatures for
anti-friction bearings will vary from unit to unit,
depending on ambient and fluid temperature. The
rise above ambient should not normally exceed 55 °C
(99 °F) or a combined maximum of 95 °C (204 °F).
c) A continuously rising temperature or an abrupt
temperature rise indicates a problem. If these
symptoms occur, stop the pump immediately and
investigate the cause.
a) Check foundation bolts for
security of attachment and corrosion.
b) Check pump running records for hourly usage to
determine if bearing lubricant requires changing.
c) The coupling should be checked for correct
alignment and worn driving elements.
Refer to the manuals of any associated
equipment for periodic checks needed.
6.2.3 Re-lubrication
Lubricant and bearing temperature analysis can be
useful in optimizing lubricant change intervals. In
general however, the following is recommended.
6.2.3.1 Oil lubrication
Maintaining the correct oil level is very
important.
If the pump is supplied with a constant level oiler the oil
level will be automatically maintained and as long as oil
is visible in the glass bottle there is no need to refill.
TIME
Grease change - every 4 000 hours or sooner
depending on the severity of the application.
a) Remove the bearing housing from the rotor
assembly.
b) Brush the bearing housing with hot kerosene (100
to 115 °C/212 to 240 °F) or other non-toxic solvent .
c) Clean and flush out the housing with a light
mineral oil.
d) Do not use waste oil to clean the housing.
Page 23 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
To clean the bearings:
a) Wipe off as much grease as possible with a clean
lint-free cloth.
b) Brush bearings with hot kerosene (80 to 90 °C/
175 to 195 °F) while gently spinning the outer
bearing ring.
c) Spin each ball to ensure that it is clean.
To remove badly oxidized grease that refuses to
come off:
a) Support the rotor in a vertical position and
immerse the bearing in hot kerosene or a mixture
of alcohol and light mineral solvent.
b) Gently spin the bearing outer ring.
c) Dry and reflush the bearing with clean light oil.
d) It is important not to under or over grease the
bearings as this will lead to overheating and
premature failure. It is recommended that the
bearings be filled with grease using a suitable
spatula. In addition the housings should be no
more than half filled.
6.2.4 Mechanical seals
No adjustment is possible. When leakage reaches
an unacceptable level the seal will need replacement.
6.2.5 Gland packing
The stuffing box gland can be backed off for re-packing
or to enable the addition of extra rings of packing.
The stuffing box is normally supplied with a lantern
ring to enable a clean or pressurised flush to the
centre of the packing. If not required, this can be
replaced by an extra two rings of packing.
There must always be a small leakage, normally a
minimum of 120 drops per minute to atmosphere to
lubricate and cool the packing is required.
6.2.6 Internal coating
If the pump has an internal coating, this coating must
be inspected periodically. Any wear or cracks of the
coating found must be immediately repaired. Failure
to do this may lead to accelerated wear of the coating
during operation and corrosion of the exposed base
metal, depending on the material and pumped liquid.
Special attention must be paid to the coating edges.
Any loss of coating material is considered to be
normal wear and tear on the pump and is not
considered as warranty. Flowserve has applied the
coatings according to the supplier's instructions but
will not be held responsible for coating wear or cracks
that may develop over time.
6.3 Spare parts
6.3.1 Ordering of spares
Flowserve keep records of all pumps that have been
supplied. When ordering spares the following
information should be quoted.
1) Pump serial number.
2) Pump size.
3) Part name – taken from section 8.
4) Part number – taken from section 8.
5) Number of parts required.
The pump size and serial number are shown on the
pump nameplate.
To ensure continued satisfactory operation, replacement
parts to the original design specification should be
obtained from Flowserve. Any change to the original
design specification (modification or use of a nonstandard part) will invalidate the pump’s safety
certification.
6.3.2 Storage of spares
Spares should be stored in a clean dry area away from
vibration. Inspection and re-treatment of metallic
surfaces (if necessary) with preservative is
recommended at 6 monthly intervals.
6.4 Recommended spares and
consumable items
For start-up purposes:
1 x 4130 - complete set of gland packing
2 x 2450 - shaft sleeves
1 x 4590 - set of gaskets and seals
(optional: 2 x 4200 - mechanical seals)
Page 24 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
For 2 years operation:
1 x 3011 - set of bearings (line and thrust)
2 x 4130 - sets of gland packing
2 x 2450 - shaft sleeves
2 x 4590 - sets of gaskets and seals
2 x 4134 - lantern rings
2 x 1500 - casing wear rings
(optional: 2 x 4200 - mechanical seals
2 x 1500 - impeller wear rings)
For 4 years operation:
1 x 3011 - set of bearings (line and thrust)
2 x 4130 - sets of gland packing
2 x 2450 - shaft sleeves
2 x 4590 - sets of gaskets and seals
2 x 4134 - lantern rings
2 x 1500 - casing wear rings
1 x 2200 - impeller
(optional: 2 x 4200 - mechanical seals
2 x 1500 - impeller wear rings)
6.5 Tools required
A typical range of tools that will be required to
maintain these pumps is listed below.
Readily available in standard tool kits, and dependent
on pump size:
• Open ended spanners (wrenches) to suit up to
M 24 (7/8 in.) screws/nuts
• Socket spanners (wrenches), up to M 24 (7/8 in.)
screws
• Allen keys, up to 6 mm (¼ in.) A/F
• Range of screwdrivers
• Soft mallet
More specialized equipment:
• Bearing pullers
• Bearing induction heater
• Dial test indicator
• C-spanner (wrench) - for removing shaft nut.
(If this is difficult to source, consult Flowserve.)
See also section 6.8.1.k.
6.6 Fastener torques
Screw/bolt size
M8 (5/16 in.)
M10 (⅜ in.)
M12 (½ in.)
M16 (⅝ in.)
M20 (¾ in.)
M24 (⅞ in.)
Torque Nm (lbf·ft)
Pump feet
fasteners
-
-
63 (46)
170 (125)
340 (250)
590 (435)
All other
fasteners
10 (7)
20 (15)
34 (25
84 (62)
165 (120)
285 (210)
Non-metallic gaskets incur creep
relaxation – before commissioning the pump, check
and retighten fasteners to tightening torques stated.
6.7 Renewal clearances
As wear takes place between the impeller and casing
wear ring the overall efficiency of the pump set will
decrease. To maintain optimum efficiency it is
recommended that rings are replaced and the
impeller renovated when the radial clearance detailed
in section 3.4.2 has doubled to 0.2 to 0.6 mm (0.008
to 0.024 in.), depending on pump size and type. On
the vertical design it is recommended that the product
lubricated bearing is renewed at a diametrical
clearance of 0.5 mm (0.02 in.).
6.8 Disassembly
Refer to section 1.6, Safety, before dismantling
the pump.
Before dismantling the pump for
overhaul, ensure genuine Flowserve replacement
parts are available.
Refer to sectional drawings for part numbers and
identification.. See section 8, Parts lists and
drawings.
6.8.1 L and U
a) Isolate motor and lock off electrical supply in
accordance with local regulations.
b) Isolate suction and discharge valves.
c) Remove coupling guards and disconnect the
coupling halves.
d) Drain pump casing [1213] Remove any auxiliary
piping if applicable.
e) Remove the pump half coupling.
f) Unbolt the glands/seal covers [4120] from the casing.
(If glands are split type, remove completely.)
g) With a suitable punch, drive out the two straight
roll pins which are used on the horizontal split
flange to align the upper and lower half casings
[1214 and 1213].
h) Remove the screws, which hold the upper and
lower half of the casing together, and remove the
upper half. Tapped holes are provided in the joint
flange to enable the use of forcing bolts to loosen
the joint.
i) Lift the casing upper half [1214] using the cast on
lifting lugs where provided. Where there are no
integral lifting lugs, remove the pipe plug [6569.1]
or fittings, if used, from the volute vent connection
located on top of the casing upper half and install
a special steel lifting eye with a threaded shank to
Page 25 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
L o w e r h a l f c a s i n g
B e a r i n g h o u s i n g
D o w e l b u s h
match the pipe tap opening in the casing.
Do NOT use these methods to lift the
bottom half or complete pump casing.
6U18H only
j) Remove the bearing housing to casing screws
[6570.1] and remove the 2 dowel bushings on
each side. A tool for removing the bushings can
be easily and economically made as shown in the
following diagrams:
Material: 25 mm (1 in.) standard weight steel pipe
P u l l e r
p a r t s
6.8.2 Bearing housing assembly
NB When dismantling, for convenience at reassembly,
lay out all parts in the order in which they are removed.
Proceed as follows:
a) Remove the guards.
b) Disconnect the coupling halves. (If oil lubricated
couplings are used, drain the oil before unbolting.)
c) Unbolt the glands/seal covers [4130] from the
casing.
d) Remove the bolts that hold the upper and lower
half of the casing together and remove the upper
half [1214].
e) Tapped holes are provided in the joint flange to
enable the use of forcing bolts to loosen the joint.
f) To lift the casing upper half only, proceed as
follows. Securely hook slings around the two
integral lifting lugs on the upper half casing or,
where there are no integral lifting lugs, remove the
pipe plug [6569.1]or fittings, if used, from the volute
vent connection located on top of the casing upper
half and install a special steel lifting eye with a
threaded shank to match the pipe top opening in
the casing.
Do NOT use these methods to lift the
bottom half or complete pump casing.
g) Remove the bearing housing to casing bolts from
the end of, and beneath the bearing housing
[6570.1].
h) Lift out rotor assembly. Use care in slinging and
handling of the rotor.
i) Loosen bearing covers [3260] and remove bearing
housing [3200].
j) Remove bearing covers, bearing housings,
bearing nut and ball bearings [3011].
k) Remove glands, packing and seal cages [4120,
4130, 4134].
l) Remove shaft sleeve nuts and shaft sleeves
[2910, 2450].
m) Remove impeller(s), casing rings and impeller key
[2200, 1500, 6700].
6.9 Examination of parts
Used parts must be inspected before
assembly to ensure the pump will subsequently run
properly. In particular, fault diagnosis is essential to
enhance pump and plant reliability.
6.9.1 Casing, seal housing and impeller
Inspect for excessive wear, pitting, corrosion, erosion
or damage and any sealing surface irregularities.
Replace as necessary.
6.9.2 Shaft and sleeve (if fitted)
Replace if grooved, pitted or worn.
6.9.3 Gaskets and O-rings
After dismantling, discard and replace.
6.9.4 Bearings
It is recommended that bearings are not re-used after
any removal from the shaft.
6.10 Assembly
To assemble the pump consult the sectional drawings,
see section 8, Parts lists and drawings.
6.10.1 Impeller wear rings
a) Impeller rings (when fitted) should be heated up
to approximately 100 ºC (212 ºF) using a hotplate
or hot oil bath and then slipped onto the impeller
and pressed down to the shoulder. (Do NOT use
a steel hammer to knock them into position.)
b) Drill and tap 3 holes approximately 120 degrees
apart into the diametral mating faces of the ring
and impeller and insert socket head grub screws.
(The existing half tapped holes from the removed
impeller ring cannot be re-used.)
Page 26 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
6.10.2 Pre-assembly of casing gasket
a) Fit casing gasket to the bottom half horizontal
flange using a small amount of contact adhesive to
prevent movement when the top half is fitted. Do
not apply adhesive to the top surface of the gasket.
b) It is important that the external corner of the
casing gasket face and the stuffing box face is as
sharp as possible.
c) Ensure threads, gasket and O-ring mating faces
are clean. Apply thread sealant to non-face
sealing pipe thread fittings.
6.10.3 Bearing housing and rotating element
assembly
a) Ensure all gaskets and O-rings are renewed and
replaced in their correct position during assembly.
b) When re-assembling the impeller(s) on the shaft, it
is important to mount the impeller so that the vane
tips point away from the apparent flow direction.
The rotor always rotates toward expanding section
of the volute.
water throwers and bearing covers.[4130,
1630,4134,1500, 4120, 2540 3260]
e) Press the bearings [3011] onto the shaft. [2100]
Note where double row bearings are fitted these
must be “back to back”.
f) Tighten the bearing shaft nut.[3712] It is
recommended that a locking compound is applied
to the threads (egg Loctite 222). Apply clean
grease to the bearings and fit the bearing
housings.[3200] Fit the coupling hub.
g) Place the complete rotating assembly into the
casing and bolt the bearing housings [3200] to the
casing.[1213]
h) Centralize the impeller(s) and then tighten up the
sleeve nuts after applying a locking compound to
the threads (e.g. Loctite 222).
i) Set the seals, if fitted, to the correct working length
and tighten the seal collar screws.
j) Fit the casing upper half [1214] ensuring that
impeller rings and anti-rotation pins [1500, 6810]
are in the correct position and the casing dowel
pins are located. Ensure the shaft rotates freely.
k) Push the seal covers into place and fasten to the
casing, where fitted.
l) Pack the gland in accordance with the required
arrangement. (See drawings.)
m) Loosely tighten the gland [4120], check coupling
alignment, fit coupling drive element(s) and fit
guards.
Suction
Pump sizes 4L13, 6L11 and 6L13 have 5 rings of packing.
c) On two stage pumps (U) fit the spacer sleeve and
interstage bushing [2410, 1610 - 6U18H only]
between the impellers.
d) When mechanical seals are fitted the rotating parts
can be slid onto the sleeves (following the seal
manufacturer's instructions) before the sleeves are
fitted onto the shaft. The seal locking collars
should be left loose. Fit the sleeves, sleeve nuts
[(loosely), packing seating rings, lantern rings,
impeller rings, glands or seal seat and covers,
All other units have 4 rings of packing.
Page 27 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
7 FAULTS; CAUSES AND REMEDIES
FAULT SYMPTOM
Pump overheats an d seiz es
⇓⇓⇓⇓
Bearings have sho rt life
⇓⇓⇓⇓
Pump vi brates or is noisy
⇓⇓⇓⇓
Mechanical seal h as short life
⇓⇓⇓⇓
Mechanical seal l eaks excessivel y
⇓⇓⇓⇓
Pump requires exc essive power
⇓⇓⇓⇓
Pump loses pri me after starting
⇓⇓⇓⇓
Insu fficient pressur e developed
⇓⇓⇓⇓
Insu fficient capacity delivered
⇓⇓⇓⇓
Pump does not deliver liquid
⇓⇓⇓⇓
POSSIBLE CAUSES POSSIBLE REMEDIES
A. SYSTEM TROUBLES
Pump not primed. Check complete filling.
Pump or suction pipe not completely filled with
liquid.
Suction lift too high or level too low.
Excessive amount of air or gas in liquid. Check and purge from pipes.
Air or vapour pocket in suction line. Check suction line design for pockets.
Air leaks into suction line. Check airtight pipe then joints and gaskets.
Air leaks into pump through mechanical seal,
sleeve joints, casing joint or pipe lugs.
Foot valve too small. Investigate replacing the foot valve.
Foot valve partially clogged. Clean foot valve.
Inlet of suction pipe insufficiently submerged. Check cut out system design.
Total head of system higher than differential head
of pump.
Total head of system lower than pump design
head.
Specific gravity of liquid different from design. Consult Flowserve.
Viscosity of liquid differs from design. Consult Flowserve.
Operation at very low capacity. Measure value and check minimum permitted.
Operation at high capacity. Measure value and check maximum permitted.
Check and complete filling.
Check NPSHA>NPSHR, proper submergence,
losses at strainers and fittings.
Check airtight assembly then joints and gaskets.
Check discharge head and head losses in
discharge pipe at the valve settings. Check back
pressure is not too high.
Throttle at discharge valve or ask Flowserve if the
impeller can be trimmed.
B. MECHANICAL TROUBLES
Misalignment due to pipe strain.
Improperly designed foundation.
Shaft bent. Check shaft run outs within acceptable values.
Rotating part rubbing on stationary part internally.
Bearings worn Replace bearings.
Wearing ring surfaces worn. Replace worn wear ring/surfaces.
Impeller damaged or eroded. Replace impeller and check reason.
Check the flange connections and eliminate
strains using elastic couplings or a method
permitted.
Check setting of baseplate: tighten, adjust, grout
base as required.
Check for signs of this and consult Flowserve if
necessary.
Page 28 of 36 flowserve.com
FAULT SYMPTOM
Pump overheats an d seiz es
⇓⇓⇓⇓
Bearings have sho rt life
⇓⇓⇓⇓
Pump vi brates or is noisy
⇓⇓⇓⇓
Mechanical seal h as short life
⇓⇓⇓⇓
Mechanical seal l eaks excessivel y
⇓⇓⇓⇓
Pump requires exc essive power
⇓⇓⇓⇓
Pump loses pri me after starting
⇓⇓⇓⇓
Insu fficient pressur e developed
⇓⇓⇓⇓
Insu fficient capacity delivered
⇓⇓⇓⇓
Pump does not deliver liquid
⇓⇓⇓⇓
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
POSSIBLE CAUSES POSSIBLE REMEDIES
Leakage under sleeve due to joint failure. Replace joint and check for damage.
Mechanical seal improperly installed.
Incorrect type of mechanical seal for operating
conditions.
Shaft running off centre because of worn
bearings or misalignment.
Impeller out of balance resulting in vibration. Check and consult Flowserve.
Abrasive solids in liquid pumped. Check and consult Flowserve.
Mechanical seal was run dry.
Internal misalignment due to improper repairs
causing impeller to rub.
Excessive thrust caused by a mechanical failure
inside the pump.
Excessive grease in ball bearings. Check method of regreasing.
Lack of lubrication for bearings.
Improper installation of bearings.
Damaged bearings due to contamination.
Check alignment of faces or damaged parts and
assembly method used.
Consult Flowserve
Check misalignment and correct if necessary.
If alignment satisfactory check bearings for
excessive wear.
Check mechanical seal condition and source of
dry running and repair.
Check method of assembly, possible damage or
state of cleanliness during assembly.
Check wear condition of impeller, its clearances
and liquid passages.
Check hours run since last change of lubricant,
the schedule and its basis.
Check method of assembly, possible damage or
state of cleanliness during assembly and type of
bearing used.
Check contamination source and replace
damaged bearings.
C. ELECTRICAL TROUBLES
Wrong direction of rotation. Reverse 2 phases on motor terminal box.
Motor running too slow. Check motor terminal box connections.
Page 29 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
8 PARTS LISTS AND DRAWINGS
8.1 Sectional drawing – L, double entry impeller, grease lubricated, gland packed
8.1.1 Parts list – L, double entry impeller
Item Description
1213 Casing lower half
1214 Casing upper half
1220 Cover
1500 Casing renewable ring
1630 Throttling Bush
2100 Shaft
2200 Impeller
2450 Shaft sleeve
2540 Flinger (liquid)
2910.1 Sleeve nut
3011.1 Ball bearing
3011.2 Ball bearing - drive side
3200 Bearing housing
3260.1 Bearing cover - far side
3260.2 Bearing cover - drive side
3645 Shaft collar *
3712 Locknut
3853 Grease nipple
4120 Gland
4130 Gland packing
4134 Lantern ring
4420 Seal connection
4590.1 Casing joint
4590.1 Gasket
6569.1 Plug
6569.2 Plug
6569.3 Plug
6570.1 Screw
6570.2 Screw
6572 Stud
6580 Nut
6700.1 Impeller key
6700.2 Coupling key
6810 Anti-rotation pin
*Shaft collar not fitted to 3L13, 4L13, 6L3, 6L11and 6L13.
Page 30 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
8.2 Sectional drawing – U Pump horizontal, grease lubricated, cartridge seal
Drawing taken from CS-601451-002
8.2.1 Parts list – 2-stage impeller
Item Description
1213 Casing half - lower
1214 Casing half - upper
1500 Casing wear ring
1610 Inter stage bush
1669 Dowel Bush*
2100 Shaft
2200.1 Impeller (first stage)
2200.2 Impeller (second stage)
2300 Impeller wear ring
2410 Inter stage sleeve
2450 Shaft sleeve **
2460 Bearing spacer
2910 Shaft nut
* Dowel bush only on 6U18
** Shaft sleeve not fitted on 2U13.
*** Impeller gasket not fitted on 2U13
3011.1 Ball bearing
3011.2 Ball bearing
3200 Bearing housing
3260.1 Bearing cover
3260.2 Bearing cover
3266 Bearing End Cover
3712 Bearing nut
3853 Grease nipple
4200 Mechanical seal (Cartridge)
4305.1 Shaft seal ring
4305.2 Shaft seal ring
4420 Seal pipe
4590.1 Gasket
4590.2 Gasket
4590.3 Gasket ***
4610.1 O-ring
4610.2 O-ring
6570.1 Screw
6570.2 Screw
6570.3 Screw
6572 Stud
6580 Nuts
6700.1 Key
6700.2 Key
6811.1 Pin
6811.2 Pin
6814.1 Grub screw
6814.2 Grub screw
Page 31 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
8.3 Sectional drawing – U Pump vertival, grease lubricated, cartridge seal
Drawing taken from 601060-003-2501
8.3.1 Parts list – 2-stage impeller Vertical
Item Description
1213 Casing half - lower
1214 Casing half - upper
1500 Casing wear ring
1610 Inter stage bush
1669 Dowel Bush*
2100 Shaft
2200.1 Impeller (first stage)
2200.2 Impeller (second stage)
2300 Impeller wear ring
2410 Inter stage sleeve
2450.1 Shaft sleeve (upper)**
2450.2 Shaft sleeve (lower)
2460 Bearing spacer
2910 Shaft nut
3011 Ball bearing
* Dowel bush only on 6U18H
** Shaft sleeve not fitted on 2U13.
*** Impeller gasket not fitted on 2U13
3200.1 Bearing housing (upper)
3200.2 Bearing housing (lower)
3260.1 Bearing cover
3260.2 Bearing cover
3300 Bearing bush
3712 Bearing nut
3853 Grease nipple
4200 Mechanical seal (Cartridge)
4305.1 Shaft seal ring
4305.2 Shaft seal ring
4420 Seal pipe
4590.1 Gasket
4590.2 Gasket
4590.3 Gasket ***
4610.1 O-ring
4610.2 O-ring
4610.3 O-ring
6415 Cap
6570.1 Screw
6570.2 Screw
6570.3 Screw
6572 Stud
6579 Socket head cap screw
6580 Nuts
6700.1 Key
6700.2 Key
6811.1 Pin
6811.2 Pin
6814.1 Grub screw
6814.2 Grub screw
Page 32 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
8.4 General arrangement drawing
The typical general arrangement drawing and any
specific drawings required by the contract will be sent to
the Purchaser separately unless the contract specifically
calls for these to be included into the User Instructions.
If required, copies of other drawings sent separately to
the Purchaser should be obtained from the Purchaser
and retained with these User Instructions.
9 CERTIFICATION
Certificates determined from the Contract requirements
are provided with these Instructions where applicable.
Examples are certificates for CE marking, ATEX
marking etc. If required, copies of other certificates sent
separately to the Purchaser should be obtained from
the Purchaser for retention with these User Instructions.
10 OTHER RELEVANT
DOCUMENTATION AND MANUALS
10.1 Supplementary User Instructions
Supplementary instructions such as for a driver,
instrumentation, controller, seals, sealant system etc
are provided as separate documents in their original
format. If further copies of these are required they
should be obtained from the supplier for retention
with these User Instructions.
10.2 Change notes
If any changes, agreed with Flowserve Pump Division,
are made to the product after its supply, a record of the
details should be maintained with these User Instructions.
10.3 Additional sources of information
Reference 1:
NPSH for Rotordynamic Pumps: a reference guide,
Europump Guide No. 1, Europump & World Pumps,
Elsevier Science, United Kingdom, 1999.
Reference 2:
Pumping Manual, 9th edition, T.C. Dickenson,
Elsevier Advanced Technology, United Kingdom, 1995.
Reference 3:
Pump Handbook, 2nd edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.
Reference 4:
ANSI/HI 1.1-1.5
Centrifugal Pumps - Nomenclature, Definitions,
Application and Operation.
Reference 5:
ANSI B31.3 - Process Piping.
Page 33 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
Notes:
Page 34 of 36 flowserve.com
Notes:
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
Page 35 of 36 flowserve.com
L and U USER INSTRUCTIONS ENGLISH 85392721 07-12
Your Flowserve factory contact:
Flowserve Pumps
Flowserve GB Limited
PO Box 17, Lowfield Works
Newark, Notts NG24 3EN
United Kingdom
Telephone (24 hours) +44 1636 494 600
Sales & Admin Fax +44 1636 705 991
Repair & Service Fax +44 1636 494 833
E.mail newarksales@flowserve.com
Your local Flowserve representative:
To find your local Flowserve representative please
use the Sales Support Locator System found at
www.flowserve.com
FLOWSERVE REGIONAL
SALES OFFICES:
USA and Canada
Flowserve Corporation
5215 North O’Connor Blvd.,
Suite 2300
Irving, Texas 75039-5421, USA
Telephone +1 972 443 6500
Fax +1 972 443 6800
Europe, Middle East, Africa
Flowserve FSG - Italy
Worthington S.r.l.
Via Rossini 90/92
20033 Desio (Milan), Italy
Telephone +39 0362 6121
Fax +39 0362 628 882
Latin America and Caribbean
Flowserve Corporation
6840 Wynnwood Lane
Houston, Texas 77008, USA
Telephone +1 713 803 4434
Fax +1 713 803 4497
Asia Pacific
Flowserve Pte. Ltd
10 Tuas Loop
Singapore 637345
Telephone +65 6771 0600
Fax +65 6779 4607
Page 36 of 36 flowserve.com
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