Flowserve Mark 3 User Manual
®
Pump Division
Mark 3 High Silicon Iron Pumps
USER INSTRUCTIONS:
INSTALLATION, OPERATION, MAINTENANCE
PCN=71569249 09-04 (E)
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04
®
CONTENTS
Page
1 INTRODUCTION AND SAFETY ...........................3
1.1 General...........................................................3
1.2 CE marking and approvals..............................3
1.3 Disclaimer .......................................................3
1.4 Copyright......................................................... 3
1.5 Duty conditions ............................................... 3
1.6 Safety..............................................................4
1.7 Name plate and safety labels ......................... 7
1.8 Noise level ...................................................... 8
2 TRANSPORT AND STORAGE............................. 9
2.1 Consignment receipt and unpacking ..............9
2.2 Handling..........................................................9
2.3 Lifting...............................................................9
2.4 Storage............................................................9
2.5 Recycling and end of product life..................10
3 DESCRIPTION.................................................... 10
3.1 Configurations...............................................10
3.2 Nomenclature................................................ 11
3.3 Design of major parts.................................... 11
3.4 Performance and operation limits................. 11
4.1 Location ........................................................ 12
4.2 Part assemblies ............................................13
4.3 Foundation....................................................13
4.4 Grouting........................................................15
4.5 Initial alignment.............................................16
4.6 Piping............................................................ 16
4.7 Electrical connections...................................19
4.8 Final shaft alignment check ..........................19
4.9 Protection systems........................................20
6.8 Examination of parts..................................... 32
6.9 Assembly of pump and seal..........................35
7 FAULTS; CAUSES AND REMEDIES................. 41
BLANK8 PARTS LIST AND DRAWINGS ............... 43
8 PARTS LIST AND DRAWINGS........................... 44
8.1 Mark 3 High Silicon Iron Pump, Group 2...... 44
8.2 General arrangement drawing...................... 46
9 CERTIFICATION................................................. 46
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS.......................................................... 46
10.1 Supplementary User Instructions ............... 46
10.2 Change notes............................................. 46
10.3 Additional sources of information ............... 46
5 COMMISSIONING, STARTUP, OPERATION AND
SHUTDOWN ......................................................20
5.1 Pre-commissioning procedure...................... 20
5.2 Pump lubricants............................................20
5.3 Impeller clearance.........................................23
5.4 Direction of rotation.......................................23
5.5 Guarding.......................................................23
5.6 Priming and auxiliary supplies......................24
5.7 Starting the pump..........................................24
5.8 Running or operation ....................................24
5.9 Stopping and shutdown.................................25
5.10 Hydraulic, mechanical and electrical duty...25
6 MAINTENANCE .................................................. 26
6.1 Maintenance schedule..................................26
6.2 Spare parts.................................................... 27
6.3 Recommended spares and consumable items
.......................................................................27
6.4 Tools required...............................................27
6.5 Fastener torques...........................................28
6.6 Setting impeller clearance and impeller
replacement................................................... 28
6.7 Disassembly.................................................. 30
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USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04
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1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilizing sophisticated quality techniques, and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at your service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws/regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety noted in the
instructions, have been met.
1.2 CE marking and approvals
It is a legal requirement that machinery and equipment
put into service within certai n regions of t he world shall
conform with the applicable CE Marking Directive s
covering Machinery and, where appli cable, Low V oltage
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 App rovals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certificatio n.)
1.3 Disclaimer
Information in these User Instructions is believed
to be reliable. In spite of all the efforts of
Flowserve Pump Division to provide sound and all
necessary information the content of this manual
may appear insufficient and is not guaranteed by
Flowserve as to its completeness or accuracy.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality
Assurance organizations. Genuine parts and
accessories have been designed, tested and
incorporated into the products to help ensure 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 authorized 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 Pump Division.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order are
going to be changed (for ex ample li quid pum ped,
temperature or duty) it is requested that the user seeks
the written agreement of Flowserve before start up.
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1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction would
cause hazards. The specific safety markings are:
This symbol indicates electrical safety
instructions where non-compliance will involve a high
risk to personal safety or the loss of life.
This symbol indicates safety instruct ions 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.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
(Lock out.)
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUOROELASTOMERS (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.
NEVER OPERATE THE PUMP WITHOUT THE
COUPLING GUARD AND ALL OTHER SAFETY
DEVICES CORRECTLY INSTALLED
This sign is not a safety symbol but indicates
an important instructio n in the assembly process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
help prevent injury to personnel and damage to
the environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
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 b e
avoided. High Silicon Iron should be heated and
cooled slowly. Changes in temperature should not
exceed 55˚C (100˚F) per hour .
MECHANICAL SHOCK
High Silicon Iron is subject to breakage from
mechanical shock. Care should be taken when
handling and operating the pump.
NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapor coul d cause an explosion.
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
equipment can present a danger to operators and
persons entering the immediate area, action mu st be
taken to avoid accidental contact (such a s shieldi ng). If
complete protection is not possible, the ma chine access
must be limited to maintenance staff only with cl ear
visual warnings and indicators to tho se entering t he
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immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
If the temperature is greater than 68 °C (175 °F) or
below 5 °C (20 °F) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate pump placement, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.
Gland packing must not be used when pumping
hazardous liquids.
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
in writing, so that their force, due to internal pressure,
acts on the pump flange.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation
and shutdown.)
NEVER EXCEED THE MAXIMUM
DESIGN PRESSURE (MDP) AT THE
TEMPERATURE SHOWN ON THE PUMP
NAMEPLATE
See section 3 for pressure versus temperature
ratings based on the material of construction.
NEVER OPERATE THE PUMP WITH
THE DISCHARGE VALVE CLOSED
(Unless otherwise instructed at a specific point in the
User Instructions.)
(See section 5, Commissioning start-up, operation
and shutdown.)
NEVER RUN THE PUMP DRY OR
WITHOUT PROPER PRIME (Casing flooded)
NEVER OPERATE THE PUMP WITH
THE SUCTION VALVE CLOSED
It should be fully opened when the pump is running.
NEVER OPERATE THE PUMP AT
ZERO FLOW OR FOR EXTENDED PERIODS
BELOW THE MINIMUM CONTINUOUS FLOW
THE PUMP SHAFT MUST TURN
CLOCKWISE WHEN VIEWED FROM THE MOTOR
END
It is absolutely essential that the rotation of the motor
be checked before installation of the coupling spa cer
and starting the pump. Incorrect rotation of the pump
for even a short period can unscrew the impeller,
which can cause significant damage.
1.6.4 Products used in potentially explosive atmospheres
Measures are required to:
•
Avoid excess temperature
•
Prevent build up of explosive mixtures
•
Prevent the generation of sparks
•
Prevent leakages
•
Maintain the pump to avoid hazard
The following instructi ons for pu mps and pump u nits
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
Both electrical and non-electri cal equi pment mu st meet
the requirements of European Directive 94/9/EC.
1.6.4.1 Scope of compliance
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of
the specific atmosphere in which they are to be
installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the pump set shall
select the coupling, driver, seal and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable
for the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor. On
pump installations controlled by a VFD, the ATEX
Certification for the motor must state that it 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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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 135ºC (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 prEn13463-5)
Gas Group (Equipment Category 2 only)
IIA – Propane (Typical)
IIB – Ethylene (Typical)
IIC – Hydrogen (T y pical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3)
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pump liquid temperature
Pumps have a temperature class as stated in the ATEX
Ex rating on the nameplate. Th ese are b ased on a
maximum ambient temperature of 4 0 ºC (104 º F); ref er
to Flowserve for higher ambient temp eratures.
The surface temperature on the pump is influenced by
the temperature of the liquid handled. The maximum
permissible liquid temperature depends on the
temperature class and must not exceed the values in the
table applicable below . The temperature rise at the seals
and bearings and due to the minimum permitted flow rate
is taken into account in the temperatures stated.
Maximum permitted liquid temperature for pumps
Temperature
class to
EN 13463-1
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant – check which is lower)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
Maximum permitted liquid temperature for pumps
with self priming casing
Temperature
class to
EN 13463-1
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is lower)
Consult Flowserve
Consult Flowserve
110 °C (230 °F) *
175 °C (347 °F) *
270 °C (518 °F) *
350 °C (662 °F) *
The responsibility for compliance with the sp ecified
maximum liquid temperature is with the plant
operator.
Temperature classification “Tx” is used when the
liquid temperature varies and the pump could be
installed in different hazard ous atmospheres. In this
case the user is responsible for ensuring that the
pump surface temperature does not exceed that
permitted in the particular hazardous atmosphere.
Do not attempt to check the direction of rotation with the
coupling element/pins fitted due to the risk of sev ere
contact between rotating and stationary compo nents.
Where there is any risk of the pump being run against a
closed valve generating high liqui d and casing exte rnal
surface temperature, it is recommended that users fit an
external surface temperature protection device.
Avoid mechanical, hydraulic or ele ctrical overloa d by
using motor overload trips, temperature monitor or a
power monitor and perform rout ine vibrat ion monito ring.
In dirty or dusty environments, regular checks must
be made and dirt removed from areas around close
clearances, bearing housings and motors.
1.6.4.4 Preventing the build up of explosive mixtures
ENSURE PUMP IS PROPERLY FILLED AND
VENTED AND DOES NOT RUN DRY
Ensure that the pump and relevant suction and discharge
piping is totally filled with liquid at all times during the
pumps 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 can not avoid this
condition it is recommended that you fit an
appropriate dry run protection device (for example
liquid detection or a power monitor).
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To avoid potential hazards from fugitive emissions of
vapor or gas to atmosphere, the surrounding area
must be well ventilated.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking
and anti-static for Category 2.
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.
Avoid electrostatic charge. Do not rub non-metallic
surfaces with a dry cloth; ensure the cloth is damp.
The coupling must be selected to comply with
94/9/EC and correct alignment must be maintained.
Additional requirements for pumps on nonmetallic baseplates
When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.
1.6.4.6 Preventing leakage
1.6.4.7 Maintenance of the centrifugal pump to
avoid a hazard
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with mainten ance
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 Name plate and safety labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity and section 3.
1.7.2 Safety labels
Pumps with mechanical seal. 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 a nd associat ed
piping due to closing of su ction an d discharg e valves,
which could cause dangerous excessiv e pressures to
occur if there is heat input t o the liqu id. This ca n 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 auxiliary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be monitored.
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
Oil lubricated units only:
DurcoShield
TM
(Splash/Shaft Guard) only:
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1.8 Noise level
When pump noise level exceeds 85 dB(A) attention
must be given to prevailing Health and Safety
Legislation, to limit the exposure of plant operating
personnel to the noise. The usual approach is to
control exposure time to the noise or to enclose the
machine to reduce emitted sound. You may have
already specified a limiting noise level when the
equipment was ordered, however if no noise
requirements were defined then machines above a
certain power level will exceed 85 dB(A). In such
situations consideration must be given to the fitting of
an acoustic enclosure to meet local regulations.
Pump noise level is dependent on a number of factors the type of motor fitted, the operati ng cap acit y, pipe work
The values are based on the noisiest non-geared
electric motors that are likely to be encountered.
They represent sound pressure levels at 1 m (3.3 ft)
from the directly driven pump, for "free field over a
reflecting plane". For estimating L
sound power
wA
level (re 1 pW) add 14dBA to the sound pressure
value.
If a pump unit only has been purchased, for fitting
with your own driver, then the "pump only" noise
levels from the table should be combined with the
level for the driver obtained from the supplier.
If the motor is driven by an inverter it may show an
increase in noise level at some speeds. Consult a
Noise Specialist for the combined calculation.
design and acoustic characteri stics of the buildin g.
Typical sou nd pressure levels measured in dB, and
A-weighted are shown in the table below. The figures
are indicative only, they are subject to a +3 dB
For units driven by equipment other than
electric motors or units contained within enclosures,
see the accompanying information sheets and
manuals.
tolerance, and cannot be guaranteed.
T ypical sound pressure l evel, dBA, LpA at 1 m reference 20 µPa
and speed
kW (hp)
<0.55 (<0.75) 71 66 64 62 64 62 63 62
0.75 (1) 74 66 67 62 67 62 63 62
1.1 (1.5) 74 68 67 64 67 64 65 64
1.5 (2) 77 70 70 66 70 66 66 66
2.2 (3) 78 72 71 68 71 68 68 68
3 (4) 81 74 74 70 74 70 70 70
4 (5) 82 75 75 71 75 71 71 71
5.5 (7.5) 90 77 83 73 76 73 72 71
7.5 (10) 90 78 83 74 77 74 73 72
11 (15) 91 80 84 76 78 76 74 73
15 (20) 92 83 85 79 80 79 76 75
18.5 (25) 92 83 85 79 80 79 76 75
22 (30) 92 83 85 79 81 79 77 75
30 (40) 100 85 93 81 84 80 80 76
37 (50) 100 86 93 82 84 80 80 76
45 (60) 100 87 93 83 84 80 80 76
55 (75) 100 88 95 84 86 81 82 77
75 (100) 100 90 95 86 88 81 83 78
90 (120) 100 90 95 86 90 81 85 78
110 (150) 100 91 95 87 91 83 86 79
150 (200) 101 92 96 88 91 83 86 79
200 (270) (1) (1) (1) (1) (1) 83 (1) 80
300 (400) - - - - (1) 84 (1) 81
(1) Motors in this range are generally job specific and noise levels should be calculated based on actual equipment installed.
For 960 r/min reduce 1450 r/min values by 5 dBA.
3550 r/min 2900 r/min 1750 r/min 1450 r/min Motor size
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
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2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve Pump Division
and must be received in writing within one month of
receipt of the equipment. Later claims cannot be
accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
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
2.3.1.4 Bare pump
Sling through the pump adapter and around the outboard
end of the bearing housing with separate slings. Choker
hitches must be used at both attachment points and
pulled tight. The sling lengths should be adjusted to
balance the load before attaching the lifting hook.
Figure 2-1
Pumps and motors often have integral
lifting lugs or eye bolts. These are intended for use in
only lifting the individual piece of equipment.
Do not use eye bolts or cast-in lifting
lugs to lift pump, motor and baseplate assemblies.
To avoid distortion, the pump unit
should be lifted as shown.
Care must be taken to lift components
or assemblies above the center of gravity to prevent
the unit from flipping. This is especially true with
In-Line pumps.
2.3.1 Lifting pump components
2.3.1.1 Casing [1100]
Use a choker hitch pulled tight around the discharge
nozzle.
2.3.1.2 Bearing housing [3200]
Insert either a sling or hook through the lifting lug
located on the top of the housing.
2.3.1.3 Power end
Same as bearing housing.
2.3.2 Lifting pump, motor and baseplate assembly
If the baseplate has lifting holes cut in the sides at the
end (Type D and Type E base s) insert lifti ng S hooks at
the four corners and use slings or chains to connect to
the lifting eye. (Figure 2-1.) Do not use slings through
the lifting holes.
For other baseplates, sling through the pump adapter,
and around the outboard end of the motor frame using
choker hitches pulled tight (Figure 2-1.). The sling
should be positioned so the weight is not carried
through the motor fan housing.
2.4 Storage
Store the pump in a clean , dry location
away from vibration. Leave flange covers in place to
keep dirt and other foreign material out of pump
casing. Turn the pump shaft at regular intervals to
prevent brinelling of the bearings and the seal faces,
if fitted, from sticking.
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The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
2.4.1 Short term storage and packaging
Normal packaging is designed to protect the pump
and parts during shipment and for dry, indoor storage
for up to six months or less. The following is an
overview of our normal packaging:
• All loose unmounted items are packaged in a
water proof plastic bag and placed under the
coupling guard
• Inner surfaces of the bearing housing, shaft (area
through bearing housing) and bearings are coated
with Cortec VCI-329 rust inhibitor, or equal.
Bearing housings are not filled with oil
prior to shipment
• Regreasable bearings are packed with grease
(EXXON POLYREX EM for horizontal pumps)
• The internal surfaces of ferrous casings, covers,
flange faces, and the impeller surface are
sprayed with Cortec VCI-389, or equal
• Exposed shafts are taped with Polywrap
• Flange covers are secured to both the suction
and discharge flanges
• In some cases with assemblies ordered with
external piping, components may be
disassembled for shipment
• The pump must be stored in a covered, dry
location
2.4.2 Long term storage and packaging
Long term storage is defined as more than six
months, but less than 12 months. The procedure
Flowserve follows for long term storage of pumps is
given below. These procedures are in addition to the
short term procedure.
• Each assembly is hermetically (heat) sealed from
the atmosphere by means of tack wrap sheeting
and rubber bushings (mounting holes)
• Desiccant bags are placed inside the tack
wrapped packaging
• A solid wood box is used to cover the assembly
This packaging will provide protection for up to twelve
months from humidity, salt laden air, dust etc.
After unpacking, protection will be the responsibility of
the user. Addition of oil to the bearing housing will
remove the inhibitor. If unit s are to be idle fo r extende d
periods after addition of lubricants, in hibitor oils and
greases should be used. Every three months, the pump
shaft should be rotated approximately 10 revolution s.
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 in accordance with local
regulations. If the product contains substances that
are harmful to the environment, these should be
removed and disposed of in accordance with current
local 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
local regulations at all times.
3 DESCRIPTION
3.1 Configurations
The Durco Mark 3 chemical process pumps are,
single stage, centrifugal pumps. The High Silicon
Iron pump conforms dimensionally to ASME B73.1M.
The pump does not have cast on flanges and does
not offer back pull out.
Figure 3-1: Nameplate mounted to housing
Serial No.
Equipment No.
Purchase Order
Model
Size
MDP
Material
Date DD/MMM/YY
2K3X1.5 H-10/9.5 OP
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3.2 Nomenclature
The pump size will be engraved on the nameplate
typically as below:
2 K 3 X 1.5 H - 10 /9.5 OP
• Frame size
“2" indicates a medium size pump frame (in this
example, a Group 2)
1 = Group 1 (small frame)
2 = Group 2 (medium frame)
3 = Group 3 (large frame)
• Power end
K = Mark 3 style power end
Mark 3A – Standard
ANSI 3A – Optional (3 year guarantee)
• “3” = nominal suction port size (in.)
• “1.5” = Nominal discharge port size (in.)
• Modifier for “specialty pumps”
H = High Silicon Iron
Blank or no letter = standard pump
M = Sealmatic
R = recessed impeller
US = unitized self-priming
V = vertical In-Line
LF = Lo-Flo
• Nominal maximum impeller diameter. “10” = 10 in.
• Pump design variation
A = This pump has been redesig ned from an earlie r
version. The impeller and casing are no longer
interchangeable with the earlier version.
H = This pump is designed for a higher flow capacity
than another pump with the same basic
designation. (Examples: 4X3-10 and 4X3-10H;
6X4-10 and 6X4-10H; 10X8-16 and 10X8-16H.
HH = This pump is designed for a higher head than
another pump with the sa me basic designati on.
(Example: 4X3-13 and 4X3-13HH.)
• Actual impeller size
“9.5” = 9 ½ in. diameter; 8.13 = 8 ⅛ in;
10.75 = 10 ¾ in
(Previous annotation: 124 = 12
4
/8 or 12 ½ in.
diameter; 83 = 8 ⅜ in.)
• Impeller style
RV = reverse vane impeller; OP = Open impeller
3.3 Design of major parts
3.3.1 Pump casing
The seal chamber is cast integral to the casing volute
and only the discharge connection is integral to the
casing. The casing must be installed prior to the
impeller.
3.3.2 Split Gland Yoke
The seal chamber is cast integral to the casing
volute. The gland yoke is clamped around the seal
chamber neck. The gland yoke allows for seal
chamber taps and provides the bolting ring for the
gland.
3.3.3 Impeller
The impeller is open type design.
3.3.4 Suction Cover
The front cover plate encapsulates the impeller and
contains the suction connection.
3.3.5 Shaft/sleeve
Solid and sleeved shafts are available, supported on
bearings, threaded impeller end and keyed drive end.
3.3.6 Pump bearings and lubrication
Ball bearings are fitted as standard and may be either
oil or grease lubricated.
3.3.7 Bearing housing
Large oil bath reservoir.
3.3.8 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.
3.3.9 Driver
The driver is normally an electric motor. Different drive
configurations may be fitted such as internal combustion
engines, turbines, hydraulic motors et c drivin g via
couplings, belts, gearboxes, drive shafts etc.
3.3.10 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operation limits
This product has been selected to meet the
specification 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 liquid being pumped, temperature, material of
construction, and seal type may influence this data. If
required, a definitive statement fo r your appli cation can
be obtained from Flowserve.
3.4.1 Alloy cross reference chart
Figure 3-2 is the Alloy cross-reference chart for all
Mark 3 pumps. E3042 is the material code for High
Silicon Iron Pump wet ends.
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Figure 3-2: Alloy cross-reference chart
Flowserve
Material Code
E3020 Ductile iron DCI None None A395, Gr. 60-40-18 1.0
E3033 High chrome iron CR28 None None A532 class 3 Cr
E4027 High chrome iron CR29 None None None Cr
E4028 High chrome iron CR35 None None None Cr
C3009 Carbon steel DS None Carbon steel A216 Gr. WCB 1.1
C3062 Durco CF8 D2 CF8 304 A744, Gr. CF8 2.1
C3069 Durco CF3 D2L CF3 304L A744, Gr. CF3 2.1
C3063 Durco CF8M D4 CF8M 316 A744, Gr. CF8M 2.2
C3067 Durco CF3M D4L CF3M 316L A744, Gr. CF3M 2.2
C3107 Durcomet 100 CD4M CD4MCuN
C4028 Durimet 20 D20 CN7M Alloy 20 A744, Gr. CN7M 3.17
C4029 Durcomet 5 DV None None None 2.2
K3005 Durco CY40 DINC CY40
K3007 Durco M35 DMM M351
K3008 Nickel DNI CZ100 Nickel 200 A494, Gr. CZ100 3.2
K4007 Chlorimet 2 DC2 N7M
K4008 Chlorimet 3 DC3 CW6M
E3041
E3042
E4035
D4036 Durco DC8 DC8 None None None H3004 Titanium Ti None Titanium B367, Gr. C3 Ti
H3005 Titanium-Pd TiP None Titanium-Pd B367, Gr. C8A Ti
H3007 Zirconium Zr None Zirconium B752, Gr. 702C Ti
® Duriron, Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation.
® Ferralium is a registered trademark of Langley Alloys.
® Hastelloy is a registered trademark of Haynes International, Inc.
® Inconel and Monel are registered trademarks of International Nickel Co. Inc.
Designation
Duriron®
Durichlor 51®
Superchlor®
3.4.2 Pressure-temperature ratings
The maximum allowable discharge pressure is
6.9 bar (100 psi) from -29 to 176˚C (-20 to 350˚F).
Durco Legacy
Codes
D None None A518, Gr. 1 No load
D51 None None A518, Gr. 2 No load
SD51 None None A518, Gr. 2 No load
ACI
Designation
Equivalent Wrought
Designation
Ferralium®
Inconel® 600
Monel® 400
Hastelloy® B
Hastelloy® C
ASTM
Specifications
A995, Gr. CD4MCuN 2.8
A494, Gr. CY40 3.5
A494, Gr. M35-1 3.4
A494, Gr. N7M 3.7
A494, Gr. CW6M 3.8
Material
Group No.
4 INSTALLATION
High Silicon Iron components
3.4.3 Suction pressure limits
Suction pressure is limited only by the pressure
temperature ratings of the pump. S pecific g ravity is
limited to 2.0.
3.4.4 Minimum continuous flow
The minimum continuous flow (MCF) is based on a
percentage of the best efficiency point (BEP). Figure
3-3 identifies the MCF.
have been made of High Silicon Iron, the following
precautionary measures should be followed:
• Use hand wrenches rather than impact wrenches
• This equipment should not be subjected to
sudden changes in temperature or pressure
• Avoid striking this equipment with any sharp blows
High Silicon Iron components
If any of the components of the pump
Figure 3-3: Minimum continuous flow
MCF % of BEP
Pump size
2K4x3H-13 20% 10%
All other sizes 10% 10%
1750/1450
r/min
1180/960
r/min
on High Silicon Iron components.
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
Avoid any repair or fabrication welds
practicable to the supply of liquid to be pumped.
Refer to the general arrangement drawing for the
pump set.
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4.2 Part assemblies
The supply of motors and baseplates are optional.
As a result, it is the responsibility of the installer to
ensure that the motor is assembled to the pump and
aligned as detailed in section 4.5 and 4.8.
4.3 Foundation
4.3.1 Protection of openings and threads
When the pump is shipped, all threads and all
openings are covered. This protection/covering
should not be removed until installation. If, for any
reason, the pump is removed from service, this
protection should be reinstalled.
4.3.2 Rigid baseplates - overview
The function of a baseplate is to provide a rigid
foundation under a pump and its driver that maintains
alignment between the two. Baseplates may be
generally classified into two types:
• Foundation-mounted, grouted de sign. (Figure 4-1. )
• Stilt mounted, or free standing. (Figure 4-2.)
Figure 4-1
Figure 4-2
Baseplates intended for grouted installation are
designed to use the grout as a stiffening member.
Stilt mounted baseplates, on the other hand, are
designed to provide their own rigidity. Therefore the
designs of the two baseplates are usually different.
Regardless of the type of baseplate used, it must
provide certain functions that ensure a reliable
installation. Three of these requirements are:
1. The baseplate must provide sufficient rigidity to
assure the assembly can be transported and
installed, given reasonable care in handling,
without damage. It must also be rigid enough
when properly installed to resist operating loads.
2. The baseplate must provide a reasonably flat
mounting surface for the pump and driver.
Uneven surfaces will result in a soft-foot condition
that may make alignment difficult or impossible.
Experience indicates that a baseplate with a top
surface flatness of 1.25 mm/m (0.015 in./ft)
across the diagonal corners of the baseplate
provides such a mounting surface. Therefore,
this is the tolerance to which we supply our
standard baseplate. Some users may desire an
even flatter surface, which can facilitate
installation and alignment. Flowserve will supply
flatter baseplates upon request at extra cost. For
example, mounting surface flatness of 0.17
mm/m (0.002 in./ft) is offered on the Flowserve
Type E “Ten Point” baseplate shown in figure 4-1.
3. The baseplate must be designed to allow the
user to final field align the pump and driver to
within their own particular standards and to
compensate for any pump or driver movement
that occurred during handling. Normal industry
practice is to achieve final alignment by moving
the motor to match the pump. Flowserve practice
is to confirm in our shop that the pump assembly
can be accurately aligned. Before shipment, the
factory verifies that there is enough horizontal
movement capability at the motor to obtain a
“perfect” final alignment when the installer puts
the baseplate assembly into its original, top
leveled, unstressed condition.
4.3.3 Stilt and spring mounted baseplates
Flowserve offers stilt and spring mounted baseplates.
(See figure 4-2 for stilt mounted option.) The low
vibration levels of Mark 3 pumps allow the use of
these baseplates - provided they are of a rigid design.
The baseplate is set on a flat surface with no tie down
bolts or other means of anchoring it to the floor.
General instructions for assembling these baseplates
are given below. For dimensional information, please
refer to the appropriate Flowserve “Sales print.”
4.3.3.1 Stilt mounted baseplate assembly
instructions
Refer to figure 4-3.
a) Raise or block up baseplate/pump above the
floor to allow for the assembly of the stilts.
b) Predetermine or measure the approximate
desired height for the baseplate above the floor.
c) Set the bottom nuts [2] above the stilt bolt head
[1] to the desired height.
d) Assemble lock washer [3] down over the stilt bolt.
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e) Assemble the stilt bolt up through hole in the
bottom plate and hold in place.
f) Assemble the lock washer [3] and nut [2] on the
stilt bolt. Tighten the nut down on the lock
washer.
g) After all four stilts have been assembled,
position the baseplate in place, over the floor
cups [4] under each stilt location, and lower the
baseplate to the floor.
h) Level and make final height adjustments to the
suction and discharge pipe by first loosening the
top nuts and turning the bottom nuts to raise or
lower the baseplate.
i) Tighten the top and bottom nuts at the lock
washer [3] first then tighten the other nuts.
j) It should be noted that the connecting pipelines
must be individually supported, and that the stilt
mounted baseplate is not intended to support
total static pipe load.
Figure 4-3
cups [7] under each stilt location, and lower the
baseplate down to the floor.
i) Level and make final height adjustments to the
suction and discharge pipe by first loosening the
top nuts, and turning the bottom nuts to raise or
lower the baseplate.
j) To make the stilt bolts more stable, tighten down
on the top nuts, compressing the top spring
approximately 25 mm (1 in.), and lock the nuts in
place.
k) It should be noted that the connecting pipelines
must be individually supported, and that the
spring mounted baseplate is not intended to
support total static pipe loads.
Figure 4-4
4.3.3.2 Stilt/spring mounted baseplate assembly
instructions
Refer to figure 4-4.
a) Raise or block up baseplate/pump above the
floor to allow for the assembly of the stilts.
b) Set the bottom nuts [4] above the stilt bolt head
[1]. This allows for 51 mm (2 in.) upward
movement for the final height adjustment of the
suction/discharge flange.
c) Assemble the lock washer [6] flat washer [5] and
bottom spring/cup assembly [2] down over the
stilt bolt [1].
d) Assemble the stilt bolt/bottom spring up through
hole in the bottom plate and hold in place.
e) Assemble top spring/cup assembly [3] down
over stilt bolt.
f) Assemble flat washer [5], lock washer [6] and
nuts [4] on the stilt bolt.
g) Tighten down top nuts, compressing the top
spring approximately 25 mm (1 in.).
h) After all four stilts have been assembled,
position the baseplate in place, over the floor
4.3.3.3 Stilt/spring mounted baseplates - motor
alignment
The procedure for motor alignment on stilt or spring
mounted baseplates is similar to grouted baseplates.
The difference is primarily in the way the baseplate is
leveled.
a) Level the baseplate by using the stilt adjusters.
(Shims are not needed as with grouted
baseplates.)
b) After the base is level, it is locked in place by
locking the stilt adjusters.
c) Next the initial pump alignment must be checked.
The vertical height adjustment provided by the
stilts allows the possibility of slightly twisting the
baseplate. If there has been no transit damage
or twisting of the baseplate during stilt height
adjustment, the pump and driver should be within
0.38 mm (0.015 in.) parallel, and 0.0025 mm/mm
(0.0025 in./in.) angular alignment. If this is not
the case, check to see if the driver mounting
fasteners are centered in the driver feet holes.
d) If the fasteners are not centered there was likely
shipping damage. Re-center the fasteners and
perform a preliminary alignment to the above
tolerances by shimming under the motor for
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vertical alignment, and by moving the pump for
horizontal alignment.
e) If the fasteners are centered, then the baseplate
may be twisted. Slightly adjust (one turn of the
adjusting nut) the stilts at the driver end of the
baseplate and check for alignment to the above
tolerances. Repeat as necessary while
maintaining a level condition as measured from
the pump discharge flange.
f) Lock the stilt adjusters.
The remaining steps are as listed for new grouted
baseplates.
4.4 Grouting
a) The pump foundation should be located as cl ose
to the source of the fluid to be pumped as
practical.
b) There should be adequate space for workers to
install, operate, and maintain the pump. The
foundation should be sufficient to absorb any
vibration and should provide a rigid support for
the pump and motor.
c) Recommended mass of a concrete foundation
should be three times that of the pump, motor
and base. Refer to figure 4-5.
Foundation bolts are imbedded in the
concrete inside a sleeve to allow some
movement of the bolt.
Figure 4-5
d) Level the pump baseplate assembly. If the
baseplate has machined coplanar mounting
surfaces, these machined surfaces are to be
referenced when leveling the baseplate. This
may require that the pump and motor be removed
from the baseplate in order to reference the
machined faces. If the baseplate is without
machined coplanar mounting surfaces, the pump
and motor are to be left on the baseplate. The
proper surfaces to reference when leveling the
pump baseplate assembly are the pump suction
and discharge flanges. DO NOT stress the
baseplate.
e) Do not bolt the suction or discharge flanges of the
pump to the piping until the baseplate foundation
is completely installed. If equipped, use leveling
jackscrews to level the baseplate. If jackscrews
are not provided, shims and wedges should be
used. (See Figure 4-5.) Check for levelness in
both the longitudinal and lateral directions.
Shims should be placed at all base anchor bolt
locations, and in the middle edge of the base if
the base is more than 1.5 m (5 ft.) long. Do not
rely on the bottom of the baseplate to be flat.
Standard baseplate bottoms are not machined,
and it is not likely that the field mounting surface
is flat.
f) After leveling the baseplate, tighten the anchor
bolts. If shims were used, make sure that the
baseplate was shimmed near each anchor bolt
before tightening. Failure to do this may result in
a twist of the baseplate, which could make it
impossible to obtain final alignment.
g) Check the level of the baseplate to make sure
that tightening the anchor bolts did not disturb the
level of the baseplate. If the anchor bolts did
change the level, adjust the jackscrews or shims
as needed to level the baseplate.
h) Continue adjusting the jackscrews or shims and
tightening the anchor bolts until the baseplate is
level.
i) Check initial alignment. If the pump and motor
were removed from the baseplate proceed with
step j) first, then the pump and motor should be
reinstalled onto the baseplate using Flowserve’s
factory preliminary alignment procedure as
described in section 4.5, and then continue with
the following. As described ab ove, pumps are
given a preliminary alignment at t he fact ory. Thi s
preliminary alignment is done in a way that ensures
that, if the installer duplicates the factory conditions,
there will be sufficient clearance between the motor
hold down bolts and motor foot hol es to move the
motor into final alignment. If the pump and motor
were properly reinstalled to the baseplate or if they
were not removed from the baseplate and there has
been no transit damage, and also if the above steps
where done properly, the pump and driver shoul d
be within 0.38 mm (0.015 in.) FIM (Full Indicator
Movement) parallel, and 0.0025 mm/mm (0.0025
in./in.) FIM angular. If this is not the case, first
check to see if the driver mounting fasteners are
centered in the driver feet holes. If not, re-center
the fasteners and perform a preliminary alignment
to the above tolerances by shimming under the
motor for vertical alignment, and by m oving the
pump for horizontal alignment.
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