Flowserve MARK 3 GROUP 4 User Manual

FLOWSERVE

USER INSTRUCTIONS

MARK 3 GROUP 4

Horizontal, end suction, centrifugal pumps for chemical process, water and general service

PCN= 71569286 08-12 (E)

Original Instructions

nstallation

Operation

Maintenance

These instructions must be read prior to installing,

operating, using, and maintaining this equipment.

MARK 3 GROUP 4 USER INSTRUCTIONS ENGLISH 71569286 08-12

CONTENTS PAGE

1 INTRODUCTION AND SAFETY ...................... 4

General ....................................................... 4

1.1

CE marking and approvals .......................... 4

1.2

Disclaimer ................................................... 4

1.3

1.4

Duty conditions ............................................ 4

1.5

Safety .......................................................... 5

1.6 If leakage of liquid to atmosphere can result in a

hazard, install a liquid detection device. ..... 8

Nameplate and warning labels .................... 9

1.7

Specific machine performance .................. 10

1.8

Noise level ................................................. 10

1.9

2 TRANSPORT AND STORAGE ...................... 11

Consignment receipt and unpacking......... 11

2.1

Handling .................................................... 11

2.2

Lifting ......................................................... 11

2.3

Storage ...................................................... 12

2.4

Recycling and end of product life .............. 12

2.5

3 PUMP DESCRIPTION ................................... 12

Configurations ........................................... 12

3.1

Name nomenclature .................................. 13

3.2

Design of major parts ................................ 13

3.3

Performance and operating limits ............. 13

3.4

Table Of Engineering Data ....................... 15

3.5

Table of Engineering Data ........................ 16

3.6

Materials of Construction .......................... 17

3.7

4 INSTALLATION ............................................. 18

Location ..................................................... 18

4.1

Part assemblies ......................................... 18

4.2

Foundation ................................................ 18

4.3

Baseplate installation ................................ 18

4.4

Initial alignment ......................................... 19

4.5

Grouting .................................................... 22

4.6

Piping ........................................................ 23

4.7

Final shaft alignment check ...................... 25

4.8

Electrical connections ............................... 26

4.9

Protection systems .................................... 26

4.10

PAGE

Recommended spares and consumable items

6.4

Tools required ............................................33

6.5

Fastener torques .......................................34

6.6

Renewal clearances ..................................34

6.7

Disassembly ..............................................34

6.8

Examination of parts ..................................35

6.9

Assembly ...................................................36

6.10

Impeller axial clearance adjustment ..........39

6.11

7 FAULTS; CAUSES AND REMEDIES ............ 41

8 PARTS LIST AND DRAWINGS ..................... 43

Mark 3 Group 4 chemical pump sectional and

8.1

parts list .....................................................43

Mark 3 Group 4 chemical pump- liquid end

8.2

exploded view ............................................45

Mark 3 Group 4 chemical pump frame

8.3

exploded view ............................................46

General arrangement drawing ...................47

8.4

9 CERTIFICATION ............................................ 47

10 OTHER RELEVANT DOCUMENTATION AND

MANUALS ................................................................ 47

Supplementary User Instruction manuals .47

10.1

Change notes ............................................47

10.2

Additional sources of information ..............47

10.3

5 COMMISSIONING, START-UP, OPERATION

AND SHUTDOWN ................................................... 27

Pre-commissioning procedure .................. 27

5.1

Pump lubricants ........................................ 28

5.2

Direction of rotation ................................... 29

5.3

Guarding ................................................... 29

5.4

Priming and auxiliary supplies .................. 29

5.5

Starting the pump ...................................... 29

5.6

Running the pump ..................................... 29

5.7

Stopping and shutdown ............................ 30

5.8

Hydraulic, mechanical and electrical duty . 31

5.9

6 MAINTENANCE ............................................. 31

General ..................................................... 31

6.1

Maintenance schedule .............................. 32

6.2

Spare parts ................................................ 33

6.3

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INDEX

PAGE

Alignment of shafting (see 4.3, 4.5and 4.7) ............. 19

CE marking and approvals (1.2) ................................ 4

Clearances (see 6.7, Renewal clearances) ............. 34

Clearance setting (6.11) .......................................... 39

Commissioning and operation (see 5) ..................... 27

Configurations (3.1) ................................................. 12

Direction of rotation (5.3) ......................................... 29

Dismantling (see 6.8, Disassembly) ........................ 34

Duty conditions (1.5) .................................................. 4

Electrical connections (4.9)...................................... 26

Examination of parts (6.9) ........................................ 35

Faults; causes and remedies (see 7) ...................... 41

General assembly drawings (see 8) ........................ 43

Grouting (4.6) ........................................................... 22

Guarding (5.4) .......................................................... 29

Handling (2.2) .......................................................... 11

Hydraulic, mechanical and electrical duty (5.9) ....... 31

Lifting (2.3) ............................................................... 11

Location (4.1) ........................................................... 18

Lubrication schedule (see 5.2, Pump lubricants)..... 29

Maintenance schedule (6.2) .................................... 32

Piping (4.7)............................................................... 23

Priming and auxiliary supplies (5.5) ......................... 29

Reassembly (see 6.10, Assembly) .......................... 36

Replacement parts (see 6.3 and 6.4) ...................... 33

Safety, electrical (see 4.9) ....................................... 26

Safety, protection systems (see 4.10) ..................... 26

Sound level (see 1.9, Noise level) ........................... 10

Specific machine performance (1.8) ........................ 10

Starting the pump (5.6) ............................................ 29

Stopping and shutdown (5.8) ................................... 30

Storage (2.4) ............................................................ 12

Supplementary manuals or information sources ..... 47

Tools required (6.5) ................................................. 33

Torques for fasteners (6.6) ...................................... 34

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MARK 3 GROUP 4 USER INSTRUCTIONS ENGLISH 71569286 08-12

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 are 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 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 platemarkings 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

1.5 Duty conditions

This product has been selected to meet the specifications of your purchaser order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.

The product must not be operated beyond the

parameters specified for the application. If there is any doubt as to the suitability of the product for the application intended, contact Flowserve for advice, quoting the serial number.

If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty) it is requested that you/the user

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seek the written agreement of Flowserve before start

up.

1.6 Safety

1.6.1 Summary of safety markings

These user instructions contain specific safety markings where non-observance of an instruction would cause hazards. The specific safety markings are:

This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life would affect personal safety.

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 (eg 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.

NEVER APPLY HEAT TO REMOVE IMPELLER Trapped lubricant or vapour could cause an explosion.

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 (176 °F) or below - 5 °C (23 °F) in a restricted zone, or excee ds local regulations, action as above shall be taken.

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HAZARDOUS LIQUIDS When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by appropriate sitting of the pump, limiting personnel access and by operator training. If the liquid is flammable and/or explosive, strict safety 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.

NEVER RUN THE PUMP DRY

ENSURE CORRECT LUBRICATION

(See section 5, Commissioning, start-up, operation and shutdown.)

START THE PUMP WITH OUTLET VALVE PART 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 or 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.)

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.

1.6.4 Products used in potentially explosive atmospheres

Measures are required to:

• Avoid excess temperature

• Prevent build up of explosive mixtures

• Prevent the generation of sparks

• Prevent leakages

• Maintain the pump to avoid hazard

The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection. For ATEX Both electrical and non-electrical equipment must meet the requirements of European Directive 94/9/EC. Always observe the regional legal Ex requirements eg Ex electrical items outside the EU may be required certified to other than ATEX eg IECEx, UL.

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific

atmosphere in which they are to be installed.

Where Flowserve has supplied only the bare shaft pump, the Ex rating applies only to the pump. The party responsible for assembling the ATEX pump set shall select the coupling, driver and any additional equipment, with the necessary CE Certificate/ Declaration of Conformity establishing it is suitable for the area in which it is to be installed.

The output from a variable frequency drive (VFD) can cause additional heating affects in the motor and so, for pumps sets with a VFD, the ATEX Certification for the motor must state that it is covers the situation where electrical supply is from the VFD. This particular requirement still applies even if the VFD is in a safe area.

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.

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Temperature class

1.6.4.2 Marking

An example of ATEX equipment marking is shown below. The actual classification of the pump will be engraved on the nameplate.

II 2 GD c IIC 135 ºC (T4)

Equipment Group I = Mining II = Non-mining

Category 2 or M2 = High level protection 3 = normal level of protection

Gas and/or Dust G = Gas; D= Dust

c = Constructional safety (in accordance with En13463-5)

Gas Group IIA – Propane (typical) IIB – Ethylene (typical) IIC – Hydrogen (typical) Maximum surface temperature (Temperature Class) (See section 1.6.4.3.)

1.6.4.3 Avoiding excessive surface temperatures

ENSURE THE EQUIPMENT TEMPERATURE

CLASS IS SUITABLE FOR THE HAZARD ZONE

Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate. These are based on a maximum ambient of 40 °C (104 °F); refer to Flowser ve 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.

Maximum permitted liquid temperature for pumps

to EN13463-1

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

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.

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.

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.

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 install an appropriate dry run protection device (eg 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.

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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.

or ATEX, the coupling must be selected to comply with

F 94/9/EC. Correct coupling alignment must be maintained.

Additional requirement for metallic pumps on nonmetallic baseplates

When metallic components are fitted on a non-metallic baseplate they shall be individual grounded.

1.6.4.6 Preventing leakage

The pump must only be used to handle liquids for which it has been approved to have the correct corrosion resistance.

Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves, which could cause dangerous excessive pressures to occur if there is heat input to the liquid. This can occur if the pump is stationary or running.

Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump and ancillary systems. Where there is the potential hazard of a loss of a seal barrier fluid or external flush, the fluid must be monitored.If leakage of liquid to atmosphere can result in a hazard, install a liquid detection device.

1.6.4.7 Maintenance to avoid the hazard

CORRECT MAINTENANCE IS REQUIRED TO

AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION

The responsibility for compliance with maintenance instructions is with the plant operator.

To avoid potential explosion hazards during maintenance, the tools, cleaning and painting materials used must not give rise to sparking or adversely affect the ambient conditions. Where there is a risk from such tools or materials, maintenance must be conducted in a safe area.

It is recommended that a maintenance plan and

schedule is adopted. (See section 6, Maintenance.

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1.7 Nameplate and warning labels

1.7.1 Nameplate

For details of nameplate, see the Declaration of Conformity or separate documentation included with

these User Instructions

1.7.2 Safety labels

MECHANICAL SEAL WARNING ROTATION WARNING

P/N 2113931-001 P/N 2113932-001

GROUT WARNING LIFTING WARNING

P/N 2113934-001 P/N 9901701-001

LUBRICATION WARNING – QF-440-R01 (2124841)

Oil lubricated units only:

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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.

capacity, pipework design and acoustic characteristics of the building. The levels specified in the table below are estimated and not guaranteed.

The dBA values are based on the noisiest ungeared electric motors that are likely to be encountered. They are Sound Pressure levels at 1 m (3.3 ft) from the directly driven pump, for "free field over a reflecting plane". For estimating L

sound power

level (re 1 pW) add 14dBA to the sound pressure

1.9 Noise level

When pump noise level exceeds 85 dBA attention must be given to prevailing Health and Safety Legislation, to limit the exposure of plant operating personnel to the noise. The usual approach is to control exposure time to the noise or to enclose the machine to reduce emitted sound. You may have already specified a limiting noise level when the

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.

equipment was ordered, however if no noise requirements were defined then machines above a certain power level will exceed 85 dBA. In such situations consideration must be given to the fitting of an acoustic enclosure to meet local regulations.

 For units driven by equipment other than

electric motors or units contained within enclosures, see the accompanying information sheets and manuals.

Pump noise level is dependent on a number of factors, the type of motor fitted, the operating

Motor size and speed

kW (hp)

<0.55(<0.75) 62 64 62 64 60 62 60 64

0.75 (1) 62 64 62 64 60 62 60 64

1.1 (1.5) 64 64 62 63 62 64 60 63

1.5 (2) 64 64 62 63 62 64 60 63

2.2 (3) 65 66 63 64 63 66 61 64 3 (4) 65 66 63 64 63 66 61 64

4 (5) 65 66 63 64 63 66 61 64

5.5 (7.5) 66 67 64 65 64 67 63 65

7.5 (10) 66 67 64 65 64 67 63 65 11(15) 70 71 68 69 68 71 67 69

15 (20) 70 71 68 69 68 71 67 69

18.5 (25) 71 71 69 71 69 71 68 70

22 (30) 71 71 69 71 69 71 68 70 30 (40) 73 73 71 73 71 73 70 72

37 (50) 73 73 71 73 71 73 70 72 45 (60) 76 76 74 76 74 76 72 75

55 (75) 76 76 74 76 74 76 72 75 75 (100) 77 77 75 77 75 77 73 76

90 (120) 77 78 75 78 75 78 73 76

110 (150) 79 80 77 80 77 78 75 78

150 (200) 79 80 77 80 77 78 76 78 200 (270) 85

300 (400) 87 90 85 86

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.

1 750 r/min 1 450 r/min 1180 r/min 980 r/min

Pump

only

Pump and

Typical sound pressure level LpA at 1 m reference 20 µPa, dBA

motor

87 83

Pump

only

Pump and

motor

85 81

Pump

only

Pump and

motor

83 80

Pump

only

Pump and

motor

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Note: For 880 and 720 r/min reduce 980 r/min values by 2 dBA.

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.

The pump should be lifted with suitably sized and located slings. Do not use the shaft for lifting and take special care to prevent the pump from rotating in the slings due to unbalanced weight distribution.

2.3 Lifting

A crane must be used for all pump sets or components in excess of 25 kg (55 lb). Fully trained personnel must carry out lifting, in accordance with local regulations. The driver and pump weights are recorded on the general arrangement drawing for the specific project. The table of engineering data in section 3.5 is for bare pump only and does not include the weight of the base, driver or auxiliary equipment.

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

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2.4 Storage

2.4.1 Short-Term Storage

When it is necessary to store a pump for a short time before it can be installed, place it in a dry, cool location. Protect it thoroughly from moisture and condensation. Protective flange covers should not be removed until the pump is being installed. Wrap the exposed portions of the shaft and coupling to protect against sand, grit or other foreign matter. Oil lubricated units should be lubricated (refer to Section III) to protect the bearings. Grease lubricated units are lubricated at the factory during assembly. Turn the rotor over by hand at least once a week to maintain a protective film on the bearing components.

2.4.2 LONG-TERM STORAGE

More than precautions are required if long-term storage in excess of 90 days from factory shipment is unavoidable.

The internal surfaces of the pump should be sprayed with a rust preventative such as a water soluble oil or other suitable alternative. Particular attention should be given to the impeller, wear plate and stuffing box.

An optional method of protection is to suspend bags of desiccant material inside casing and completely seal all openings from the surrounding atmosphere. The stuffing box should be packed with clean, dry rags. Use of this method requires that the casing be initially free of liquid. The desiccant material should be checked at regular intervals to ensure that it has not absorbed excessive water vapour. A warning instruction, advising that the desiccant must be removed prior to installation should be wired to the pump.

A rust inhibitor should be added to the lubricating oil of oil lubricated units to give additional protection without destroying the lubricating properties of the oil. For specific recommendations, consult your lubrication dealer. Grease lubricated units, which can be identified by the grease fitting at each bearing location, should be well lubricated prior to placing in storage. Small amounts of additional grease should be added at regular intervals during storage. Refer to Section III for additional information related to grease lubrication.

Storage of pumps in areas of high ambient vibration should be avoided to prevent bearing damage due to brinelling. The risk of such damage can be reduced by frequent rotation of the shaft.

The pump half coupling and key should be removed from the shaft, coated with rust preventative and wrapped to prevent metal-to-metal contact. Exposed surfaces of the pump shaft should be protected with a rust preventative. All dismantled parts should be wrapped and tagged according to pump serial number and a record kept of their location.

Pumps covered with plastic should not be stored in a cool environment because resulting condensation can cause rusting.

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 PUMP DESCRIPTION

3.1 Configurations

Flowserve "MARK 3" pumps are single stage, end suction centrifugal pumps specifically designed for the chemical process industry and consequently are ideally suited to many process fluids. A volute type casing with integrally cast feet and top centerline discharge nozzle is standard. The semi-open impeller with rear pump-out vanes is designed for high efficiency and prevents clogging. Sealing is provided at the impeller to shaft fit to prevent corrosion and thereby facilitate impeller removal. The thrust bearing housing uses a threaded adjustment that will permits precision bearing alignment and impeller setting. The back pull-out feature, typical of all MARK 3 pumps, permits quick removal of the entire rotor/frame assembly without disturbing the casing or driver.

The pump is sealed using non-asbestos packing in the stuffing box, various mechanical seal designs as specified by the customer may be installed at the factory or retrofitted in the field.

All pumps are carefully inspected and prepared for shipment. All exterior machined surfaces are coated

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with a rust preventative compound and openings are provided with covers or plugs. Shaft packing, when required, is shipped with the pump and should not be installed until the pump is ready to run. Mechanical seals, when provided, are factory installed and adjusted prior to shipment. The axial impeller running clearance is preset at the factory but should be checked prior to final alignment in case of tampering.

3.2 Name nomenclature

The pump size will be engraved on the nameplate. The following example explains how the pump name identifies the construction features and options.

4K10x6-18OP

Group size

Power end

Nominal suction branch size

Nominal discharge branch size

Nominal maximum impeller diameter

Open impeller

3.3 Design of major parts

3.3.1 Pump casing

The pump casing is a volute type casing with integrally cast feet and top centerline discharge nozzle. It is a one piece pressure retaining casting with gasket connections to the stuffing box head and the suction and discharge flanges.

3.3.2 Impeller

The impeller is semi-open design, keyed to the shaft and secured with a contoured impeller nut. The vanes of the impeller are Francis type.

3.3.3 Shaft

The large diameter stiff shaft, mounted on bearings, has a keyed drive end.

3.3.4 Pump bearings and lubrication

Ball bearings are fitted as standard and may be either oil or grease lubricated. Oil lubrication is only available where the pump shaft is horizontal.

3.3.5 Bearing housing

For oil lubricated bearings, a bulls eye level gauge is supplied. Constant level oilers can also be fitted. Two grease nipples enable grease lubricated bearings to be replenished between major service intervals.

3.3.6 Stuffing box housing

The stuffing box housing has a spigot (rabbet) fit between the pump casing and bearing housing for optimum concentricity. The design enables 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.

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.

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 up to+177 ºC (350 ºF) Minimum ambient temperature -20 ºC (-4 ºF) Maximum ambient temperature +50 ºC (122 ºF) Maximum soft solids in suspension up to 7 % by volume Maximum pump speed Refer to the nameplate

3.4.2 Speed torque curves

To bring a centrifugal pump up to rated speed, the driver must be capable of providing more torque at each speed than required by the pump. The margin between the available and required torque affects the time it takes the unit to reach full speed. If the torque required by the pump exceeds the torque capability of the drive at any run-up speed, the unit will not accelerate to full speed. Normally, this is not a problem with standard induction or synchronous motors provided the proper voltage is supplied at the motor.

For pumps started at shut valve conditions, 100 percent full speed torque can be calculated by using the formula:

Torque (Nm) = 9545 Shutoff Power (kW) r/min

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MARK 3 GROUP 4 USER INSTRUCTIONS ENGLISH 71569286 08-12

Torque (lbfx ft) = 5250 Shutoff Power (hp) r/min

Torque required by the pump at any other speed during start-up can be determined from the curve. Note that the driver manufacturer usually bases 100 percent torque on the design power of the driver and consequently the speed-torque curves should be plotted in torque units (e.g. Nm) instead of percentage torque to avoid confusion.

pressures shall be derated.

Do not conduct a hydro test on the namplete pump set without the specific approval of Flowserve. While the duty requirement will have been covered, auxiliary items, flange drillings and suction pressure limits may impose a reduced static and dynamic pressure rating compared to that of the pump casting rating itself.

Note: all flanges are ANSI 125 (Cast Iron or Ductile Iron-flat faced) or ANSI 150 (Stainless-raised face) unless otherwise stated. All flange facings on the casings are 250 rms – circular finish

3.4.3 MAXIMUM WORKING PRESSURES -bar (psi).

Above ambient temperature these maximum

CONSTRUCTION CAST IRON AND C.I.S.S. FITTED

TEMPERATURE

°C ( °F)

-30 to 38 (-20 to100) 10.3 (150) 10.3 (150) 13.8 (200)

65 (150) 10.3 (150) 9.7 (140) 13.8 (200)

95 (200) 10.3 (150) 9.3 (135) 13.4 (195)

120 (250) 10.3 (150) 9.0 (130) 12.6 (185)

150 (300)

UP TO 12”

DISCHARGE

Consult factory for applications in this range. Cast

iron not recommended due to thermal shock risks.

14 TO 16”

DISCHARGE

316,317L, WORTHITE, ETC.

175 (350) 11.0 (160)

STAINLESS STEEL

UP TO 16”

DISCHARGE

12.1 (175)

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MARK 3 GROUP 4 USER INSTRUCTIONS ENGLISH 71569286 08-12

3.5 Table Of Engineering Data

3.5.1 (GROUP 4 - LIQUID END)

ENGINEERING DATA

4K8x4-18OP

4K10X8-18OP

4K12X10-18OP

4K10X6-18OP

4K14X12-18OP

4K14X14-18OP

4K16X16-18OP

PUMP DATA

SUCTION DIAMETER mm (in.) 200 (8) 250 (10) 300 (12) 250 (10) 350 (14) 350 (14) 400 (16)

DISCHARGE DIAMETER mm (in.) 100 200 (8) 250 (10) 150 (6) 300 (12) 350 (14) 400 (16)

CASINGTHICK NESS

C.I. mm (in.) 16 (0.63) 21 (0.82) 21 (0.82) 18 (0.69) 19 (0.75) 21 (0.82) 21 (0.82)

S.S.mm (in.) 12 (0.50) 16 (0.63) 18 (0.69) 14(0.56) 16 (0.63) 18 (0.69) 18 (0.69)

CASING TYPE SV DV SV DV-DUAL VOLUTE GAUGE CONNECTION 1 / 2 NPT DRAIN CONNECTION 3/4 NPT 1 NPT 1 - 1 / 4 NPT

NO. OF VANES 4 6 5

IMPELLER EYE AREA m2 (in.2)

0.020 (31.0)

0.036 (55.6)

0.043 (66.0)

0.029 (45.2)

0.076 (117)

0.083 (130)

0.108 (169)

MAX. SPHERE DIA. mm (in.) 28 (1.1) 56 (2.2) 68 (2.7) 48 (1.9) 97 (3.8) 41 (1.6) 41 (1.6)

WK2 kg•m2 (lb•ft.2)

PUMP WT. kg (lb.)

0.57

(13.6)

473

(1040)

1.00

(23.9)

555

(1220)

1.32

(31.3)

718

(1580)

0.83

(19.8)

644

(1420)

0.93

(22.0)

816

(1800)

1.57

(37.2)

902

(1990)

1.39

(33.0)

1021

(2250)

Max. BACK PULLOUT WT kg (lb.) 340 (750)

IMPELLER AXIAL mm (in.) FRONT CLEARANCE

MAXIMUMTEM PERATURE

NO COOLING

WITH COOLING

0.38/0.50

(0.015 /0.020)

120 °C (250 °F)

176 °C (350 °F)

STUFFING BOX DATA – CBS

O.D. SLEEVE mm (in.) 76.20 (3.000) 95.25 (3.750)

STUFFING BOX BORE mm (in.) 101.6 (4.000) 127.0 (5.000)

DEPTH OF BOX mm (in.) 99.0 (3.90) 122.2 (4.81)

PACKING SIZE (in.) 1 /2 X 1 /2 5 / 8 X 5 / 8

PACKING STD. 2L3 ARRANGEMENT ALT. 3L2 DISTANCE TO FIRST mm (in.)

OBSTRUCTION (gland)

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