Flowserve Mark 3 Sealed Metallic Durco User Manual

USER INSTRUCTIONS

Durco® Mark 3 Sealed Metallic Pumps

Mark 3 Standard, In-Line, Lo-Flo, Recessed Impeller, Unitized Self Priming and Sealmatic Pumps

PCN=71569102 – 01-13 (E) Original Instructions

Installation

Operation

Maintenance

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

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 ......................... 8

1.8 Specific machine performance ....................... 8

1.9 Noise level ...................................................... 8

2 TRANSPORT AND STORAGE ............................ 9

2.1 Consignment receipt and unpacking ............ 9

2.2 Handling ........................................................ 9

2.3 Lifting ............................................................ 9

2.4 Storage ....................................................... 11

2.5 Recycling and end of product life ............... 11

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

3.1 Configurations ............................................. 12

3.2 Nomenclature ............................................. 12

3.3 Design of major parts .................................. 12

3.4 Performance and operation limits ............... 13

4 INSTALLATION .................................................. 19

4.1 Location ...................................................... 19

4.2 Part assemblies .......................................... 19

4.3 Foundation .................................................. 19

4.4 Baseplate Mounting .................................... 20

4.5 Initial alignment ........................................... 22

4.6 Piping .......................................................... 24

4.7 Electrical connections ................................. 34

4.8 Final shaft alignment check ........................ 34

4.9 Protection systems ..................................... 35

5 COMMISSIONING, STARTUP, OPERATION AND

SHUTDOWN ...................................................... 35

5.1 Pre-commissioning procedure .................... 35

5.2 Pump lubricants .......................................... 36

5.3 Impeller clearance ...................................... 39

5.4 Direction of rotation ..................................... 39

5.5 Guarding ..................................................... 39

5.6 Priming and auxiliary supplies .................... 41

5.7 Starting the pump........................................ 41

5.8 Running or operation .................................. 41

5.9 Stopping and shutdown .............................. 42

5.10 Hydraulic, mechanical and electrical duty .. 42

6 MAINTENANCE .................................................. 43

6.1 Maintenance schedule ................................ 43

6.2 Spare parts .................................................. 44

6.3 Recommended spares and consumable

7 FAULTS; CAUSES AND REMEDIES ................. 62

8 PARTS LIST AND DRAWINGS .......................... 64

9 CERTIFICATION ................................................ 71

10 OTHER RELEVANT DOCUMENTATION AND

items ............................................................ 44

6.4 Tools required .............................................. 44

6.5 Fastener torques ......................................... 45

6.6 Setting impeller clearance and impeller

replacement ................................................ 45

6.7 Disassembly ................................................ 47

6.8 Examination of parts ................................... 51

6.9 Assembly of pump and seal ........................ 55

8.1 Standard Mark 3 pump, Group 1 ................. 64

8.2 Standard Mark 3 pump, Group 2 & Group 365

8.3 Mark 3 Sealmatic pump, Group 2 ............... 66

8.4 Mark 3 Lo-Flo, Group 2 ............................... 66

8.5 Mark 3 Unitized Self Priming pump, Group 2 67

8.6 Mark 3 Recessed Impeller pump, Group 2 . 67

8.7 Mark 3 In-Line pump, Group 1 .................... 68

8.8 Mark 3 In-Line pump, Group 2 .................... 69

8.9 Mark 3 C-Face Adapter, Group 1 & Group 2 70

8.10 General arrangement drawing .................... 71

MANUALS ........................................................... 71

10.1 Supplementary User Instructions ................ 71

10.2 Change notes .............................................. 71

10.3 Additional sources of information ................ 71

Page

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MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

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 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 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

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.

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MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty) it is requested that the user seeks the written agreement of Flowserve before start up.

1.6 Safety

1.6.1 Summary of safety markings

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

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

This symbol indicates safety instructions where non-compliance would affect personal safety and could result in loss of life.

This symbol indicates “hazardous and toxic fluid” safety instructions where non-compliance would affect personal safety and could result in loss of life.

This symbol indicates safety instructions where non-compliance will involve some risk to safe operation and personal safety and would damage the equipment or property.

This symbol indicates explosive atmosphere zone marking according to ATEX. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.

safety requirements and applicable safety and health laws and regulations.

1.6.3 Safety action

This is a summary of conditions and actions to help prevent injury to personnel and damage to the environment and to equipment. For products used in potentially explosive atmospheres section 1.6.4 also applies.

NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER (Lock out.)

GUARDS MUST NOT BE REMOVED WHILE

THE PUMP IS OPERATIONAL

NEVER OPERATE THE PUMP WITHOUT THE COUPLING GUARD AND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED

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.

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

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 vapor could cause an explosion.

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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 must be taken to avoid accidental contact (such as shielding). 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) or below -5 °C (23 °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 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.

the motor and cause cavitation. Low flow rates may cause a reduction in pump/bearing life, overheating of the pump, instability and cavitation/vibration.

NEVER EXCEED THE MAXIMUM DESIGN PRESSURE (MDP) AT THE TEMPERATURE SHOWN ON THE PUMP NAMEPLATE

ENSURE CORRECT LUBRICATION (See section 5, Commissioning, startup, operation and shutdown.) See section 3 for pressure versus temperature ratings based on the material of construction.

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 spacer 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

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

OR WITHOUT PROPER PRIME (Casing flooded)

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 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

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

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

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

Scope of compliance

Use equipment only in the zone for which it is

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MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

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. 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.

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 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

Pump liquid temperature

Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate. These are based on a maximum ambient temperature of 40 ºC (104 ºF); refer to Flowserve for higher ambient temperatures.

The surface temperature on the pump is influenced by the temperature of the liquid handled. The maximum permissible liquid temperature depends on the

temperature class and must not exceed the values in the table applicable below.

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

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

*The tables only takes the ATEX temperature class into consideration. Pump design or material, as well as component design or material, may further limit the maximum working temperature of the liquid.

Maximum surface

temperature

permitted

85 °C (185 °F) 100 °C (212 °F) 135 °C (275 °F) 200 °C (392 °F) 300 °C (572 °F) 450 °C (842 °F)

Temperature limit of

liquid handled

Consult Flowserve Consult Flowserve

110 °C (230 °F) * 175 °C (347 °F) * 270 °C (518 °F) * 350 °C (662 °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 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..

Do not attempt to check the direction of rotation with the coupling element/pins fitted due to the risk of severe contact between rotating and stationary components.

Avoid mechanical, hydraulic or electrical overload by using motor overload trips, temperature monitor or a power monitor and perform routine vibration monitoring.

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 temperature, fit an external surface temperature protection device.

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MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

Additional requirements for self-priming casing pumps

Where the system operation does not ensure control of priming, as defined in these User Instructions, and the maximum permitted surface temperature of the T Class could be exceeded, install 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 that the pump and relevant suction and discharge

piping system 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 fit an appropriate dry run protection device (for example liquid detection or a power monitor).

To avoid potential hazards from fugitive emissions of vapor or gas to atmosphere, the surrounding area must be well ventilated.

Preventing sparks

1.6.4.5

To prevent a potential hazard from mechanical contact, the coupling guard must be non-sparking for Category 2.

To avoid the potential hazard from random induced current generating a spark, the baseplate must be properly 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 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, 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.)

Avoid electrostatic charge. Do not rub nonmetallic surfaces with a dry cloth; ensure the cloth is damp.

For ATEX the coupling must be selected to comply with 94/9/EC. Correct coupling alignment must be maintained.

Additional requirements for metallic pumps on non-metallic baseplates

When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.

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MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

THIS DEVICE IS NOT A CONTAINMENT

1.7 Name plate 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:

DurcoShieldTM (Splash/Shaft Guard) only:

SYSTEM OR A SEAL BACKUP SYSTEM IT IS A LIMITED PROTECTION DEVICE. IT WILL REDUCE BUT NOT ELIMINATE THE PROBABILITY OF INJURY.

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 14 dBA to the sound pressure value.

1.8 Specific machine performance

For performance parameters see section 1.5, Duty conditions. Where performance data has been supplied separately to the purchaser these should be obtained and retained with these User Instructions

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MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

<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)

85 87 83 85

300

(400) 87 90 85 86

Motor size and speed

kW (hp)

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.

Pump

only

1 1 1 1

2 TRANSPORT AND STORAGE

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

3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

Pump

only

Pump and

motor

2.3 Lifting

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 Solution group and must be received within ten days 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.

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.

Slings, ropes and other lifting gear should be positioned where they cannot slip and where a balanced lift is obtained. The angle between sling or ropes used for lifting must not exceed 60°.

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.

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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

Rear cover [1220]

Insert an eye hook in the drilled and tapped hole at the top of the cover. Use either a sling or hook through the eye bolt.

2.3.1.3

Bearing housing [3200]

Group 1: insert a sling between the upper and lower support ribs between the housing barrel and the casing attachment flange. Use a choker hitch when slinging. (Make sure there are no sharp edges on the bottom side of the ribs that could cut the sling.)

Group 2 and 3: insert either a sling or hook through the lifting lug located on the top of the housing.

2.3.1.4

Power end

Same as bearing housing.

2.3.1.5

Bare pump

Horizontal pumps: sling around the pump discharge nozzle and around the outboard end of the bearing housing with separate slings. Choker hitches must be used at both attachment points and pulled tight. Make sure the completion of the choker hitch on the discharge nozzle is toward the coupling end of the pump shaft as shown in figure 2-1. The sling lengths should be adjusted to balance the load before attaching the lifting hook.

Figure 2.1

Figure 2.2

2.3.2 Lifting pump, motor and baseplate

assembly

2.3.2.1

Horizontal assemblies

If the baseplate has lifting holes cut in the sides at the end (Type A Group 3, Type D and Type E bases) insert lifting S hooks at the four corners and use slings or chains to connect to the lifting eye. (Figure 2-3.) Do not use slings through the lifting holes.

Figure 2.3

In-Line pumps: lift with two slings through the pump adapter on opposite sides of the shaft. (Figure 2-2.)

Bare pump with motor adapter (In-Line only): lift with two slings through the motor adapter shaft holes. This method is also used to lift the bare motor adapter. (Figure 2-2.)

For other baseplates, sling around the pump discharge nozzle, and around the outboard end of the motor frame using choker hitches pulled tight. (Figure 2-4.) T5000 type bases should not be lifted with motor attached (i.e. pump and base only).

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MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

Figure 2.4

The sling should be positioned so the weight is not carried through the motor fan hood. Make sure the completion of the choker hitch on the discharge nozzle is toward the coupling end of the pump shaft as shown in figure 2-4.

2.3.2.2

If the pump is to be lifted as a complete assembly, the motor lifting lugs must be used to ensure that the assembly does not flip over. Check with motor supplier for lifting lug capacities. If there is any uncertainty, the motor should be removed prior to moving the pump. (Figure 2-2.)

In-Line assemblies

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.

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 and EXXON UNIREX N3 for In-Line 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 units are to be idle for extended periods after addition of lubricants, inhibitor oils and greases should be used. Every three months, the pump shaft should be rotated approximately 10 revolutions.

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.

Page 11 of 72 flowserve.com

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

3 DESCRIPTION

3.1 Configurations

The Durco Mark 3 chemical process pumps are metallic , single stage, sealed, centrifugal pumps. The horizontal family conforms to ASME B73.1M, which has a centerline discharge and is represented by our Standard, Sealmatic, Unitized self-priming, Recessed impeller and Lo-Flo pump models. The vertical pump or In-Line conforms to ASME B73.2M.

Figure 3-1: Nameplate mounted to housing

Serial No.

Equipment No.

Purchase Order

Date DD/MMM/YY

The Prima

Model

Size

MDP

Material

3 TM

2K6X4 M-13A/12.5 RV

is an ANSI 3A power end adapted to other pump models from Flowserve as well as from other pump manufacturers. Only the information in this manual involving the ANSI 3A power end may be used when Installing, Operating or Maintaining a pump that has been upgraded to a Prima

3 TM

. All other information regarding the pump type must be obtained from the original pump manufacturer's User Instructions.

3.2 Nomenclature

The pump size will be engraved on the nameplate typically as below:

2 K 6 X 4 M - 13 A /12.5 RV

• 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) J = Mark 3 style PE arranged for Mark 2 wet end

(No letter and no preceding number indicates a Mark 2 power end)

HD = Heavy Duty variant of the Mark 3 power end

(suffix)

• “6” = nominal suction port size (in.)

• “4” = Nominal discharge port size (in.)

• Modifier for “specialty pumps”

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. “13” = 13 in.

• Pump design variation

A = This pump has been redesigned from an earlier

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 same basic designation. (Example: 4X3-13 and 4X3-13HH.)

• Actual impeller size “12.5” = 12 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

Removal of the casing is not required when performing maintenance of the rotating element. The pump is designed with a gasket perpendicular to the shaft allowing the rotating element to be easily removed (back pull out).

3.3.2 Impeller

Depending on the product, the impeller is either reverse vane or open.

3.3.3 Shaft/sleeve

Solid and sleeved shafts are available, supported on bearings, threaded impeller end and keyed drive end.

3.3.4 Pump bearings and lubrication

Ball bearings are fitted as standard and may be either oil or grease lubricated.

3.3.5 Bearing housing

Large oil bath reservoir.

3.3.6 Seal chamber (cover plate)

The seal chamber has a spigot (rabbet) fit between the pump casing and bearing housing (adapter) for

Page 12 of 72 flowserve.com

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

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 C-flange motor adapters

Avaliable option for Mark3 group 1 and 2 and NEMA motors from 182TC to 405TSC frames. Motors above 324TSC must be short shaft type

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 for your application 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.

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

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.

Page 13 of 72 flowserve.com

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

3.4.2 Pressure-temperature ratings

The pressure–temperature (P-T) ratings for Mark 3 pumps are shown in figures 3-3 to 3-5. Determine the appropriate casing “Material Group No.” in Figure 3-2. Interpolation may be used to find the pressure rating for a specific temperature.

a) The correct pressure-temperature chart is

Figure 3-5C.

b) From Figure 3-2, the correct material group for

CF8M is 2.2

c) From Figure 3-5C, the pressure-temperature

rating is 21.5 bar.

Example: The pressure temperature rating for an ANSI std. GP2-10” pump with Class 300 flanges and CF8M construction at an operating temperature of 149˚C is found as follows:

The maximum discharge pressure must be less than or equal to the P-T rating. Discharge pressure may be approximated by adding the suction pressure and the differential head developed by the pump.

Figure 3-3 12x10-18HD Only

Material Group No.

Temp

˚C

-73 13.8 13.8 13.8 9.7 13.8 13.8 13.8 13.8 13.8 13.8

-29 13.8 13.8 13.8 13.8 13.8 9.7 13.8 13.8 13.8 13.8 13.8 13.8

-18 13.8 13.8 13.8 13.8 13.8 9.7 13.8 13.8 13.8 13.8 13.8 13.8 12.6 38 13.8 13.8 13.8 13.8 13.8 9.7 13.8 13.8 13.8 13.8 13.8 13.8 12.6 93 13.8 13.8 13.8 13.8 13.8 9.7 13.8 13.8 13.8 13.8 13.8 13.8 12.6

149 13.8 13.8 13.8 13.8 13.8 9.7 13.1 12.4 13.8 13.8 12.4 13.8 12.6 171 13.8 13.8 13.7 13.8 13.8 9.7 13.0 12.1 13.8 13.8 11.9 13.8 12.6 204 13.8 13.8 13.1 13.4 13.8 9.7 12.8 11.7 13.8 13.8 11.0 13.8 260 11.7 11.7 11.7 11.7 11.7 9.7 11.7 11.0 11.7 11.7 10.3 11.7

1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti Cr bar

Material Group No.

Temp

˚F

-100 200 200 200 140 200 200 200 200 200 200

-20 200 200 200 200 200 140 200 200 200 200 200 200 100 200 200 200 200 200 140 200 200 200 200 200 200 183

200 200 200 200 200 200 140 200 200 200 200 200 200 183 300 200 200 200 200 200 140 190 180 200 200 180 200 183 340 200 200 199 200 200 140 188 176 200 200 172 200 183 400 200 200 190 195 200 140 185 170 200 200 160 200 500 170 170 170 170 170 140 170 160 170 170 150 170

1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti Cr psi

0 200 200 200 200 200 140 200 200 200 200 200 200 183

Page 14 of 72 flowserve.com

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

Figure 3-4 Class 150 Flanges

Material Group No.

Temp

˚C

-73 19.0 19.0 19.7 9.7 15.9 15.2 20.0 20.0 15.9 20.0

-29 17.2 19.7 19.0 19.0 19.7 9.7 15.9 15.2 20.0 20.0 15.9 20.0

-18 17.2 19.7 19.0 19.0 19.7 9.7 15.9 15.2 20.0 20.0 15.9 20.0 12.6 38 17.2 19.7 19.0 19.0 19.7 9.7 15.9 15.2 20.0 20.0 15.9 20.0 12.6 93 16.2 17.9 15.9 16.2 17.9 9.7 13.8 13.8 17.9 17.9 13.8 17.9 12.6

149 14.8 15.9 14.1 14.8 15.9 9.7 13.1 12.4 15.9 15.9 12.4 15.9 12.6 171 14.4 15.0 13.7 14.3 15.0 9.7 13.0 12.1 15.0 15.0 11.9 15.0 12.6 204 13.8 13.8 13.1 13.4 13.8 9.7 12.8 11.7 13.8 13.8 11.0 13.8 260 11.7 11.7 11.7 11.7 11.7 9.7 11.7 11.0 11.7 11.7 10.3 11.7 316 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 9.7 343 8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.6 371 7.6 7.6 7.6 7.6 7.6 7.6 7.6 7.6

1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti Cr bar

Material Group No.

Temp

˚F

-100 275 275 285 140 230 220 290 290 230 290

-20 250 285 275 275 285 140 230 220 290 290 230 290

100 250 285 275 275 285 140 230 220 290 290 230 290 183 200 235 260 230 235 260 140 200 200 260 260 200 260 183 300 215 230 205 215 230 140 190 180 230 230 180 230 183 340 209 218 199 207 218 140 188 176 218 218 172 218 183 400 200 200 190 195 200 140 185 170 200 200 160 200 500 170 170 170 170 170 140 170 160 170 170 150 170 600 140 140 140 140 140 140 140 140 140 140 140 140 650 125 125 125 125 125 125 125 125 125 700 110 110 110 110 110 110 110 110

1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti Cr psi

0 250 285 275 275 285 140 230 220 290 290 230 290 183

Figure 3-5A Group 2-13” In-Lines and Group 3 Pumps with Class 300 Flanges

Material Group No.

Temp

˚C

-73 24.1 24.1 24.1 17.4 24.1 24.1 24.1 24.1 24.1 24.1

-29 24.1 24.1 24.1 24.1 17.4 24.1 24.1 24.1 24.1 24.1 24.1

-18 24.1 24.1 24.1 24.1 17.4 24.1 24.1 24.1 24.1 24.1 24.1 38 24.1 24.1 24.1 24.1 17.4 24.1 24.1 24.1 24.1 24.1 24.1 93 22.0 20.1 20.8 23.2 17.4 21.3 22.9 24.1 24.1 20.9 21.4

149 21.4 18.1 18.8 21.4 17.4 19.9 21.4 23.5 23.5 18.7 18.7 204 20.7 16.6 17.3 19.8 17.4 19.3 19.9 22.7 22.7 16.9 15.9 260 19.6 15.3 16.1 18.5 17.4 19.1 19.3 21.4 21.4 15.7 13.2 316 17.9 14.6 15.1 17.9 17.4 19.1 19.2 19.5 19.5 14.5 10.5 343 17.4 14.4 14.9 19.1 19.0 19.0 19.0 9.1 371 17.4 14.2 14.4 19.1 18.9 18.3 18.3 7.7

1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti bar

Material Group No.

Temp

˚F

-100 350 350 350 252 350 350 350 350 350 350

-20 350 350 350 350 252 350 350 350 350 350 350

100 350 350 350 350 252 350 350 350 350 350 350 200 319 292 301 336 252 309 332 350 350 303 310 300 310 263 272 310 252 289 310 341 341 271 271 400 300 241 250 287 252 280 288 329 329 245 231 500 284 222 233 268 252 277 280 310 310 228 191 600 260 211 219 259 252 277 278 282 282 210 152 650 253 209 216 277 276 275 275 132 700 253 207 209 277 274 266 266 112

1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti psi

0 350 350 350 350 252 350 350 350 350 350 350

Page 15 of 72 flowserve.com

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

Figure 3-5B Group2-13” Lo-Flo Pumps with Class 300 Flanges

Material Group No.

Temp

˚C

-73 31.0 31.0 31.0 17.4 24.1 27.6 31.0 31.0 24.1 31.0

-29 31.0 31.0 31.0 31.0 31.0 17.4 24.1 27.6 31.0 31.0 24.1 31.0

-18 31.0 31.0 31.0 31.0 31.0 17.4 24.1 27.6 31.0 31.0 24.1 31.0 38 31.0 31.0 31.0 31.0 31.0 17.4 24.1 27.6 31.0 31.0 24.1 31.0 93 29.1 28.3 25.9 26.7 29.8 17.4 21.3 26.1 31.0 31.0 20.9 27.5

149 27.4 27.5 23.3 24.1 27.5 17.4 19.9 24.4 30.2 30.2 18.7 24.0 204 25.5 26.6 21.3 22.2 25.4 17.4 19.3 22.7 29.2 29.2 16.9 20.5 260 24.0 25.2 19.7 20.7 23.8 17.4 19.1 22.1 27.5 27.5 15.7 17.0 316 22.5 23.1 18.7 19.4 23.0 17.4 19.1 21.9 25.0 25.0 14.5 13.4 343 21.8 22.4 18.5 19.2 19.1 21.8 24.4 24.4 11.7 371 22.4 18.3 18.5 19.1 21.6 23.6 23.6 9.9

1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti bar

Material Group No.

Temp

˚F

-100 450 450 450 252 350 400 450 450 350 450

-20 450 450 450 450 450 252 350 400 450 450 350 450

100 450 450 450 450 450 252 350 400 450 450 350 450 200 422 410 375 388 432 252 309 379 450 450 303 399 300 397 398 338 350 399 252 289 354 438 438 271 348 400 369 386 309 322 369 252 280 330 423 423 245 297 500 348 365 285 300 345 252 277 320 399 399 228 246 600 327 334 272 281 333 252 277 318 363 363 210 195 650 316 325 269 278 277 316 354 354 170 700 325 266 269 277 313 342 342 144

1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti psi

0 450 450 450 450 450 252 350 400 450 450 350 450

Figure 3-5C All other Class 300 Flanges

Material Group No.

Temp

˚C

-73 27.6 27.6 27.6 17.4 24.1 24.1 27.6 27.6 24.1 27.6

-29 27.6 27.6 27.6 27.6 17.4 24.1 24.1 27.6 27.6 24.1 27.6

-18 27.6 27.6 27.6 27.6 17.4 24.1 24.1 27.6 27.6 24.1 27.6 38 27.6 27.6 27.6 27.6 17.4 24.1 24.1 27.6 27.6 24.1 27.6 93 25.2 23.0 23.7 26.5 17.4 21.3 22.9 27.6 27.6 20.9 24.5

149 24.4 20.7 21.5 24.5 17.4 19.9 21.4 26.8 26.8 18.7 21.3 204 23.7 19.0 19.7 22.6 17.4 19.3 19.9 25.9 25.9 16.9 18.2 260 22.4 17.5 18.4 21.1 17.4 19.1 19.3 24.5 24.5 15.7 15.1 316 20.5 16.7 17.2 20.4 17.4 19.1 19.2 22.2 22.2 14.5 12.0 343 19.9 16.5 17.0 19.1 19.0 21.7 21.7 10.4 371 19.9 16.3 16.5 19.1 18.9 21.0 21.0 8.8

Temp

˚F

-100 400 400 400 252 350 350 400 400 350 400

-20 400 400 400 400 252 350 350 400 400 350 400

0 400 400 400 400 252 350 350 400 400 350 400 100 400 400 400 400 252 350 350 400 400 350 400 200 365 333 344 384 252 309 332 400 400 303 355 300 354 300 311 355 252 289 310 389 389 271 309 400 343 275 286 328 252 280 288 376 376 245 264 500 324 253 267 307 252 277 280 355 355 228 219 600 297 242 250 296 252 277 278 323 323 210 173 650 289 239 247 277 276 315 315 151 700 289 236 239 277 274 304 304 128

1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti bar

Material Group No.

1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti psi

Page 16 of 72 flowserve.com

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

Specific Gravity

3.4.3 Suction pressure limits

The suction pressure limits for Mark 3 pumps with reverse vane impellers is limited by the values given in figure 3-6 and by the P-T ratings.

Suction pressure for pump sizes 10x8-14, 8x6-16A, 10x8-16, 10x8-16H, and 12x10-18HD (up through 2.0 specific gravity) are limited only by the P-T ratings.

Figure 3-6A: Suction pressure limits 1750 r/min

27.5

22.5

17.5

12.5

7.5

Maximum Allowable Suction Pressure - bar

2.5

0.4 0.8 1.2 1.6 2 2.4

Figure 3-6B: Suction pressure limits 3500 r/min

27.5

Suction pressure for pumps with open impellers are also limited only by the P-T ratings.

The suction pressure limits for Sealmatic pumps are determined by the repeller head capability found in Bulletin P-18-102e.

400

360

320

280

240

200

160

120

Maximum Allowable Suction Pressure - psi

400

22.5

17.5

12.5

7.5

Maximum Allowable Suction Pressure - bar

2.5

0.4 0.8 1.2 1.6 2 2.4

Specific Gravity

16 15 14 13 12 11

987

360

320

280

240

200

160

120

Maximum Allowable Suction Pressure - psi

Page 17 of 72 flowserve.com

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

Figure 3-7: Suction pressure reference numbers

Pump Size 1750 3500

1K 1.5x1-6 7 10 1K 3x1.5-6 10 15

1K 3x2-6 and US-6 10 12

1K 2 x1.5V-6

1K 1.5x1-8

1K 1.5x1.5US-8

1K 2x1.5V-8

1K 3x1.5-8 4 4

1K 3x2V-7 2K 3x2-8 and US-8 10 7 2K 4x3-8 and US-8 10 13

2K 2x1-10A 8 3

2K 2x1.5V-10A

2K 2x1.5US-10A

2K 3x1.5-10A 10 17

2K 3x2-10A 10 14

2K 3x2V-10

2K 4x3-10H 3

2K 6x4-10H 10

2K 3x1.5-13 9 5

2K 4x3-13/13 1 2K 4x3-13/12 1

2K 4x3-13/11 max 1 2

2K 4x3-13HH 10

2K 6x4-13A 1

2K 6x4-13A/10.25 1

3K 8x6-14A 2

3K 10x8-14

3K 8x6-16A

3K 10x8-16 & 16H

3K 10x8-17 3

12X10-18HD

Recessed Impellers

Lo-Flo Pumps

Open Impellers

Notes:

1. Self-Primer and In-Line pumps not specifically listed above are to use the standard pump ratings given. For example: 2K 3x2V-13 and 2K 3x2US-13 pumps utilize the standard 2K 3x2-13 ratings.

2. P-T: Only limited by Pressure-Temperature ratings.

3. Open impeller pumps including the Lo-Flo and Recessed Impeller products are limited in suction pressure only by the Pressure-Temperature Ratings.

4. Sealmatic Pump suction pressure is limited by the repeller

In-Line

2K 4x3-10 6 2

2K 6x4-10 5 8

2K 3x2-13 5 1

3K 6x4-16

7 6

8 3

11 9

PT na PT na PT na PT na

PT na PT PT PT PT PT PT

na na

na na ? na

3.4.4 Minimum continuous flow

The minimum continuous flow (MCF) is based on a percentage of the best efficiency point (BEP). Figure 3-8 identifies the MCF for all Mark 3 pump models with the exception of the Lo-Flo pump line; there is no MCF associated with this product line.

Figure 3-8: Minimum continuous flow

Pump size

1K3x2-6 20% 10% 10% 1K3x2-7 25% 10% 10% 2K3x2-8 20% 10% 10% 2K4x3-8 20% 10% 10% 2K3x2-10 30% 10% 10% 2K4x3-10 30% 10% 10% 2K6x4-10 40% 10% 10% 2K6x4-10H n.a. 20% 10% 2K3x1.5-13 30% 10% 10% 2K3x2-13 40% 10% 10% 2K4x3-13 40% 20% 10% 2K4x3-13HH n.a. 50% 30% 2K6x4-13 60% 40% 10% 3K8x6-14 n.a. 40% 15% 3K10x8-14 n.a. 40% 10% 3K6x4-16 n.a. 50% 10% 3K8x6-16 n.a. 50% 10% 3K10x8-16 n.a. 50% 10% 3K10x8-17 n.a. 50% 10%

3K12x10-18HD

All other sizes 10% 10% 10%

3500/2900

r/min

n.a. 60% 10%

MCF % of BEP

1750/1450

r/min

1180/960

r/min

3.4.5 Minimum suction pipe submergence

To avoid priming problems, consideration should be given to minimum suction pipe submergence when installing Unitized self-priming pumps.

Page 18 of 72 flowserve.com

MARK 3 USER INSTRUCTIONS ENGLISH 71569102 01-13

4 INSTALLATION

Zirconium 702 or high chrome iron components

If any of the components of the pump have been made of zirconium or high chrome 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

Zirconium 705 and high chrome iron components

Avoid any repair or fabrication welds on Zirconium 705 and high chrome 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 practicable to the supply of liquid to be pumped. Refer to the general arrangement drawing for the pump set.

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.

The most advantageous method is the one that permits the pump to move with the piping. This eliminates problems due to thermal expansion, as the pump is designed to withstand forces that the piping is normally capable of transmitting.

4.3.3 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 design. (Figure 4-1.)

• Stilt mounted, or free standing. (Figure 4-2.)

Figure 4-1

Figure 4-2

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 In-Line pump mounting

The Mark 3 In-Line can be supported in several ways:

• The pump may be supported by the piping; in

which case it is recommended that the suction and discharge pipes be supported adjacent to the pump nozzles

• The pump may be supported under the casing

foot or on the optional “pump stand”

The “pump stand” will allow the pump to free stand without the aid of piping. The pump stand may be bolted (and grouted) into place. In this case, the piping loads must be within the limits of the casing and of the “pump stand” as found in section 4.6.

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,

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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.

4.4 Baseplate Mounting

4.4.1 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.”

4.4.1.1

Refer to figure 4-3. a) Raise or block up baseplate/pump above the

b) Predetermine or measure the approximate c) Set the bottom nuts [2] above the stilt bolt head d) Assemble lock washer [3] down over the stilt bolt.

e) Assemble the stilt bolt up through hole in the f) Assemble the lock washer [3] and nut [2] on the

g) After all four stilts have been assembled,

Stilt mounted baseplate assembly

instructions

floor to allow for the assembly of the stilts. desired height for the baseplate above the floor. [1] to the desired height.

bottom plate and hold in place. stilt bolt. Tighten the nut down on the lock

washer. 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

4.4.1.2

Refer to figure 4-4. a) Raise or block up baseplate/pump above the

b) Set the bottom nuts [4] above the stilt bolt head

c) Assemble the lock washer [6] flat washer [5] and

d) Assemble the stilt bolt/bottom spring up through e) Assemble top spring/cup assembly [3] down f) Assemble flat washer [5], lock washer [6] and g) Tighten down top nuts, compressing the top

h) After all four stilts have been assembled,

i) Level and make final height adjustments to the

Stilt/spring mounted baseplate assembly

instructions

floor to allow for the assembly of the stilts. [1]. This allows for 51 mm (2 in.) upward

movement for the final height adjustment of the suction/discharge flange.

bottom spring/cup assembly [2] down over the stilt bolt [1].

hole in the bottom plate and hold in place. over stilt bolt. nuts [4] on the stilt bolt. spring approximately 13 mm (0.5 in.). Additional

compression may be required to stabilize the baseplate.

position the baseplate in place, over the floor cups [7] under each stilt location, and lower the baseplate down to the floor.

suction and discharge pipe by first loosening the top nuts, and turning the bottom nuts to raise or lower the baseplate.

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j) Recompress the top spring to the compression

established in step g) 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

4.4.1.3

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.

b) After the base is level, it is locked in place by c) Next the initial pump alignment must be checked.

d) If the fasteners are not centered there was likely

e) If the fasteners are centered, then the baseplate

Stilt/spring mounted baseplates - motor

alignment

(Shims are not needed as with grouted baseplates.)

locking the stilt adjusters. 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.

shipping damage. Re-center the fasteners and perform a preliminary alignment to the above tolerances by shimming under the motor for vertical alignment, and by moving the pump for horizontal alignment.

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.

4.4.2 Mounting Grouted Baseplates

a) The pump foundation should be located as close

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.

4.4.2.1

concrete inside a sleeve to allow some movement of the bolt.

Figure 4-5

d) Level the pump baseplate assembly. If the

Mounting Instructions - All Grouted Bases

(Except T5000 Base)

Foundation bolts are imbedded in 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.

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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 above, pumps are given a preliminary alignment at the factory. This 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 holes 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 should 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 moving the pump for horizontal alignment.

j) Grout the baseplate. A non-shrinking grout

should be used. Make sure that the grout fills the

area under the baseplate. After the grout has cured, check for voids and repair them. Jackscrews, shims and wedges should be removed from under the baseplate at this time. If they were to be left in place, they could rust, swell, and cause distortion in the baseplate.

k) Run piping to the suction and discharge of the

pump. There should be no piping loads transmitted to the pump after connection is made. Recheck the alignment to verify that there are no significant loads.

4.4.2.2

Refer to standard pump foundation for installation of grouted and adjustable type baseplates. It may be necessary to remove the pump from the baseplate to access the grout hole.

Refer to standard pump piping for piping recommendations.

Temporary supports (installed for shipping only) should be removed from under the motor.

Mounting instructions Pump with C-flange

motor adapter

4.5 Initial alignment

4.5.1 Horizontal initial alignment procedure

The purpose of factory alignment is to ensure that the user will have full utilization of the clearance in the motor holes for final job-site alignment. To achieve this, the factory alignment procedure specifies that the pump be aligned in the horizontal plane to the motor, with the motor foot bolts centered in the motor holes. This procedure ensures that there is sufficient clearance in the motor holes for the customer to field align the motor to the pump, to zero tolerance. This philosophy requires that the customer be able to place the base in the same condition as the factory. Thus the factory alignment will be done with the base sitting in an unrestrained condition on a flat and level surface. This standard also emphasizes the need to ensure the shaft spacing is adequate to accept the specified coupling spacer.

The factory alignment procedure is summarized below: a) The baseplate is placed on a flat and level

workbench in a free and unstressed position.

b) The baseplate is leveled as necessary. Leveling

is accomplished by placing shims under the rails of the base at the appropriate anchor bolt hole locations. Levelness is checked in both the longitudinal and lateral directions.

c) The motor and appropriate motor mounting

hardware is placed on the baseplate and the motor is checked for any planar soft-foot

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