Flowserve Mark 3 Sealed Metallic Durco User Manual

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

USER 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

		Page
6 MAINTENANCE..................................................		43
6.1	Maintenance schedule ................................	43
6.2	Spare parts ..................................................	44

6.3Recommended spares and consumable

	items............................................................	44
6.4	Tools required..............................................	44
6.5	Fastener torques .........................................	45

6.6Setting impeller clearance and impeller

		replacement ................................................	45
	6.7	Disassembly................................................	47
	6.8	Examination of parts ...................................	51
	6.9	Assembly of pump and seal........................	55
7	FAULTS; CAUSES AND REMEDIES.................		62
8	PARTS LIST AND DRAWINGS ..........................		64
	8.1	Standard Mark 3 pump, Group 1.................	64

8.2Standard 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

8.5Mark 3 Unitized Self Priming pump, Group 2 67

8.6Mark 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

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

8.10	General arrangement drawing ....................	71
9 CERTIFICATION ................................................		71
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS...........................................................		71
10.1	Supplementary User Instructions................	71
10.2	Change notes..............................................	71
10.3	Additional sources of information................	71

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	1	INTRODUCTION AND SAFETY	machinery and equipment and the satisfactory provision
			of technical documents and safety instructions. Where
	1.1	General	applicable this document incorporates information
			relevant to these Directives and Approvals.
			To confirm the Approvals applying and if the product is
		These instructions must always be kept	CE marked, check the serial number plate markings and
	close to the product's operating location or		the Certification. (See section 9, Certification.)
	directly with the product.		1.3	Disclaimer
	Flowserve products are designed, developed and		Information in these User Instructions is believed
	manufactured with state-of-the-art technologies in		to be complete and reliable. However, in spite of
	modern facilities. The unit is produced with great		all of the efforts of Flowserve Corporation to
	care and commitment to continuous quality control,		provide comprehensive instructions, good
	utilizing sophisticated quality techniques, and safety		engineering and safety practice should always be
	requirements.		used.
	Flowserve is committed to continuous quality		Flowserve manufactures products to exacting
	improvement and being at your service for any further		International Quality Management System Standards
	information about the product in its installation and		as certified and audited by external Quality
	operation or about its support products, repair and		Assurance organizations. Genuine parts and
	diagnostic services.		accessories have been designed, tested and
			incorporated into the products to help ensure their
	These instructions are intended to facilitate		continued product quality and performance in use.
	familiarization with the product and its permitted use.		As Flowserve cannot test parts and accessories
	Operating the product in compliance with these		sourced from other vendors the incorrect
	instructions is important to help ensure reliability in		incorporation of such parts and accessories may
	service and avoid risks. The instructions may not		adversely affect the performance and safety features
	take into account local regulations; ensure such		of the products. The failure to properly select, install
	regulations are observed by all, including those		or use authorized Flowserve parts and accessories is
	installing the product. Always coordinate repair		considered to be misuse. Damage or failure caused
	activity with operations personnel, and follow all plant		by misuse is not covered by the Flowserve warranty.
	safety requirements and applicable safety and health		In addition, any modification of Flowserve products or
	laws and regulations.		removal of original components may impair the safety
			of these products in their use.
		These instructions must be read prior to	1.4	Copyright
	installing, operating, using and maintaining the
			All rights reserved. No part of these instructions may
	equipment in any region worldwide. The
	equipment must not be put into service until all		be reproduced, stored in a retrieval system or
	the conditions relating to safety noted in the		transmitted in any form or by any means without prior
	instructions, have been met. Failure to follow and		permission of Flowserve.
	apply the present user instructions is considered		1.5	Duty conditions
	to be misuse. Personal injury, product damage,
			This product has been selected to meet the
	delay or failure caused by misuse are not covered
	by the Flowserve warranty.		specifications of your purchase order. The
	1.2 CE marking and approvals		acknowledgement of these conditions has been sent
			separately to the Purchaser. A copy should be kept
	It is a legal requirement that machinery and equipment		with these instructions.
	put into service within certain regions of the world shall			The product must not be operated beyond
	conform with the applicable CE Marking Directives
	covering Machinery and, where applicable, Low Voltage		the parameters specified for the application. If
	Equipment, Electromagnetic Compatibility (EMC),		there is any doubt as to the suitability of the
	Pressure Equipment Directive (PED) and Equipment for		product for the application intended, contact
	Potentially Explosive Atmospheres (ATEX).		Flowserve for advice, quoting the serial number.

Where applicable, the Directives and any additional

Approvals, cover important safety aspects relating to

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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.

1.6Safety

1.6.1Summary of safety markings

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

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

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

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

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

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

This symbol is used in safety instructions to remind not to rub non-metallic surfaces with a dry cloth; ensure the cloth is damp. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.

This sign is not a safety symbol but indicates an important instruction in the assembly process.

1.6.2Personnel 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.

1.6.3Safety 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.

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.

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

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.

1.6.4Products 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

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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); refe r 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	Maximum surface	Temperature limit of
	class to EN	temperature
			liquid handled
	13463-1	permitted
	T6	85 °C (185 °F)	Consult Flowserve *
	T5	100 °C (212 °F)	Consult Flowserve *
	T4	135 °C (275 °F)	115 °C (239 °F) *
	T3	200 °C (392 °F)	180 °C (356 °F) *
	T2	300 °C (572 °F)	275 °C (527 °F) *
	T1	450 °C (842 °F)	400 °C (752 °F) *

Maximum permitted liquid temperature for pumps with self priming casing

Temperature	Maximum surface	Temperature limit of
class to EN	temperature	liquid handled
13463-1	permitted
T6	85 °C (185 °F)	Consult Flowserve
T5	100 °C (212 °F)	Consult Flowserve
T4	135 °C (275 °F)	110 °C (230 °F) *
T3	200 °C (392 °F)	175 °C (347 °F) *
T2	300 °C (572 °F)	270 °C (518 °F) *
T1	450 °C (842 °F)	350 °C (662 °F) *

*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.

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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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.

1.6.4.4Preventing 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.

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

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.

1.6.4.5 Preventing sparks

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.

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.

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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1.7Name plate and safety labels

1.7.1Nameplate

For details of nameplate, see the Declaration of Conformity or separate documentation included with these User Instructions.

1.7.2Safety labels

Oil lubricated units only:

DurcoShieldTM (Splash/Shaft Guard) only:

THIS DEVICE IS NOT A CONTAINMENT

SYSTEM OR A SEAL BACKUP SYSTEM

IT IS A LIMITED PROTECTION DEVICE.

IT WILL REDUCE BUT NOT ELIMINATE

THE PROBABILITY OF INJURY.

1.8Specific 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

1.9Noise 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.

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	Motor size			Typical sound pressure level LpA at 1 m reference 20 µPa, dBA
	and speed		3 550 r/min		2 900 r/min		1 750 r/min		1 450 r/min
	kW (hp)
			Pump	Pump and	Pump	Pump and	Pump	Pump and	Pump	Pump and
			only	motor	only	motor	only	motor	only	motor
	<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)	1	1	1	1	85	87	83	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.

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.

2 TRANSPORT AND STORAGE

2.1Consignment 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.

2.2Handling

Boxes, crates, pallets or cartons may be unloaded using fork lift vehicles or slings dependent on their size and construction.

2.3Lifting

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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2.3.1Lifting 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

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.)

Figure 2.2

2.3.2Lifting 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

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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	Figure 2.4	∙ 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
	The sling should be positioned so the weight is not	location
		2.4.2 Long term storage and packaging
	carried through the motor fan hood. Make sure the
	completion of the choker hitch on the discharge	Long term storage is defined as more than six
	nozzle is toward the coupling end of the pump shaft	months, but less than 12 months. The procedure
	as shown in figure 2-4.	Flowserve follows for long term storage of pumps is
	2.3.2.2 In-Line assemblies	given below. These procedures are in addition to the
		short term procedure.
	If the pump is to be lifted as a complete assembly, the
		∙ Each assembly is hermetically (heat) sealed from
	motor lifting lugs must be used to ensure that the	the atmosphere by means of tack wrap sheeting

	assembly does not flip over. Check with motor	and rubber bushings (mounting holes)
	supplier for lifting lug capacities. If there is any
		∙ Desiccant bags are placed inside the tack
	uncertainty, the motor should be removed prior to
		wrapped packaging
	moving the pump. (Figure 2-2.)
		∙ A solid wood box is used to cover the assembly

2.4Storage

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.

2.4.1Short 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)

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.

2.5Recycling 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.

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3 DESCRIPTION

3.1Configurations

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

Model

Size 2K6X4 M-13A/12.5 RV

MDP

Material

Date DD/MMM/YY

The Prima3 TM 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 Prima3 TM. All other information regarding the pump type must be obtained from the original pump manufacturer's User Instructions.

3.2Nomenclature

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

3.3Design of major parts

3.3.1Pump 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).

3.3.2Impeller

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

3.3.3Shaft/sleeve

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

3.3.4Pump bearings and lubrication

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

3.3.5Bearing housing

Large oil bath reservoir.

3.3.6Seal chamber (cover plate)

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

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optimum concentricity. The design enables a number of sealing options to be fitted.

3.3.7Shaft 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.

3.3.8Driver

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.

3.3.9C-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

Figure 3-2: Alloy cross-reference chart

3.3.10 Accessories

Accessories may be fitted when specified by the customer.

3.4Performance 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.

3.4.1Alloy cross reference chart

Figure 3-2 is the Alloy cross-reference chart for all Mark 3 pumps.

	Flowserve	Designation	Durco Legacy	ACI	Equivalent Wrought	ASTM	Material
	Material Code		Codes	Designation	Designation	Specifications	Group No.
	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	Ferralium®	A995, Gr. CD4MCuN	2.8
	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	Inconel® 600	A494, Gr. CY40	3.5
	K3007	Durco M35	DMM	M351	Monel® 400	A494, Gr. M35-1	3.4
	K3008	Nickel	DNI	CZ100	Nickel 200	A494, Gr. CZ100	3.2
	K4007	Chlorimet 2	DC2	N7M	Hastelloy® B	A494, Gr. N7M	3.7
	K4008	Chlorimet 3	DC3	CW6M	Hastelloy® C	A494, Gr. CW6M	3.8
	E3041	Duriron®	D	None	None	A518, Gr. 1	No load
	E3042	Durichlor 51®	D51	None	None	A518, Gr. 2	No load
	E4035	Superchlor®	SD51	None	None	A518, Gr. 2	No load
	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.

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3.4.2Pressure-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.

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:

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.

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	1.0	1.1		2.1		2.2		2.8		3.2	3.4		3.5		3.7	3.8	3.17		Ti		Cr
˚C												bar
-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
										Material Group No.
Temp	1.0	1.1		2.1		2.2		2.8		3.2		3.4		3.5	3.7	3.8	3.17		Ti		Cr
˚F												psi
-100				200		200		200		140		200		200	200	200	200		200
-20	200	200		200		200		200		140		200		200	200	200	200		200
0	200	200		200		200		200		140		200		200	200	200	200		200		183
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

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Figure 3-4 Class 150 Flanges

											Material Group No.
Temp	1.0	1.1		2.1		2.2		2.8			3.2	3.4			3.5			3.7		3.8		3.17			Ti		Cr
˚C														bar
-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
											Material Group No.
Temp	1.0	1.1		2.1		2.2		2.8			3.2		3.4			3.5		3.7		3.8		3.17			Ti		Cr
˚F														psi
-100				275		275		285			140		230			220		290		290		230			290
-20	250	285		275		275		285			140		230			220		290		290		230			290
0	250	285		275		275		285			140		230			220		290		290		230			290		183
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
Figure 3-5A Group 2-13” In-Lines and Group 3 Pumps with Class 300 Flanges
								Material Group No.
Temp	1.1	2.1		2.2		2.8		3.2			3.4			3.5			3.7		3.8		3.17			Ti
˚C											bar
-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
								Material Group No.
Temp	1.1	2.1		2.2		2.8		3.2			3.4		3.5			3.7		3.8		3.17				Ti
˚F											psi
-100		350		350		350		252			350		350			350		350		350				350
-20	350	350		350		350		252			350		350			350		350		350				350
0	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

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

							Material Group No.
Temp	1.0	1.1	2.1	2.2	2.8		3.2			3.4		3.5		3.7		3.8		3.17	Ti
˚C								bar
-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
							Material Group No.
Temp	1.0	1.1	2.1	2.2	2.8		3.2		3.4			3.5		3.7		3.8		3.17	Ti
˚F								psi
-100			450	450	450		252		350			400		450		450		350	450
-20	450	450	450	450	450		252		350			400		450		450		350	450
0	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

Figure 3-5C All other Class 300 Flanges

					Material Group No.
Temp	1.1	2.1	2.2	2.8	3.2		3.4		3.5		3.7		3.8		3.17	Ti
˚C							bar
-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
					Material Group No.
Temp	1.1	2.1	2.2	2.8	3.2		3.4		3.5		3.7		3.8		3.17	Ti
˚F							psi
-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

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3.4.3Suction 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 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.

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					400
	25				11
						360
- bar	22.5				10		- psi
					9	320
Pressure							Pressure
	20				8
				7	6	280
	17.5				4
					5
Suction						240	Suction
	15
						200
Allowable	12.5						Allowable
	10					160
					3	120
Maximum	7.5						Maximum
	5					80
						40
	2.5
	0			1	2	0
	0.4	0.8	1.2	1.6	2	2.4

Specific Gravity

Figure 3-6B: Suction pressure limits 3500 r/min
	27.5									400
	25									360
bar	22.5									320	psi
-											-
Pressure	20									280	Pressure
									18
	17.5									240
Suction									17		Suction
	15
									16	200
Allowable	12.5										Allowable
									15
										160
	10								14
									13
										120
									12
Maximum	7.5										Maximum
									11
	5									80
									10
		3
										40
	2.5
	0	1	2	4	5	6	7	8	9	0
	0.4	0.8	1.2			1.6		2		2.4

Specific Gravity

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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		PT		18
1K 1.5x1-8		7		6
1K 1.5x1.5US-8
1K 2x1.5V-8		PT		16
1K 3x1.5-8		4		4
1K 3x2V-7		PT		11
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		8		3
2K 2x1.5US-10A
2K 3x1.5-10A		10		17
2K 3x2-10A		10		14
2K 3x2V-10 In-Line		11		9
2K 4x3-10		6		2
2K 4x3-10H		3		na
2K 6x4-10		5		8
2K 6x4-10H		10		na
2K 3x1.5-13		9		5
2K 3x2-13		5		1
2K 4x3-13/13		1		na
2K 4x3-13/12		1		na
2K 4x3-13/11 max		1		2
2K 4x3-13HH		10		na
2K 6x4-13A		1		na
2K 6x4-13A/10.25		1		?
3K 8x6-14A		2		na
3K 10x8-14		PT		na
3K 6x4-16		PT		na
3K 8x6-16A		PT		na
3K 10x8-16 & 16H		PT		na
3K 10x8-17		3		na
12X10-18HD		PT		na
Recessed Impellers		PT		PT
Lo-Flo Pumps		PT		PT
Open Impellers		PT		PT

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

3.4.4Minimum 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

		MCF % of BEP
Pump size	3500/2900	1750/1450	1180/960
	r/min	r/min	r/min
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	n.a.	60%	10%
All other sizes	10%	10%	10%

3.4.5Minimum suction pipe submergence

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

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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.

4.1Location

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.

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.

4.3.3Rigid 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

4.2Part assemblies

The supply of motors and baseplates are optional. As a result, it is the responsibility of the installer to ensure that the motor is assembled to the pump and aligned as detailed in section 4.5 and 4.8.

4.3Foundation

4.3.1Protection 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.

4.3.2In-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.

4.4Baseplate Mounting

4.4.1Stilt 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.”

4.4.1.1Stilt mounted baseplate assembly instructions

Refer to figure 4-3.

a)Raise or block up baseplate/pump above the floor to allow for the assembly of the stilts.

b)Predetermine or measure the approximate desired height for the baseplate above the floor.

c)Set the bottom nuts [2] above the stilt bolt head [1] to the desired height.

d)Assemble lock washer [3] down over the stilt bolt.

e)Assemble the stilt bolt up through hole in the bottom plate and hold in place.

f)Assemble the lock washer [3] and nut [2] on the stilt bolt. Tighten the nut down on the lock washer.

g)After all four stilts have been assembled, position the baseplate in place, over the floor cups [4] under each stilt location, and lower the baseplate to the floor.

h)Level and make final height adjustments to the suction and discharge pipe by first loosening the top nuts and turning the bottom nuts to raise or lower the baseplate.

i)Tighten the top and bottom nuts at the lock washer [3] first then tighten the other nuts.

j)It should be noted that the connecting pipelines must be individually supported, and that the stilt mounted baseplate is not intended to support total static pipe load.

Figure 4-3

4.4.1.2Stilt/spring mounted baseplate assembly instructions

Refer to figure 4-4.

a)Raise or block up baseplate/pump above the floor to allow for the assembly of the stilts.

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

[1].This allows for 51 mm (2 in.) upward movement for the final height adjustment of the suction/discharge flange.

c)Assemble the lock washer [6] flat washer [5] and bottom spring/cup assembly [2] down over the stilt bolt [1].

d)Assemble the stilt bolt/bottom spring up through hole in the bottom plate and hold in place.

e)Assemble top spring/cup assembly [3] down over stilt bolt.

f)Assemble flat washer [5], lock washer [6] and nuts [4] on the stilt bolt.

g)Tighten down top nuts, compressing the top spring approximately 13 mm (0.5 in.). Additional compression may be required to stabilize the baseplate.

h)After all four stilts have been assembled, position the baseplate in place, over the floor cups [7] under each stilt location, and lower the baseplate down to the floor.

i)Level and make final height adjustments to the suction and discharge pipe by first loosening the top nuts, and turning the bottom nuts to raise or lower the baseplate.

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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

4.4.1.3Stilt/spring mounted baseplates - motor alignment

The procedure for motor alignment on stilt or spring mounted baseplates is similar to grouted baseplates. The difference is primarily in the way the baseplate is leveled.

a)Level the baseplate by using the stilt adjusters. (Shims are not needed as with grouted baseplates.)

b)After the base is level, it is locked in place by locking the stilt adjusters.

c)Next the initial pump alignment must be checked. The vertical height adjustment provided by the stilts allows the possibility of slightly twisting the baseplate. If there has been no transit damage or twisting of the baseplate during stilt height adjustment, the pump and driver should be within 0.38 mm (0.015 in.) parallel, and 0.0025 mm/mm (0.0025 in./in.) angular alignment. If this is not the case, check to see if the driver mounting fasteners are centered in the driver feet holes.

d)If the fasteners are not centered there was likely shipping damage. Re-center the fasteners and perform a preliminary alignment to the above tolerances by shimming under the motor for vertical alignment, and by moving the pump for horizontal alignment.

e)If the fasteners are centered, then the baseplate may be twisted. Slightly adjust (one turn of the adjusting nut) the stilts at the driver end of the baseplate and check for alignment to the above tolerances. Repeat as necessary while

maintaining a level condition as measured from the pump discharge flange.

f)Lock the stilt adjusters.

The remaining steps are as listed for new grouted baseplates.

4.4.2Mounting 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.

4.4.2.1Mounting Instructions - All Grouted Bases (Except T5000 Base)

Foundation bolts are imbedded in the concrete inside a sleeve to allow some movement of the bolt.

Figure 4-5

d)Level the pump baseplate assembly. If the baseplate has machined coplanar mounting surfaces, these machined surfaces are to be referenced when leveling the baseplate. This may require that the pump and motor be removed from the baseplate in order to reference the machined faces. If the baseplate is without machined coplanar mounting surfaces, the pump and motor are to be left on the baseplate. The proper surfaces to reference when leveling the pump baseplate assembly are the pump suction and discharge flanges. DO NOT stress the baseplate.

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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.

4.4.2.2Mounting instructions Pump with C-flange motor adapter

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.

4.5Initial alignment

4.5.1Horizontal 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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