Flowserve MF User Manual
®
Pump Division
Type: MF
Horizontal close-coupled
CENTRIFUGAL PUMPS
USER INSTRUCTIONS:
INSTALLATION, OPERATION, MAINTENANCE
PCN = 71569191 12 – 04 (E) (Incorporating MF.IM)
These instructions should be read prior to installing
operating, using and maintaining this equipment
.
®
MF USER INSTRUCTIONS ENGLISH 71569191 12/04
CONTENTS
PAGE
CONTENTS............................................................... 2
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 plates and warning labels..................... 8
1.8 Noise level ......................................................8
1.9 Specific machine performance........................9
2 TRANSPORT AND STORAGE............................. 9
2.1 Consignment receipt and unpacking ..............9
2.2 Handling........................................................ 10
2.3 Lifting.............................................................10
2.4 Storage..........................................................11
2.5 Recycling and end of product life.................. 12
3 DESCRIPTION .................................................... 12
3.1 Configurations............................................... 12
3.2 Nomenclature................................................13
3.3 Design of major parts.................................... 13
3.4 Performance and operating limits................. 14
4 INSTALLATION................................................... 15
4.1 Location ........................................................15
4.2 Part assemblies ............................................15
4.3 Foundation....................................................15
4.4 Grouting ........................................................ 17
4.5 Initial alignment.............................................18
4.6 Piping ............................................................20
4.7 Electrical connections ...................................21
4.8 Final shaft alignment check .......................... 22
4.9 Protection systems........................................22
5 COMMISSIONING, STARTUP, OPERATION AND
SHUTDOWN.................................................... 22
5.1 Pre-commissioning procedure...................... 22
5.2 Pump lubricants ............................................23
5.3 Impeller clearance.........................................27
5.4 Direction of rotation....................................... 27
5.5 Guarding .......................................................27
5.6 Priming and auxiliary supplies ...................... 27
5.7 Starting the pump..........................................28
5.8 Running or operation ....................................29
5.9 Stopping and shutdown.................................30
5.10 Hydraulic, mechanical and electrical duty... 31
6 MAINTENANCE .................................................. 31
6.1 Maintenance schedule..................................32
6.2 Spare parts....................................................38
6.3 Suggested spares and consumable items.... 39
6.4 Tools required ............................................... 39
6.5 Fastener torques........................................... 40
6.6 Renewal clearances......................................40
PAGE
6.7 Disassembly ..................................................40
6.8 Examination of parts......................................42
6.9 Assembly.......................................................42
7 FAULTS; CAUSES AND REMEDIES..................44
8 PARTS LIST AND DRAWINGS...........................46
8.1 Grease lubricated MF....................................46
8.2 Oil lubricated MF ...........................................48
8.3 General arrangement drawing.......................49
9 CERTIFICATION .................................................49
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS........................................................49
10.1 Supplementary user instructions.................49
10.2 Change notes ..............................................49
INDEX
PAGE
Alignment of shafting (see 4.5, 4.7 and 4.3)
CE marking and approvals (1.2) ................................3
Clearances (see 6.6, Renewal clearances) .............40
Commissioning and operation (see 5.0) ..................22
Configurations (3.1)..................................................12
Direction of rotation (5.4)..........................................27
Dismantling (see 6.7, Disassembly).........................40
Duty conditions (1.5) ..................................................3
Electrical connections (4.7)......................................21
Examination of parts (6.8)........................................42
Faults; causes and remedies (7.0)...........................44
General assembly drawings (see 8.0) .....................46
Grouting (4.4)...........................................................17
Guarding (5.5)..........................................................27
Handling (2.2)...........................................................10
Hydraulic, mechanical and electrical duty (5.10) .....31
Lifting (2.3) ...............................................................10
Location (4.1) ...........................................................15
Lubrication schedule (see 5.2, Pump lubricants).....23
Maintenance schedule (6.1).....................................31
Piping (4.6)...............................................................20
Priming and auxiliary supplies (5.6).........................27
Reassembly (see 6.9 Assembly) .............................42
Replacement parts (see 6.3 and 6.4).......................39
Safety, protection systems (see 1.6 and 4.9)
Sound level (see 1.8, Noise level) .............................8
Specific machine performance (1.9) ..........................9
Starting the pump (5.7) ............................................28
Stopping and shutdown (5.9)...................................30
Storage (2.4) ............................................................11
Supplementary manuals or information sources .....49
Tools required (6.4)..................................................39
Torques for fasteners (6.5) ......................................40
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MF USER INSTRUCTIONS ENGLISH 71569191 12/04
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's 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 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 should be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety noted in the
instructions, have been met.
1.2 CE marking and approvals
It is a legal requirement that machinery and
equipment put into service within 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 reliable. In spite of all the efforts of
Flowserve Pump Division to provide sound and
all necessary information the content of this
manual may appear insufficient and is not
guaranteed by Flowserve as to its completeness
or accuracy.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality
Assurance organizations. Genuine parts and
accessories have been designed, tested, and
incorporated into the products to help ensure their
continued product quality and performance in use. As
Flowserve cannot test parts and accessories sourced
from other vendors the incorrect incorporation of
such parts and accessories may adversely affect the
performance and safety features of the products.
The failure to properly select, install, or use
authorized Flowserve parts and accessories is
considered to be misuse. Damage or failure caused
by misuse is not covered by Flowserve's warranty. In
addition, any modification of Flowserve products or
removal of original components may impair the safety
of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any means without prior
permission of Flowserve Pump Division.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order
are going to be changed (for example liquid pumped,
temperature or duty) it is required that the user seeks
Flowserve’s written agreement before start up.
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MF USER INSTRUCTIONS ENGLISH 71569191 12/04
1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction would
cause hazards. The specific safety markings are:
This symbol indicates electrical safety
instructions where non-compliance will involve a high
risk to personal safety or the loss of life.
This symbol indicates safety instructions where
non-compliance would affect personal safety and
could result in loss of life.
This symbol indicates “hazardous and toxic fluid”
safety instructions where non-compliance would affect
personal safety and could result in loss of life.
This symbol indicates safety
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but
indicates an important instruction in the assembly
process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection, and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided.
If required the operator may commission the
manufacturer/supplier to provide applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
prevent injury to personnel and damage to the
environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
contact must be avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
in damage or breakage of components and should be
avoided.
APPLYING HEAT TO REMOVE IMPELLER
There may be occasions when the impeller has either
been shrunk fit onto the pump shaft or has become
difficult to remove due to products that are corrosive in
nature.
If you elect to use heat to remove the impeller, it must
be applied with a great care and before applying heat
ensure any residual hazardous liquid trapped between
the impeller and pump shaft is thoroughly drained out
through the impeller keyway to prevent an explosion or
emission of toxic vapor.
Impeller design vary and so are the heat, applying
location and the duration of heat application. Contact
your nearest Flowserve service center for help
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MF USER INSTRUCTIONS ENGLISH 71569191 12/04
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area.
Bearing housings must not be insulated
and drive motors and bearings may be hot.
If the temperature is greater than 68 °C (175 °F) or
below 5 °C (20 °F) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.
Gland packing must not be used when pumping
hazardous liquids.
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
in writing, so that their force, due to internal pressure,
acts on the pump flange.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation,
and shutdown.)
START THE PUMP WITH OUTLET
VALVE PARTLY OPENED (Unless otherwise
instructed at a specific point in the User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve
further open only on installations where this situation
cannot occur. The pump outlet control valve may
need to be adjusted to comply with the duty following
the run-up process. (See section 5, Commissioning
startup, operation, and shutdown).
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a
flow rate with no backpressure on the pump may
overload the motor and cause cavitation. Low flow
rates may cause a reduction in pump/bearing life,
overheating of the pump, instability, and cavitation /
vibration.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
• Avoid 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.
Both electrical and non-electrical equipment must
meet the requirements of European Directive
94/9/EC.
1.6.4.1 Scope of compliance
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of the
specific atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the pump set shall
select the coupling, driver, and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and the
ATEX Certification for the motor must state that it is
covers the situation where electrical supply is from
the VFD. This particular requirement still applies
even if the VFD is in a safe area.
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MF USER INSTRUCTIONS ENGLISH 71569191 12/04
1.6.4.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D= Dust
c = Constructional safety
(in accordance with prEn13463-5)
Gas group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(See section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 °C (104 °F); refer to
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 that follows.
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
Temperature
class to
prEN 13464-5
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
lower)
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
Temperature classification “Tx” is used
when the liquid temperature varies and the pump
could be installed in different hazarous atmospheres.
In this case the user is responsible for ensuring that
the pump surface temperature does not exceed that
permitted in the particular hazardous atmosphere.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
contact between rotating and stationary components.
Where there is any risk of the pump being run against
a closed valve generating high liquid and casing
external surface temperatures it is recommended that
users fit an external surface temperature protection
device.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
power monitor and make routine vibration
measurements.
In dirty or dusty environments, regular checks must
be made and dirt removed from areas around close
clearances, bearing housings and motors.
1.6.4.4 Preventing the build up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
atmosphere is prevented.
In addition it is essential to make sure that seal
chambers, auxiliary shaft seal systems and any
heating and cooling systems are properly filled.
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If the operation of the system cannot avoid this
condition the fitting of an appropriate dry run
protection device is recommended (eg 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
and anti-static for Category 2.
To avoid the potential hazard from random induced
current generating a spark, the earth contact on the
baseplate must be used.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
The coupling must be selected to comply with 94/9/EC
and correct alignment must be maintained.
1.6.4.6 Preventing leakage
The pump must only be used to handle liquids
for which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump and
associated piping due to closing of suction and
discharge valves, which could cause dangerous
excessive pressures to occur if there is heat input to
the liquid. This can occur if the pump is stationary or
running.
Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the pump
and ancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
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 to include the following. (See
section 6, Maintenance).
a) Any auxillary systems installed must be
monitored, to ensure they function correctly.
b) Gland packings must be adjusted correctly to
give visible leakage and concentric alignment of
the gland follower to prevent excessive
temperature of the packing or the follower.
c) Check for any leaks from gaskets and seals. The
correct functioning of the shaft seal must be
checked regularly.
d) Chck bearing lubricant level,and verify if the
hours run show a lubricant change is required.
e) Check the duty condition is in the safe operating
range for the pump.
f) Check vibration, noise level and surface
temperarture at the bearings to confirm
satisfactory operation.
g) Check that dirt and dust are removed from areas
around close clearances, bearing housings and
motors.
h) Check coupling alignment and re-align if
necessary.
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1.7 Name plates and warning labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity.
1.7.2 Warning labels
Oil lubricated units only:
1.8 Noise level
Whenever pump noise level exceeds 85 dBA,
attention must be given to the prevailing Health and
Safety Legislation, to limit the exposure of plant
operating personnel to the noise. Typical safety level
requires limiting sound level to 90 dBA, for 8 hours of
exposure. Thereafter, the allowable dBA value
increases 5 dBA for each halving of exposure time.
The usual approach is to control exposure time to the
noise or to enclose the machine to reduce emitted
sound.
You may have already specified a limiting noise level
when the equipment was ordered, however if no
noise requirements were defined then machines
above a certain power level will exceed 85 dBA. In
such situations, consideration must be given to the
fitting of an acoustic enclosure to meet local
regulations.
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1.8.1 Typical sound levels for MF pumps
Pump noise level is dependent on a number of factors such as: the type of motor fitted, the operating capacity,
pipe work design and acoustics of the building. Typical sound pressure levels measured in dB, and are Aweighted.
Motor
Frame
Size.
NEMA
RPM Motor Only
Sound
Pressure
(dBA )
1800 60.0 65 70 180
1200 & slower 55.0 55 63
1800 60.0 65 69 210
1200 & slower 55.0 56 63
1800 70.0 77 77 250
1200 & slower 60.0 68 69
1800 70.0 77 77 280
1200 & slower 60.0 68 69
1800 65.0 77 77 320
1200 & slower 65.0 69 69
1800 65.0 77 78 360
1200 & slower 65.0 68 69
1800 70.0 77 78 400
1200 & slower 65.0 68 69
1800 70.0 77 78 440
1200 & slower 65 68 69
Pump only
Sound
Pressure
(dBA )
Combination
of pump and
motor
Sound
pressure
(dBA)
Sound pressure values indicated for the motor are extracted from typical motor manufacturer’s data at no load
conditions and are not guaranteed. They may vary depending on the type of motor, enclosure used, and the
manufacturer. The sound pressure values for the pump are estimated levels in free field measured 1 meter from the
nearest major pump surface and at a height of 1.5 meters above the floor, using motor speed, flow rate, motor
horsepower, number of impeller vanes, and other variables. Therefore values indicated are for reference only and
could exceed the estimated values by as much as 8~10 dBA depending upon factors such as installed conditions,
building acoustics, foundation, piping, operating conditions, and surrounding machinery. It is highly recommended to
take actual field measurement of sound pressure values, apply enclosures and safety measures mandated by the
local authorities and prevailing safety regulations. For all other pump and motor frame size combinations, the sound
levels have to be measured and safety measures have to be adopted.
For units driven by equipment other than electric motors or units contained within enclosures, see the
accompanying information sheets and manuals.
1.9 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. In cases where performance data
has been supplied separately to the purchaser these
should be obtained and retained with these User
Instructions, if required.
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery and shipping
Any shortage and or damage must be reported
immediately to Flowserve Pump Division and
received in writing within one month of receipt of the
equipment. Later claims cannot be accepted.
Check any crate, boxes, and wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to the
sidewalls 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.
documents for its completeness and that there has
been no damage in transportation.
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2.2 Handling
Boxes, crates, pallets, or cartons may be unloaded
using forklift vehicles or slings dependent on their
size and construction.
2.3 Lifting
To avoid distortion, the pump unit
should be lifted as shown in sections 2.3.1 & 2.3.3.
It is strongly recommended to attempt lifting with
appropriate tools and equipments only. It is strongly
recommended to employ experts or approved weighthandling methods to avoid injury or loss of life.
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.
2.3.1 Pump only - lifting methods
a) Small pumps are easily lifted by straps or slings
looped around the gland housing (make sure to
take precautions to prevent straps/slings from
sliding).
b) Eyebolt lifting method
c) Lifting of pump with the skid attached
USE FORK LIFT
2.3.2 Driver only - lifting method
Use driver lifting lugs/ or follow instructions in
driver manufacturer instruction manual.
2.3.3 Pump + driver + base plate lifting method
Use hooks to the lifting lugs (if provided to the base
plate) or use strap as shown in the figure around the
bolted wooden support. Depending on the pump size
and weight of the driver, the driver may be supplied
separately and it is the responsibility of the end user
to make sure that the right lifting method is adopted
for the safety reasons.
Use lifting lugs (if provided) or strap the base plate as
shown. It is the responsibility of the end user
to use proper lifting arrangement considering the
weight and size limitations of the equipment. Contact
your nearest Flowserve Service Center for unloading
and installation tips.
If you are not sure about pump/driver weights,
contact Flowserve.
Attach lifting lugs or
eyebolts atleast
at two places on each
side of the casing.
Use threaded holes
on the casing.
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2.4 Storage
Store the pump in a clean and dry
location away from vibration. Leave piping
connection covers in place to keep dirt and other
foreign material out of pump casing. Turn pump at
intervals to prevent brinelling of the bearings and the
seal faces (if fitted) from sticking.
2.4.1 Inspection before storage
a) Inspect the preservative coating/painted surfaces
on the various parts. Touch up the areas, If
necessary.
b) Inspect all covers over pump openings and piping
connections. If found damaged, remove the
covers and inspect interiors of the opening for any
deposits of foreign materials or water.
c) If necessary, clean and preserve the interior parts
as noted above to restore the parts to the "as
shipped" condition. Replace covers and fasten
securely.
2.4.2 Short term storage (less than 6 months)
When it is necessary to store a pump for a short
period of time, place it in a dry location and protect it
thoroughly from moisture.
When protective flanges are bolted to the suction and
discharge nozzles at the factory, they should not be
removed. Protect the bearings and the shaft against
moisture, dirt, or other foreign matter. To prevent
rusting in or seizing, lubricate the unit; see section
5.2, Pump Lubricants. Rotate the pump shaft a
minimum of 5 revolutions at least every two weeks to
keep the bearings coated with lubricant and to
minimize the effects of brinelling.
Oil lubricated anti-friction bearings are
factory lubricated to prevent rusting for a short period
of time only. Immediately upon receiving equipment,
fill the oil reservoir to the proper level with the proper
lubricant.
2.4.3 Long term storage (6 months and over)
More thorough precautions are required, if
the pump is scheduled to be stored for an extended
period of time. Contact Flowserve before long-term
storage is attempted for specific storage
requirements and warranty information.
The following is a general procedure and could vary
depending on the pump design or specific
application.
The storage area must be clean & dry
location not subject to rapid changes in the
temperature, light or humidity, and relatively free of
ground transmitted vibration due to heavy
construction and/or machinery.
A temperature range of 5 to 50 oC (40 to 120 oF) with
humidity control is recommended.
a) Drain fluid from the pump, rotate the pump rotor
once in the proper direction and blow the liquid
end dry with air.
b) Coat the interior surfaces of the liquid end with
rust inhibitor by brushing, spraying or fogging.
Rotate the pump shaft one turn in the proper
direction while coating.
c) Remove the packing and seal cage from the
stuffing box to prevent corrosion due to
condensation. Coat the interior machined
surfaces of stuffing box with a rust inhibitor. This
step may be omitted if the pumps are stored prior
to initial use.
d) For grease lubricated bearing frames, fill the
cavity between the bearing covers and bearings
with a good grade of NGLI No. 2 lithium base
grease to prevent contamination of the bearings.
Ensure that the bearings are thoroughly packed
with grease. Lubrication quality and quantity
must be checked every six months and replaced
or replenished as necessary. For oil lubricated
bearing frames, upon receipt of the equipment fill
the bearing frame with a good quality R&O oil
capable of providing rust protection to the parts.
Check the oil bi-monthly for signs of water. See
section 5.2, Pump Lubricants.
e) Coat all threaded openings with rust inhibitor and
plug. Coat machined surfaces of exposed
flanges with rust inhibitor and then cover with
fiberboard or wood flange covers. Desiccant
bags should be secured to the covers prior to
putting them in place and must not contact metal
surfaces.
f) Coat exposed, unpainted, and machined
surfaces with a rust inhibitor.
g) Cover openings in the stuffing box head between
the casing and bearing frame with plastic, taped
in place, to prevent entrance of contaminants into
the stuffing box and line bearing area.
h) Cover the entire pump with a clear plastic sheet
for protection from dust, dirt moisture, etc. and to
allow for visual inspection. The cover should be
open near the top to allow for ventilation.
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i)
Rotate the pump shaft a minimum of 5
revolutions every two weeks to keep the bearings
coated with lubricant and to minimize the effects
of brinelling.
j)
Refer to the vendors instruction manuals for
extended storage procedure for motors, controls,
coupling, etc.
k)
Prior to installation or start up, a Flowserve
representative should be hired to inspect all
equipment to determine, if any damage or
deterioration of parts has occurred and that the
equipment is in "as shipped" condition.
2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and local regulations. If the
product contains substances that are harmful to the
environment, these should be removed and disposed
of in accordance with current regulations. This also
includes the liquids and or gases that may be used in
the "seal system" or other utilities.
MF USER INSTRUCTIONS ENGLISH 71569191 12/04
3.1 Configurations
The type MF pumps are installed in any of the
following three nozzle positions.
Nozzle position 1
Nozzle position 2
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the current
regulations at all times.
3 DESCRIPTION
The MF type pump is a single stage, volute type dry
pit, horizontal centrifugal pump designed for handling
sewage, storm water, dry dock and industrial waste
applications with end suction side discharge mix flow
non-clog design.
It should be noted that unscreened raw sewage may
introduce some chances of clogging and therefore
clogging may be totally avoided if appropriate level of
screening is applied.
The information contained in this book covers
horizontal close-coupled pumps only where the pump
and driver are installed on a common base plate.
Nozzle position 3
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MF USER INSTRUCTIONS ENGLISH 71569191 12/04
3.2 Nomenclature
The pump size is engraved on the nameplate
typically as below:
16- MF- 18
Nominal discharge branch size
(in inches only)
Type: Horizontal close coupled
Nominal impeller diameter (in inches only)
Measurement shown above for discharge
branch size and impeller diameter are always
provided in inches.
The typical nomenclature above is the general guide
to the MF configuration description. Identify the
actual pump size and serial number from the pump
nameplate. Check that this agrees with the
applicable certification provided. The driver will have
separate nameplate attached to it.
3.3 Design of major parts
3.3.1 Pump casing and stuffing box head
The pump casing with its integrally cast discharge
nozzle is of the volute type. It is machined to provide
a rabbet fit for the stuffing box head and suction
head. The heads are removable and are bolted to
and centered in the casing. The casing and suction
head are each provided with one hand hole for
inspection and cleaning of the pump without
dismantling. The pump has its main casing gasket
axial to the shaft allowing maintenance to the rotating
element by separating the impeller assembly from
the casing. Suction and discharge branches remain
undisturbed.
3.3.2 Impeller
The impeller hub is keyed to the shaft and held in
position by an impeller nut which is set screwed to
the impeller to prevent its backing off. A pair of
replaceable wearing rings (optional) between the
rotating impeller and the stationary suction head are
provided for impeller wear resistance.
3.3.2.1 Impeller and wearing ring arrangement
IMPELLER
IMPELLER
WEARING RING
SUCTION HEAD
WEARING RING
SUCTION HEAD
3.3.3 Shaft and shaft sleeve
The pump shaft is sized to transmit the rated loads
encountered with liberal safety factors, and is
accurately machined over its full length. Generous
fillets are used to minimize stress concentrations. It
is protected from wear at the stuffing box by a
removable shaft sleeve.
3.3.4 Pump bearings
MF pumps are equipped with anti-friction bearings
(for frames 3A, 4A and 5A) and tapered roller types
(for frames 4T,5T,6A and 7A). The line and thrust
bearings are arranged in opposed mounting and can
be furnished with either grease or oil lubrication.
Bearings are grease lubricated as standard.
3.3.5 Bearing housing
Bearings are mounted in a removable cast iron
bearing frame. The frame casting offers rigid support
and location to the bearings and two grease nipples
enable grease-lubricated bearings to be replenished
between major service intervals.
3.3.6 Stuffing box housing
The stuffing box housing cast integrally with the back
head and has designed to accommodate number of
sealing options. For applications requiring
mechanical seals refer to the mechanical seal
manufacturer's User Instructions.
Packing within the pump stuffing box seals the pump
against leakage along the shaft at the point where it
passes through the stuffing box. It should be packed
with rings of braided, non-asbestos packing and a
seal cage as shown in detail under this section. It is
equipped with a removable split packing gland.
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MF USER INSTRUCTIONS ENGLISH 71569191 12/04
Always place two rings of packing below the seal
cage and the remaining rings above the seal cage.
The number of packing rings used is listed in table
6.1.8.1.
PACKING GLAND
SEAL WATER
CONNECTION
SEAL CAGE
PACKING
SHAFT SLEEVE
Typical gland arrangement
PUMP SHAFT
IMPELLER
STUFFING BOX
HEAD
The stuffing box is not packed when
the pump is shipped.
A water supply of approximately 0.113 to 0.227 m3/h
(0.5 to 1.0 gpm) is to be introduced to the seal water
connection to provide for packing lubrication and
sealing. A steady "trickle" of water from the stuffing
box will indicate proper adjustment. The sealing
water supply pressure should be 0.35 to 0.69 bar (5
to 10 psi) above the pump discharge pressure.
When grease sealing is used, a similar grease
pressure should be maintained. A slight leakage of
liquid from the stuffing box is to be expected and the
gland MUST NOT be tightened to the point of
stopping the leakage.
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. See
section 6.1.9 for mechanical seal maintenance
information.
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. Fully flexible couplings are normally used for
connecting pump and drive shafts. For operating
instructions, refer to the coupling manufacturer's User
Instructions.
3.3.9 Couplings
Flexible couplings are normally used for connecting
pump and drive shafts. Many variations of make and
models are available. These couplings provide
compensation for angular and parallel misalignment.
For coupling installation, operating and maintenance
refer to the coupling manufacturer's User
Instructions.
3.3.10 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operating limits
This product has been selected to meet the
specifications of your purchase order. See section 1.5.
The following data is included as additional
information to help with your installation. It is typical,
and factors such as temperature, materials, and seal
type may influence this data. If required, a definitive
statement for your particular application can be
obtained from Flowserve.
3.4.1 Operating limits
Pumped liquid temperature
limits*
Maximum ambient
temperature*
Maximum pump speed refer to the nameplate
*Subject to written agreement from Flowserve. Special designs
and materials may be available for pumps operating above and
below these specified limits. Contact Flowserve for upgrade
options available for your specific application.
3.4.2 Pump and impeller data
Details such as impeller diameter, wearing ring
diameter are normally provided along with the test
curves. If not provided with the pump
documentation, please contact Flowserve.
5 ºC (40 ºF) to +80 ºC (176 ºF)
5 ºC (40 ºF) to +40 ºC (104 ºF)
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MF USER INSTRUCTIONS ENGLISH 71569191 12/04
4 INSTALLATION
Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
Inspection prior to installation: Six months prior to
the scheduled installation date, a Flowserve Pump
Division representative is to be employed to conduct
an inspection of the equipment and the facility. If any
deterioration of equipment is noticed, the Flowserve
Pump Division representative may require a partial or
complete dismantling of the equipment including
restoration and replacement of some components.
4.1 Location
The pump should be placed so as 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.
4.1.1 General installation check-list
The following checks should be made before starting
actual installation.
a) Make sure that the motor nameplate ratings and
the power supply system match correctly.
b) Check the sump depth and suction pipe length
match up.
c) Check the liquid level in the sump.
d) Check the installation equipment to be sure that it
will safely handle the pump weight and size.
e) Check all pump connections (bolts, nuts etc) for
any shipping and handling related problems.
f) Check for any evidence of lubricant leakage at
the bearings.
g) Check that the shaft rotates freely.
4.1.2 Cleaning prior to installation
Remove the rust inhibitor, flange protectors, plastic
covers, desiccant, and inspect the inside of the
pump. Repack the stuffing box and ensure that the
stuffing box drain is clear. Flush the bearings using a
hot, light oil at 82o to 93oC (180o to 200o F) while the
shaft is slowly rotated. Re-lubricate the bearings as
explained in Section 5.0.
4.1.3 Manufacturer’s service
It is recommended that the services of Flowserve
Company Service Representative be employed for
installing and starting the pump as proper installation
is vital for designed functioning, performance and
reliability of the equipment.
4.1.4 Site preparation
Care should be taken to prevent an out of service
pump from freezing during cold weather. Draining
the pump is recommended when there is any
possibility of freezing.
Observe extreme caution when
priming, venting and draining hazardous liquids.
Wear protective clothing in the presence of
hazardous, caustic, volatile, flammable and hot
liquids. Do not breathe toxic vapors. Do not
swallow. Do not allow sparking, flames or hot
surfaces in the vicinity of the equipment.
4.1.5 General tools required for installation
a) Mobile crane capable of hoisting and lowering the
pump and/or motor.
b) Sets of chains, tongs and cable slings for
attaching it to the pump and motor lifting eyes.
c) General purpose hand tools, pipe wrenches, end
wrenches, socket set, screwdrivers, Allen
wrenches, wire brush, scraper and fine emery
cloth.
d) Thread sealing compound designed for stainless
steel and light machinery oil.
4.2 Part assemblies
Motors may be supplied separately for some of the
larger models of MF pumps. It is the responsibility of
the installer to ensure that the motor is assembled to
the pump and lined up as detailed in section 4.5. It is
also the responsibility of the installer to take note of
the pump and driver weights for proper handling
before assembly is attempted.
4.3 Foundation
There are many methods of installing
pump units to their foundations. The correct method
depends on the size of the pump unit, its location and
limitations on its noise/vibrations. Non-compliance
with the provision of correct foundation and
installation may lead to failure of the pump and, as
such, would be outside the terms of the warranty.
The foundation may consist of material that will afford
permanent, rigid support to the discharge head and
will absorb expected stresses that may be
encountered in service.
Concrete foundations should have anchor bolts
installed in sleeves that are twice the diameter of the
bolt to allow alignment and has holes in the mounting
plate as illustrated in the detail below.
Page 15 of 50
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