Flowserve MP1 Sier-Bath User Manual
USER INSTRUCTIONS MANUAL
Sier-Bath® MP1
User
Instructions
Manual
Multiphase Twin Screw Rotary Pumps
PCN= 26999958– 10/12 (E). Original instructions
These instructions must be read prior to installing,
operating, using, and maintaining this equipment.
MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
CONTENTS
PAGE
CONTENTS ............................................................. II
INDEX .................................................................... III
1 INTRODUCTION AND SAFETY ....................... 4
1.1 General .......................................................... 4
1.2 CE marking and approvals .............................. 4
1.3 Disclaimer ...................................................... 4
1.4 Copyright ........................................................ 4
1.5 Duty conditions ............................................... 4
1.6 Safety ............................................................ 5
1.7 Nameplate and warning labels ........................ 9
1.8 Specific machine performance ...................... 10
1.9 Noise level.................................................... 10
2 TRANSPORT AND STORAGE ....................... 11
2.1 Consignment receipt and unpacking ............. 11
2.2 Handling ....................................................... 11
2.3 Lifting ................................ ........................... 11
2.4 Storage ........................................................ 11
2.5 Recycling and end of product life .................. 12
3 PUMP DESCRIPTION .................................... 12
3.1 Configurations .............................................. 12
3.2 Name structure ............................................. 12
3.3 Design of major parts.................................... 12
3.4 Performance and operating limits.................. 13
3.5 Table of Engineering Data (Table 3) .............. 14
4 INSTALLATION .............................................. 14
4.1 Location ....................................................... 14
4.2 Part assemblies ............................................ 14
4.3 Foundation ................................................... 15
4.4 Baseplate installation .................................... 15
4.5 Initial alignment ............................................ 15
4.6 Grouting ....................................................... 17
4.7 Piping ........................................................... 18
4.8 Pressure gauges .......................................... 19
4.9 Final shaft alignment check .......................... 19
4.10 Electrical connections ................................. 19
4.11 Protection systems...................................... 20
PAGE
6 MAINTENANCE ............................................. 27
6.1 General ........................................................ 27
6.2 Maintenance schedule ................................. 27
6.3 Spare parts .................................................. 28
6.4 Recommended spare parts (Table 7) ........... 29
6.5 Tools required .............................................. 29
6.6 Torques for fasteners ................................... 29
6.7 Renewal of clearances ................................. 29
6.8 Disassembly ................................................ 29
6.9 Removing inner casing from outer casing ..... 31
6.10 Examination of parts .................................. 31
6.11 Inserting inner casing into outer casing ....... 31
6.12 Re-assembly .............................................. 32
6.13 Free movement .......................................... 33
6.14 Timing gear replacement ............................ 33
7 FAULTS; CAUSES AND REMEDIES ............. 36
8 PARTS LIST AND DRAWINGS ...................... 38
8.1 Sectional Drawing – Typical ......................... 38
8.2 General Arrangement Drawing ..................... 42
9 CERTIFICATION ........................................... 44
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ..................................................... 44
10.1 Supplementary User Instruction manuals ... 44
10.2 Change notes ............................................ 44
10.3 Additional sources of information ................ 44
11 OPTIONAL EQUIPMENT AND
ARRANGEMENTS......................................... 44
11.1 Jacketed components. ............................... 44
NOTES: ................................................................ 45
NOTES: ................................................................ 47
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN .......................................... 20
5.1 Pre-commissioning procedure ...................... 20
5.2 Lubricants................................................... 21
5.3 Direction of rotation ...................................... 22
5.4 Guarding ...................................................... 23
5.5 Priming and auxiliary supplies....................... 23
5.6 Starting the pump ......................................... 23
5.7 High temperature start up ............................. 23
5.8 Post start-up ................................................ 23
5.9 Running the pump ........................................ 24
5.10 Stopping and shutdown .............................. 25
5.11 Hydraulic, mechanical and electrical duty .... 25
ii flowserve.com
INDEX
PAGE
Alignment of shafting (see 4.5 and 4.9) ........... 15, 19
CE marking and approvals (1.2) ............................... 4
Clearances (see 6.7, Renewal clearances) ............ 29
Commissioning and operation (see 5) .................... 20
Configurations (3.1) ............................................... 12
Direction of rotation (5.3) ........................................ 22
Dismantling (see 6.8, Disassembly) ....................... 29
Duty conditions (1.5) ................................................ 4
Electrical connections (4.10) .................................. 19
Examination of parts (6.10) .................................... 31
Grouting (4.6) ........................................................ 17
Guarding (5.4) ....................................................... 23
Handling (2.2) ........................................................ 11
Hydraulic, mechanical and electrical duty (5.11) ..... 25
Lifting (2.3) ............................................................ 11
Location (4.1)......................................................... 14
Lubrication schedule (see 5.2, Pump lubricants) .... 21
Maintenance schedule (6.2) ................................... 27
Piping (4.7) ............................................................ 18
Priming and auxiliary supplies (5.5) ........................ 23
Reassembly (see 6.12) .......................................... 32
Replacement parts (see 6.3) .................................. 28
Safety, protection systems (see 1.6 and 4.11) ... 5, 20
Sound level (see 1.9, Noise level) .......................... 10
Specific machine performance (1.8) ....................... 10
Starting the pump (5.6) .......................................... 23
Stopping and shutdown (5.10) ............................... 25
Storage (2.4).......................................................... 11
Tools required (6.5) ............................................... 29
Torques for fasteners (6.6) ..................................... 29
MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
iii flowserve.com
MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve'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,
utilising sophisticated quality techniques, and safety
requirements.
We are committed to continuous quality
improvement and being at your service for any
further information about the product in its
installation and operation or about its support
products, repair and diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
These instructions 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. Failure to follow
and apply the present user instructions is
considered to be misuse. Personal injury,
product damage, delay or failure caused by
misuse are not covered by the Flowserve
warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and
equipment put into service within certain regions of
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED) and Equipment for Potentially Explosive
Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
incorporates information relevant to these Directives.
To establish approvals and if the product itself is CE
marked, check the serial number plate and the
Certification (See section 9 CERTIFICATION).
1.3 Disclaimer
Information in these User Instructions is
believed to be complete and reliable. However,
in spite of all of the efforts of Flowserve
Corporation to provide comprehensive
instructions, good engineering and safety
practice should always be used.
Flowserve manufactures products to exacting
International Quality Management System
Standards as certified and audited by external
Quality Assurance organisations. Genuine parts
and accessories have been designed, tested and
incorporated into the products to help ensure their
continued product quality and performance in use.
As Flowserve cannot test parts and accessories
sourced from other vendors the incorrect
incorporation of such parts and accessories may
adversely affect the performance and safety features
of the products. The failure to properly select, install
or use authorised Flowserve parts and accessories
is considered to be misuse. Damage or failure
caused by misuse is not covered by 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.
Page 4 of 48 flowserve.com
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 pumping,
temperature or duty) it is requested that you/the user
seek our written agreement before start up.
1.6 Safety
1.6.1 Summary of safety markings
These user instructions contain specific safety
markings where non-observance of an instruction
would cause hazards. The specific safety markings
are:
This symbol indicates electrical safety
instructions where non-compliance would affect
personal safety.
This symbol indicates safety instructions where
non-compliance would affect personal safety.
This symbol indicates safety instructions where
non-compliance would affect protection of a safe life
environment.
This symbol indicates safety
instructions where non-compliance would affect the
safe operation or protection of the pump or pump unit.
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.
MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
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.)
RELIEF VALVE PIPED BACK TO THE
SUCTION PIPE REQUIRED
The Twin Screw Pumps are positive displacement
pumps and will build up considerable pressure if
discharge line is blocked.
Customer shall include a properly sized safety relief
valve for the maximum expected flow at the
maximum expected operating pressure + 10% or the
maximum allowed working pressure (MAWP),
whichever is the lowest. Safety relief valve shall be
connected close to the discharge of the pump. The
pipeline discharging from the safety relief valve
should go back to the suction tank, if at all possible;
if not, it could be connected to the suction line of the
pump but only if well upstream so as to not create
excessive combined pressure. This discharge line
shall not be blocked at all. Customer shall also
include additional provisions to stop the process if
the discharge pressure is above the maximum
allowable pressure criteria; the pump shall not be
recirculating the flow for other than a very short time
due to the safety risk of the temperature exceeding
the allowable limit.
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
START THE PUMP WITH OUTLET
VALVE FULLY 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 zero flow. The pump outlet control valve
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MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
may need to be adjusted to comply with the duty
following the run-up process.
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 seals.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH FLOWRATES OR
ABNORMALLY LOW/HIGH DIFFERENTIAL
PRESSURES.
Operating at flow rates higher than specified can
overload the motor and/or cause cavitation and
vibration and/or low pressure at the seal chamber
potentially affecting the mechanical seals. Low
differential pressure may create too low bearings’
loads and skidding. High differential pressure may
create too high bearing loads. Both cases affect the
bearings’ life.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate sitting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.
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 fluoro-
elastomers (e.g. 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.
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
in damage or breakage of components and should
be avoided.
NEVER APPLY HEAT TO REMOVE ROTOR
Trapped lubricant or vapour could cause an
explosion.
HOT (and cold) PARTS
Hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not
be insulated and drive motors and bearings may be
hot.
If the temperature is greater than 80 °C (175 °F)
or below -5 °C (23 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.
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
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MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
Temperature
class to
EN13463-1
Maximum surface
temperature
permitted
Temperature limit
of liquid handled
T6
T5
T4
T3
T2
T1
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
65 °C (149 °F) *
80 °C (176 °F) *
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
the 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 effects in the motor
and so, for pumps sets with 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 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D= Dust
c = Constructional safety
(In accordance with EN13463-5)
Gas Group
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(See section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40°C (104°F); refer to
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 listed in Table 1.
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
The operator is responsible to ensure that the
specified maximum liquid temperature is not
exceeded.
Table 1 Maximum permitted liquid temperature
for pumps
* The table 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 operator is responsible to ensure that the
specified maximum liquid temperature is not
exceeded.
Temperature classification “Tx” is used when the liquid
temperature varies and when the pump is required to
be used in differently classified potentially explosive
atmospheres. In this case the user is responsible for
ensuring that the pump surface temperature does not
exceed that permitted in its actual installed location.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
contact between rotating and stationary
components.
Where there is any risk of the pump being run against
a closed valve generating high liquid and casing
external surface temperatures fit an external surface
temperature protection device.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
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MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
power monitor and make routine vibration monitoring
checks.
In dirty or dusty environments, make regular checks
and remove dirt from areas around close
clearances, bearing housings and motors.
1.6.4.4 Preventing the build-up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and
discharge pipeline system is totally filled with liquid
at all times during the pump operation, so that an
explosive atmosphere is prevented.
In addition it is essential to make sure that seal
chambers, auxiliary shaft seal systems and any
heating and cooling systems are properly filled.
If the operation of the system cannot avoid this
condition, fit an appropriate dry run protection device
(for example liquid detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking.
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
The coupling must be selected to comply with
94/9/EC and correct alignment must be maintained.
1.6.4.6 Preventing leakage
the liquid. This can occur if the pump is stationary or
running.
Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the pump
and ancillary systems.
Where there is the potential hazard of a loss of a
seal barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to atmosphere can result in a
hazard, install a liquid detection device.
1.6.4.7 Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED
TO AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with
maintenance instructions is with the plant
operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where
there is a risk from such tools or materials,
maintenance must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6
MAINTENANCE.)
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
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MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
1.7 Nameplate and warning labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of Conformity.
1.7.2 Safety labels
P/N 2113931-001 P/N 2113932-001
MECHANICAL SEAL WARNING ROTATION WARNING
GROUT WARNING LIFTING WARNING
P/N 2113934-001 P/N 9901701-001
LUBRICATION WARNING – QF-440-R01 (2124841)
Oil lubricated units only
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MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
Multiphase Twin
Screw
pump size
Sound Pressure
Level
dBA @ 1 m (3.3 ft)
Pump
Speed
rpm
MP1-150-xxx
90
1780
MP1-275-xxx
90
1780
MP1-380-xxx
90
1780
MP1-390-xxx
100
1780
1.8 Specific machine performance
For performance parameters see section 1.5 Duty
conditions. Where performance data has been
supplied separately to the purchaser these should be
obtained and retained with these User Instructions.
1.9 Noise level
Attention must be given to the exposure of personnel
to the noise, and local legislation will define when
guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA.
The usual approach is to control the exposure time to
the noise or to enclose the machine to reduce emitted
sound. You may have already specified a limiting
noise level when the equipment was ordered, however
if no noise requirements were defined, then attention is
drawn to Table 2 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.
Table 2 Max Sound Levels of Pumps
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.
For units driven by equipment other than
electric motors or units contained within enclosures,
see the accompanying information sheets and
manuals.
Page 10 of 48 flowserve.com
MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve and must be
received in writing within one month of receipt of the
equipment. Later claims cannot be accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side walls
of the box or equipment.
Each product has a unique serial number. Check that
this number corresponds with that advised; always
quote this number in correspondence as well as when
ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork-lift vehicles or slings dependent on their size
and construction.
The pump should be lifted with suitably
sized and located slings. Do not use the shaft for lifting
and take special care to prevent the pump from rotating
in the slings due to unbalanced weight distribution. The
angle between sling or ropes used for lifting must not
exceed 60°.
2.3 Lifting
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. The driver
and pump weights are recorded on their respective
nameplates or mass plates.
Before lifting the driver alone, refer to the
manufacturer’s instructions.
2.4 Storage
2.4.1 Short-Term Storage
When it is necessary to store a pump for a short time
before it can be installed, place it in a dry, cool
location. Protect it thoroughly from moisture and
condensation. Protective flange covers should not be
removed until the pump is being installed.
Wrap the exposed portions of the shaft and coupling to
protect against sand, grit or other foreign matter. Oil
lubricated units should be lubricated (refer to section
5.1.3 Lubrication) to protect the bearings. Grease
lubricated units are lubricated at the factory during
assembly. Turn the rotor over by hand at least once a
week to maintain a protective film on the bearing
components.
2.4.2 Long-term storage
More thorough precautions are required if long-term
storage in excess of 90 days from factory shipment is
unavoidable.
The internal surfaces of the pump should be sprayed
with a rust preventative, such as water soluble oil or
other suitable alternative. Particular attention should
be given to the integral shafts, rotors and stuffing box.
Install gasketed metal flange covers on the suction and
discharge flanges (pipe plugs in the case of tapped
connections).
A rust inhibitor should be added to the lubricating oil of
oil lubricated units to give additional protection without
destroying the lubricating properties of the oil. For
specific recommendations, consult your lubrication
dealer. Grease lubricated units, which can be identified
by the grease fitting at each bearing location, should
be well lubricated prior to placing in storage. Small
amounts of additional grease should be added at
regular intervals during storage. Refer to Section 5.1.3
Lubrication for additional information related to grease
lubrication.
Storage of pumps in areas of high ambient vibration
should be avoided to prevent bearing damage due to
false brinelling. The risk of such damage can be
reduced by frequent rotation of the shaft.
The pump half coupling and key should be removed
from the shaft, coated with rust preventative and
wrapped to prevent metal-to-metal contact. Exposed
surfaces of the pump shaft should be protected with a
rust preventative. All dismantled parts should be
wrapped and tagged according to pump serial number
and a record kept of their location.
Pumps covered with plastic should
not be stored in a cool environment because
resulting condensation can cause rusting.
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MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
2.5 Recycling and end of product life
At the end of the service life of the product or its parts,
the relevant materials and parts should be recycled or
disposed of, using an environmentally acceptable
method and in accordance with local regulations. If the
product contains substances that are harmful to the
environment, these should be removed and disposed
of in accordance with current local regulations. This
also includes the liquids and/or gases that may be
used in the “seal system” or other utilities.
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the current
local regulations at all times.
3 PUMP DESCRIPTION
3.1 Configurations
Flowserve Twin Screw Pumps are single stage,
positive displacement pumps especially designed for
the petroleum industries in the transfer of oils and
other liquids of varying viscosities. The flow of liquid
through the pump is accomplished by the progressive
movement of sealed cavities formed by the
intermeshing of matched pumping screws (one right
hand, one left hand) rotating in the precision ground
bores of the pump body. To balance the hydraulic
thrust created by the pumping action, two sets of
meshed screws are used, moving the liquid from both
ends of the body to the discharge port located at the
center of the body.
The key assembly of the screw pump is the rotating
element. Each rotating element consists of a drive
shaft and a driven shaft running on parallel axes at a
fixed center distance. Each shaft holds bearings, one
timing gear and two opposing pumping screws plus the
assorted hardware (lock nuts, spacers) required for
mounting. With integral design, the pumping screws
and the shaft are an integral piece machined from a
single steel bar. Precise clearances are maintained
between meshing screws to limit the internal leakage
(slip) in the pump. The timing gears maintain these
clearances, prevent contact between the pumping
screws and turn the driven shaft. Heavy duty roller
bearings eliminate radial contact between the pumping
screws and the body bores and support the loading on
the shafts produced by the pumping action. Ball
bearings position the shafts axially and prevent contact
between the flanks (sides) of the meshing screws.
Generally lubrication of the bearings is provided by oil
contained in housings (sumps).
The rear timing gear configuration provides a rear pullout feature which permits the quick removal of the
entire rotating element without disturbing the pump
body or the drive. (Refer to Section 6.8 Disassembly).
The use of a spacer type coupling between the pump
and driver is necessary to apply this feature.
Shaft sealing is typically provided and installed by
factory. Mechanical seals require no adjustment prior
to or during pump operation.
All pumps are shop performance tested to ensure
mechanical reliability and compliance with the
specified conditions of service. They are carefully
inspected and prepared for shipment. All exterior
machined surfaces are coated with rust preventative
and all openings are provided with covers or plugs.
3.2 Name structure
The pump size will be engraved on the nameplate. The
following example explains how the pump name
identifies the construction features
MP1-275-355
MP indicates pump is for multiphase application
275 indicates screws OD in mm
355 indicates bore length in mm
3.3 Design of major parts
3.3.1 Pump casing
The pump casing is a casting with side suction and top
discharge connections, or both connections on top.
Refer to the Outline or General Arrangement drawings
for further details. It is a two pieces (Outer Casing and
Inner Casing or also typically named Liner) pressure
retaining casting assembly, with gasket connections
between the Outer and Inner Casing, as well as to the
seal housings and the suction and discharge flanges.
3.3.2 Pumping Rotors
The pumping rotors (screws) are single start and
mounted to a shaft in opposing configuration i.e. one
left and one right hand rotor to each shaft. The
intermeshing screws integral part of drive and driven
shafts create a positive displacement pumping action
inside the pump body.
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MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
Pumped liquid temperature limits
up to +177 ºC (300 ºF)
Maximum ambient temperature
up to +50 ºC (122 ºF)
Maximum soft solids in suspension
up to 1% by volume
Maximum pump speed
Refer to the nameplate
3.3.3 Shaft
The drive shaft is mounted on bearings with the
pumping rotor and timing gear mounted to the shaft. It
has a keyed drive end. The driven shaft is also
mounted on bearings with the pumping rotor and
timing gear mounted to the shaft.
3.3.4 Timing Gears
The timing gears are mounted to the drive and driven
shafts with accurately located keys to maintain the
pumping rotors in mesh with no contact with each
other.
3.3.5 Pump bearings and lubrication
Antifriction radial and thrust bearings are mounted on
each shaft to support the induced loads. An external
lube oil system and/or an oil bath might be provided at
each end of the pump to lubricate the bearings and
timing gears. An oil site gage might be supplied in the
bearing housings.
Certain multiphase applications may require a
separate lubrication and lube oil cooling system
depending on the condition of service.
3.3.6 Stuffing box/seal housing
The stuffing box housing is doweled to both the pump
casing and the bearing housing to ensure proper
alignment. It is supplied to fit appropriate mechanical
seals.
3.3.7 Shaft seal
The mechanical seals, attached to the pump shaft,
seal the pumped liquid from the environment.
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 etc.
3.3.9 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operating limits
This product has been selected to meet the
specifications of your purchase order (See section 1.5
Duty conditions). 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
3.4.2 Speed torque curves
To bring a rotary pump up to rated speed, the driver
must be capable of providing more torque at each
speed than required by the pump. Normally, this is not
a problem with standard induction or synchronous
motors, provided the proper voltage is supplied at the
motor.
The margin between the available and required torque
affects the time it takes the unit to reach full speed. If
the torque required by the pump exceeds the torque
capability of the drive at any run-up speed, the unit will
not accelerate to full speed.
For pumps started at set system resistance conditions,
100 % full speed torque can be calculated by using the
formula:
Torque (Nm) = 9545 Power (kW)
RPM
Torque (lbf · ft) = 5250 Power (hp)
RPM
Torque required by the pump at any other speed
during start-up can be determined from the curve
above. Note that the driver manufacturer usually
bases 100 % torque on the design power of the driver
and consequently the speed-torque curves should be
plotted in torque units (e.g. Nm or lbf · ft) instead of
percentage torque to avoid confusion.
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3.5 Table of Engineering Data (Table 3)
PUMP SIZE
MP1-150-200
MP1-275-255
MP1-275-355
MP1-380-305
SHAFT/SCREW DESIGN
INTEGRAL
INTEGRAL
INTEGRAL
INTEGRAL
STD SUCTION SIZE
6 in.- 600#
10 in.- 300#
10 in. - 300#
10 in. - 300#
STD DISCHARGE SIZE
4 in. - 600#
110 in. - 300#
10 in. - 300#
10 in. - 300#
STD OD CLEARANCE mm (in.)
0.30/0.45
(0.012/0.018)
0.51/0.76
(0.020/0.030)
0.51/0.76
(0.020/0.030)
0.51/0.76
(0.020/0.030)
APPROX PUMP WEIGHT kg (lb.)
658 (1450)
4490 (9900)
5900 (12990)
6591 (14500)
ROT ELEMENT WEIGHT kg (lb.)
136 (300)
508 (1120)
670 (1470)
990 (2175)
MOMENT OF INERTIA kgm^2 (lb·in2)
0.250 (855)
3.670 (12 540)
3.670 (12 540)
2.356 (8050)
SHAFT DIAMETER @ COUPLING mm (in.)
53.98 (2.125)
92.08 (3.625)
92.08 (3.625)
92.08 (3.625)
SHAFT TAPER @ COUPLING mm/m (in/ft.)
60 (¾)
40 (½)
40 (½)
40 (½)
SHAFT DIAMETER @ ST BOX mm (in.)
73.0 (2.875)
130.2 (5.125)
130.2 (5.125)
130.2 (5.125)
NO OF SEALING CHAMBERS
4 4 4
4
OIL FILL TIMING GEAR HSG liters (qt.)
3.0 (3.2)
21 (22.2)
21 (22.2)
3.4 (3.6)
OIL FILL BEARING HSG liters (qt.)
0.25 (0.26)
8.5 (9.0)
8.5 (9.0)
1.5 (1.6)
PUMP SIZE
MP1-390-305
MP1-380-355
MP1-390-610
MP1-390-406
SHAFT/SCREW DESIGN
INTEGRAL
INTEGRAL
INTEGRAL
INTEGRAL
STD SUCTION SIZE
10 in. - 1500#
10 in. - 300#
16 in. - 300#
16 in. - 600#
STD DISCHARGE SIZE
8 in. - 1500#
10 in. - 300#
16 in. - 300#
16 in. - 600#
STD OD CLEARANCE mm (in.)
0.51/0.76
(0.020/0.030)
0.51/0.76
(0.020/0.030)
0.76/0.89
(0.030/0.035)
0.76/0.89
(0.030/0.035)
APPROX PUMP WEIGHT kg (lb.)
8300 (18 300)
6804 (15 000)
10 500 (23 148)
10 560 (23 280)
ROT ELEMENT WEIGHT kg (lb.)
975 (2150)
1157(2550)
1009(4583)
7612 (3460)
MOMENT OF INERTIA kgm^2 (lbs·in2)
12.759 (43 600)
14.354 (49 050)
25.433 (86 909)
18.041 (61 650)
SHAFT DIAMETER @ COUPLING mm (in.)
92.08 (3.625)
92.08 (3.625)
111.13 (4.375)
111.13 (4.375)
SHAFT TAPER @ COUPLING mm/m (in/ft.)
40 (½)
60 (¾)
40 (1/2)
40 (½)
SHAFT DIAMETER @ ST BOX mm (in.)
130.2 (5.125)
130.2 (5.125)
209.5 (8.25)
209.5 (8.25)
NO OF SEALING CHAMBERS
4 4 4
4
OIL FILL TIMING GEAR HSG liters (qt.)
3.4 (3.6)
3.4 (3.6)
3.4 (3.6)
3.4 (3.6)
OIL FILL BEARING HSG liters (qt.)
1.5 (1.6)
1.5 (1.6)
1.5 (1.6)
1.5 (1.6)
Table 3 Engineering data
MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
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.
The recommended order of operations to install a
pump skid is as follows:
a) Construct Foundation (Section 4.3)
b) Install Baseplate (Section 4.4)
c) Initial Alignment (Section 4.5)
d) Grouting (Section 4.6)
e) Fabrication and Installation of Piping (Section 4.7)
f) Final Shaft Alignment (Section 4.9)
g) Electrical Connections (Section 4.10)
h) Commissioning (Section 5.0)
4.1 Location
The pump should be located to allow room for access,
ventilation, maintenance and inspection and should be
as close as practicable to the supply of liquid to be
pumped. There should be ample room to allow the use
of an overhead crane or lifting device with sufficient
capacity to lift the heaviest part of the unit. Simple
suction and discharge piping layouts are desired.
Allow sufficient room to facilitate the back pull-out
feature.
Refer to the general arrangement drawing for the
pump set.
4.2 Part assemblies
Motors may be supplied loose on Twin Screw pumps,
typically on frame sizes 400 and above. It is the
responsibility of the installer to ensure that the motor is
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MP1 USER INSTRUCTIONS ENGLISH 26999958 – 10-12
assembled to the pump and lined up as detailed in
section 4.5.2 Alignment method.
4.3 Foundation
The foundation may consist of any
material that will afford permanent, rigid support to the
full area of the pump or driver supporting member. It
should be of sufficient size and mass to absorb
expected strains and shocks that may be encountered
in service. Concrete foundations built on solid ground
are desirable.
The purpose of foundation bolts is to anchor the pump
unit securely to the foundation such that the foundation
and pump assembly become a single structural unit.
High strength steel foundation bolts (SAE Gr. 5 or
better) of the specified diameter should be located
according to the elevation drawing provided. Each bolt
should be surrounded by a pipe sleeve two or three
times the diameter of the bolt (see Figure 1). The
sleeves should be securely anchored and designed to
allow the bolts to be adjusted to conform to the holes
in the baseplate. The bolts should be sufficiently long
to allow for wedges or shims or levelling nuts under the
baseplate, and a washer, heavy hex nut and hex jam
nut for retention. Since baseplate levelling is
performed after the foundation has cured, it is best to
use extra-long bolts which can be shortened after the
installation is complete.
Remove the flange covers and check inside the pump
nozzles for cleanliness. Kerosene is recommended as
the best solvent for removing factory applied rust
preventative. Ensure that all traces of rust preventative
are removed from the discharge and suction flange
faces, the exposed shafting and all coupling surfaces.
Flush the pump internals of any rust preventative
applied for long term storage.
Lift the baseplate assembly, remove the shipping skids
and clean the underside of the baseplate. Position the
baseplate over the foundation and lower the unit over
the foundation bolts and onto the wedges, shims or
jacking nuts.
With the aid of a machinist's level, adjust the wedges,
shims or jacking nuts to level the pump and driver
mounting pads in each direction. Check to ensure that
the suction and discharge flanges are plumb, level,
and at the correct elevation. It is normal practice to set
the mounting pads slightly low in order to permit
lowering of units which may be required to suit future
piping or minor changes. Place washers over the
foundation bolts and install nuts. Tighten finger tight
only. Check that the rotor turns freely by hand.
Note: Grout shall not be poured until an initial
preliminary alignment of the pump and driver has
been performed.
4.5 Initial alignment
4.5.1 Thermal expansion
The pump and motor will normally have
to be aligned at ambient temperature and should be
corrected to allow for thermal expansion at operating
temperature. In pump installations involving high liquid
temperatures, the unit should be run at the actual
operating temperature, shut down and the alignment
re-checked and re-adjusted as deemed necessary
Figure 1 – Grout Installation
4.4 Baseplate installation
Position the baseplate and pump next to the
foundation and clean the foundation surface
thoroughly. Remove the rag packing from the pipe
sleeves and place wedges or shims as close to the
foundation bolts as possible. These may be omitted if
a jacking nut on the foundation anchor bolts is
preferred for levelling. Initial levelling should be within
0.75 mm (0.030 in.).
Page 15 of 48 flowserve.com
immediately.
4.5.2 Alignment methods
Ensure pump and driver are isolated
electrically and the half couplings are disconnected.
The alignment MUST be checked.
Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.
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