5.5 Priming and auxiliary supplies ....................... 29
5.6 Starting the pump .......................................... 29
5.7 Running or operation ..................................... 30
5.8 Stopping and shutdown ................................. 31
5.9 Hydraulic, mechanical and electrical duty ..... 31
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INDEX
Page
Additional sources of information (10.3) 58
Assembly of pump (6.9) 47
CE marking and approvals (1.2) 4
Change notes (10.2) 58
Configurations (3.1) 12
Consignment receipt and unpacking (2.1) 10
Copyright (1.4) 4
Design of major parts (3.3) 12
Direction of rotation (5.3) 28
Disclaimer (1.3) 4
Drawing Group A and 1 Close Coupled (8.1) 55
Drawing Group A and 1 Long Coupled (8.2) 55
Drawing Group B and 2 Close Coupled (8.3) 56
Drawing Group B and 2 Long Coupled (8.4) 56
Duty conditions (1.5) 4
Electrical connections (4.7) 25
Examination of parts (6.8) 44
Fastener torques (6.5) 35
Final shaft alignment check (4.8) 25
Foundation (4.3) 15
General (1.1) 4
Grouting (4.4) 17
Guarding (5.4) 28
Handling (2.2) 10
Hydraulic, mechanical and electrical duty (5.9) 31
Impeller (6.6) 35
Initial alignment (4.5) 18
Page
Lifting (2.3) 10
Location (4.1) 15
Maintenance schedule (6.1) 32
Nameplate and safety labels (1.7) 8
Noise level (1.8) 9
Nomenclature (3.2) 12
Part assemblies (4.2) 15
Parts List Group A and 1 (8.5) 57
Parts List Group B and 2 (8.6) 57
Performance and operation limits (3.4) 13
Piping (4.6) 18
Pre-commissioning procedure (5.1) 26
Priming and auxiliary supplies (5.5) 29
Protection systems (4.9) 25
Pump lubricants (5.2) 26
Pump removal and disassembly (6.7) 37
Recommended spares and consumable items (6.3)
33
Recycling and end of product life (2.5) 11
Running or operation (5.7) 30
Safety (1.6) 5
Spare parts (6.2) 33
Starting the pump (5.6) 29
Stopping and shutdown (5.8) 31
Storage (2.4) 11
Supplementary user instructions (10.1) 58
Tools required (6.4) 33
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1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilising sophisticated quality techniques and safety
requirements.
Flowserve is 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 must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow and
apply the present user instructions is considered
to be misuse. Personal injury, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and equipment
put into service within certain regions of the world shall
conform with the applicable CE Marking Directives
covering Machinery and, where applicable, Low Voltage
Equipment, Electromagnetic Compatibility (EMC),
Pressure Equipment Directive (PED) and Equipment for
Potentially Explosive Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory provision
of technical documents and safety instructions. Where
applicable this document incorporates information
relevant to these Directives and Approvals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certification.)
1.3 Disclaimer
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality
Assurance organisations. Genuine parts and
accessories have been designed, tested and
incorporated into the products to help ensure their
continued product quality and performance in use.
As Flowserve cannot test parts and accessories
sourced from other vendors the incorrect
incorporation of such parts and accessories may
adversely affect the performance and safety features
of the products. The failure to properly select, install
or use authorised Flowserve parts and accessories is
considered to be misuse. Damage or failure caused
by misuse is not covered by the Flowserve warranty.
In addition, any modification of Flowserve products or
removal of original components may impair the safety
of these products in their use.
1.4 Copyright
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 purchase order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application.
If there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user seeks
the written agreement of Flowserve before start up.
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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 "strong magnetic
field" safety instructions where non-compliance would
affect personal safety, pacemakers, instruments or
stored data sensitive to magnetic fields.
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 help
prevent injury to personnel and damage to the
environment and to equipment. For products used
in potentially explosive atmospheres section 1.6.4
also applies.
MAGNETIC FIELD PRESENT: This
equipment may affect electronic equipment or other
devices that are influenced by magnetic fields.
Because magnetic drive pumps contain powerful
magnets, anyone with a heart pacemaker MUST
NOT disassemble these pumps. Also, keep all credit
cards, bank cards, watches, computer disks and
anything else which can be damaged by magnetic
fields away from these pumps when disassembled.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER (Lock
out.)
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
This symbol indicates explosive atmosphere zone
marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but indicates
an important instruction in the assembly process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the personnel
in question do not already possess the necessary
knowledge and skill, appropriate training and instruction
must be provided. If required the operator may
commission the manufacturer/supplier to provide
applicable training.
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.
NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapour could cause an explosion.
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HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
If the temperature is greater than 80 ºC (175 ºF) or
below -5 ºC (23 ºF) 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.
ALWAYS USE THE JACKBOLTS TO
SEPARATE THE POWER END FROM THE WET
END ASSEMBLIES.
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not mount
expansion joints, unless allowed by Flowserve in writing,
so that their force, due to internal pressure, acts on the
pump flange.
NEVER RUN THE PUMP DRY
Operating the magnetic coupling dry may cause
immediate damage to the bearings, magnets, etc..
NEVER OPERATE THE PUMP WITH
THE SUCTION VALVE CLOSED
It should be fully opened when the pump is running.
NEVER OPERATE THE PUMP AT
ZERO FLOW OR FOR EXTENDED PERIODS
BELOW THE MINIMUM CONTINUOUS FLOW
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow
rate with no back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/vibration.
THE PUMP SHAFT MUST TURN
CLOCKWISE WHEN VIEWED FROM THE MOTOR
END
It is absolutely essential that the rotation of the motor
be checked before installation of the coupling spacer
and starting the pump.
PolyChem M-series pumps are sized
based on a specific application. In the event the user
elects to operate this pump in a service other than
what it was originally sized for, a Flowserve sales
engineer should be contacted to evaluate the new
application.
1.6.4 Products used in potentially explosive
atmospheres
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation and shutdown.)
NEVER EXCEED THE MAXIMUM
DESIGN PRESSURE (MDP) AT THE
TEMPERATURE SHOWN ON THE PUMP
NAMEPLATE
See section 3 for pressure versus temperature
ratings based on the material of construction.
NEVER OPERATE THE PUMP WITH
THE DISCHARGE VALVE CLOSED
(Unless otherwise instructed at a specific point in the
User Instructions.)
(See section 5, Commissioning start-up, operation and shutdown.)
Measures are required to:
Avoid excess temperature
Prevent build up of explosive mixtures
Prevent the generation of sparks
Prevent leakages
Maintain the pump to avoid hazard
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
For ATEX, both electrical and non-electrical equipment
must meet the requirements of European Directive
94/9/EC. Always observe the regional legal Ex
requirements eg Ex electrical items outside the EU may
be required certified to other than ATEX eg IECEx, UL.
1.6.4.1 Scope of compliance
NEVER RUN THE PUMP DRY OR
WITHOUT PROPER PRIME (Pump flooded).
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly and pump equipment are suitably
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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)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
rated and/or certified for the classification of the specific
atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the ATEX pump set
shall select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating effects in the motor and so,
for pumps sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
where electrical supply is from the VFD. This
particular requirement still applies even if the VFD is
in a safe area.
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 ºC (104 ºF); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends on
the ATEX temperature class and must not exceed the
values in the table that follows.
* 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 temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
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 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.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitors or a
power monitor and make routine vibration monitoring
checks.
In dirty or dusty environments, make regular checks
and remove dirt from areas around close clearances,
bearing housings and motors.
Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures fit an external surface
temperature protection device.
1.6.4.4 Preventing the build up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
atmosphere is prevented.
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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.
For ATEX the coupling must be selected to comply
with 94/9/EC. Correct coupling alignment must be
maintained.
Additional requirement for metallic pumps on
non-metallic baseplates
When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.
1.6.4.6 Preventing leakage
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.)
1.7 Nameplate and safety labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity and section 3.
1.7.2 Safety labels
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.
If leakage of liquid to atmosphere can result in a
hazard, install a liquid detection .
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.
Oil lubricated units only:
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. Where performance data has been supplied
separately to the purchaser these should be obtained
and retained with these User Instructions.
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Motor size
and speed
kW (hp)
Typical sound pressure level LpA at 1 m reference 20 μPa, dBA
3 550 r/min
2 900 r/min
1 750 r/min
1 450 r/min
Pump
only
Pump and
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
<0.55(<0.75)
72
72
64
65
62
64
62
64
0.75 (1)
72
72
64
66
62
64
62
64
1.1 (1.5)
74
74
66
67
64
64
62
63
1.5 (2)
74
74
66
71
64
64
62
63
2.2 (3)
75
76
68
72
65
66
63
64
3 (4)
75
76
70
73
65
66
63
64
4 (5)
75
76
71
73
65
66
63
64
5.5 (7.5)
76
77
72
75
66
67
64
65
7.5 (10)
76
77
72
75
66
67
64
65
11(15)
80
81
76
78
70
71
68
69
15 (20)
80
81
76
78
70
71
68
69
18.5 (25)
81
81
77
78
71
71
69
71
22 (30)
81
81
77
79
71
71
69
71
30 (40)
83
83
79
81
73
73
71
73
37 (50)
83
83
79
81
73
73
71
73
45 (60)
86
86
82
84
76
76
74
76
55 (75)
86
86
82
84
76
76
74
76
75 (100)
87
87
83
85
77
77
75
77
1.9 Noise level
Attention must be given to the exposure of personnel
to the noise, and local legislation will define when
guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA.
The usual approach is to control the exposure time to
the noise or to enclose the machine to reduce emitted
sound. You may have already specified a limiting
noise level when the equipment was ordered,
however if no noise requirements were defined, then
attention is drawn to the following table to give an
indication of equipment noise level so that you can
take the appropriate action in your plant.
Pump noise level is dependent on a number of factors the type of motor fitted, the operating capacity, pipework
design and acoustic characteristics of the building.
Typical sound pressure levels measured in dB, and
A-weighted are shown in the table below. The figures
are indicative only, they are subject to a +3 dB
tolerance, and cannot be guaranteed.
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.
If a pump unit only has been purchased, for fitting
with your own driver, then the "pump only" noise
levels from the table should be combined with the
level for the driver obtained from the supplier.
If the motor is driven by an inverter it may show an
increase in noise level at some speeds. Consult a
Noise Specialist for the combined calculation.
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.
Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.
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2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve Pump Division
and must be received in writing within ten days of
receipt of the equipment. Later claims cannot be
accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check
that this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
2.3.1.2 Bearing holder [3830]
Group B and 2: Insert an eye hook in the drilled and
tapped hole located on the outside diameter of the
bearing holder. Use either a sling or hook through
the eye bolt.
2.3.1.3 Bearing housing [3200]
Group B and 2: insert either a sling or hook through
the lifting lug located on the top of the housing.
2.3.1.4 Power end
Same as bearing housing.
2.3.1.5 Bare pump
Horizontal pumps: sling around the pump discharge
nozzle and around the outboard end of the bearing
housing with separate slings. Choker hitches must be
used at both attachment points and pulled tight. Make
sure the completion of the choker hitch on the discharge
nozzle is toward the coupling end of the pump shaft as
shown in Figure 2-1. The sling lengths should be
adjusted to balance the load before attaching the lifting
hook.
Figure 2-1
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
Pumps and motors often have integral
lifting lugs or eye bolts. These are intended for use in
only lifting the individual piece of equipment.
Do not use eye bolts or cast-in lifting
lugs to lift pump, motor and baseplate assemblies.
To avoid distortion, the pump unit
should be lifted as shown.
Care must be taken to lift components
or assemblies above the center of gravity to prevent
the unit from flipping.
2.3.1 Lifting pump components
2.3.1.1 Casing [1100]
Use a choker hitch pulled tight around the discharge
nozzle.
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2.3.2 Lifting pump, motor and baseplate
assembly
If the baseplate has lifting holes cut in the sides at the
end (Type D and Type E bases) insert lifting S hooks at
the four corners and use slings or chains to connect to
the lifting eye. Do not use slings through the lifting
holes.
For other baseplates, sling around the pump discharge
nozzle, and around the outboard end of the motor frame
using choker hitches pulled tight. (Figure 2-1)
The sling should be positioned so the weight is not
carried through the motor fan housing. Make sure the
completion of the choker hitch on the discharge
nozzle is toward the coupling end of the pump shaft
as shown in Figure 2-1.
2.4 Storage
Store the pump in a clean, dry location
away from vibration. Leave flange covers in place to
keep dirt and other foreign material out of pump
casing. Turn the pump shaft at regular intervals to
prevent brinelling of the bearings.
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
2.4.1 Short term storage and packaging
Normal packaging is designed to protect the pump
and parts during shipment and for dry, indoor storage
for up to six months or less. The following is an
overview of our normal packaging:
All loose unmounted items are packaged in a
water proof plastic bag and placed under the
coupling guard
Inner surfaces of the bearing housing, shaft (area
through bearing housing) and bearings are coated
with Cortec VCI-329 rust inhibitor, or equal.
2.4.2 Long term storage and packaging
Long term storage is defined as more than six
months, but less than 12 months. The procedure
Flowserve follows for long term storage of pumps is
given below. These procedures are in addition to the
short term procedure.
Each assembly is hermetically (heat) sealed from
the atmosphere by means of tack wrap sheeting
and rubber bushings (mounting holes)
Desiccant bags are placed inside the tack
wrapped packaging
A solid wood box is used to cover the assembly
This packaging will provide protection for up to twelve
months from humidity, salt laden air, dust etc.
After unpacking, protection will be the responsibility of
the user. Addition of oil to the bearing housing will
remove the inhibitor. If units are to be idle for extended
periods after addition of lubricants, inhibitor oils and
greases should be used. Every three months, the pump
shaft should be rotated approximately 10 revolutions.
2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and in accordance with local
regulations. If the product contains substances that
are harmful to the environment, these should be
removed and disposed of in accordance with current
local regulations.
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.
shipment
Regreasable bearings are packed with grease
Exposed shafts are taped with Polywrap
Flange covers are secured to both the suction
In some cases with assemblies ordered with
The pump must be stored in a covered, dry
Bearing housings are not filled with oil prior to
(EXXON POLYREX EM)
and discharge flanges
external piping, components may be
disassembled for shipment
location
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Serial No.
Equipment No.
Purchase Order
Model
Size
MDP
Material
Date DD/MMM/YY
PJ 2 X 1 - 10 / 8.25CL
3 DESCRIPTION
3.1 Configurations
The PolyChem M-series chemical process pumps are
fluoropolymer lined, magnetically coupled, horizontal,
end suction, single stage, centrifugal pumps. The
ISO version of this pump conforms dimensionally to
ISO 2858/5199 while the ANSI model agrees
dimensionally with ASME B73.1, both have centerline
discharge.
3.2 Nomenclature
The pump size will be engraved on the nameplate
typically as below:
P = PolyChem pump line
A = Magnetic coupling (small) Group A/1
B = Magnetic coupling (medium) Group A/1
C = Magnetic coupling (large) Group A/1
J = Magnetic coupling (small) Group B/2
K = Magnetic coupling (medium) Group B/2
L = Magnetic coupling (large) Group B/2
References to Group A and Group B relate to ISO
pumps, whilst references to Group 1 and Group 2
relate to ANSI pumps
An example of the nameplate used on the PolyChem
pump is shown in Figure 3-1. This nameplate is
mounted on either the lantern or the bearing housing.
Figure 3-1: Nameplate
3.3 Design of major parts
3.3.1 Casing
Removal of the casing is not required when
performing maintenance of the rotating element. The
rotating element is easily removed (back pull out).
3.3.2 Impeller
The impeller is closed vane.
3.3.3 Wetted bearing system
This system is comprised of silicon carbide bearings.
It is made up of a shaft, thrust journals and bushings,
as well as radial journals and bushings.
3.3.4 Power end bearings and lubrication –
Long-coupled
Ball bearings are fitted as standard and may be either
oil or grease lubricated.
3.3.5 Bearing housing – Long-coupled
Large oil bath reservoir.
3.3.6 Bearing holder
Supports the inboard radial pump bearing.
3.3.7 Magnetic coupling
Comprised of an inner and outer magnet assembly.
The outer assembly is supported by the power end
(long-coupled) or the motor (close-coupled). The
inner assembly is encapsulated and mounted on a
silicon carbide shaft.
3.3.8 Containment shell
Nonmetallic construction to avoid eddy currents
losses.
3.3.9 Lantern
Used to connect the casing to the power end on a
long-coupled pump or to the motor on a closedcoupled pump.
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MCF % of BEP
Pump Size
3500/2900
rpm
1750/1450
rpm
1180/960
rpm
P_3x2-6
20%
10%
10%
P_3x2-10
P_50-250
30%
10%
10%
P_4x3-10
P_65-250
N/A
10%
10%
All other sizes
10%
10%
10%
3.3.10 Driver
The driver is normally an electric motor. Different
drive configurations may be fitted such as internal
combustion engines, turbines, hydraulic motors etc
driving via couplings, belts, gearboxes, drive shafts
etc.
3.3.11 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operation limits
This product has been selected to meet the
specification of your purchase order. See section 1.5.
The following data is included as additional information
to help with your installation. It is typical, and factors
such as liquid being pumped, temperature, and material
of construction may influence this data. If required, a
definitive statement for your application can be obtained
from Flowserve.
3.4.1 Material cross reference chart
Figure 3-3 is the material cross-reference chart for all
PolyChem M-series pumps.
3.4.2 Pressure-temperature ratings
PN 16 flanges are standard for the ISO model pump
while Class 150 flanges are standard for the ANSI
model. Refer to Figure 3-4A and 3-4B for each
pump’s pressure-temperature (P-T) rating.
Figure 3-2: Minimum continuous flow
than or equal to the P-T rating. Discharge pressure
may be approximated by adding the suction pressure
to the differential pressure developed by the pump.
3.4.3 Suction pressure limits
The suction pressure limits for PolyChem M-series
pumps is limited by the P-T rating.
3.4.4 Minimum continuous flow
The minimum continuous flow (MCF) is based on a
percentage of the best efficiency point (BEP). Figure
3-2 identifies the MCF for all PolyChem M-series
pumps.
The maximum discharge pressure must be less
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Flowserve
Material Code
Designation
Durco
Legacy
Codes
Equivalent
wrought
Designation
EN / ASTM
specifications
Nozzle load
material
group
Z0L48
PFA lined Ductile iron (cast)
DIPA
None
Note 1
1.0
E2025
Ductile Iron Casting
7043
None
EN1563, Gr. JS 1025
1.0
E3020
Ductile Iron Casting
DCI
None
A395, Gr. 60-40-18
1.0 A0024
Paper P None N/A
D0005
Carbon Steel
SR
None N/A
D2044
Quenched and Tempered Steel
CK45
None
EN 10083-1
N/A
D3013
1018 Carbon Steel
Z
None N/A
D3058
304 Stainless Steel
304
None
A276, Type 304
N/A
D3277
Carbon Steel
BB
1144
UNS G11440
N/A
D4035
304, 305, 316, Stainless steel
18-8
None N/A
E2008
Ductile Iron Casting
7040
None
EN1563, Gr. JS 1030
N/A
E3006
Cast Iron Casting
CI
None
A48, Gr. 25A
N/A
E3007
Cast Iron Casting
GG25
None
EN1561, Gr. JL 1040
N/A
E3035
Ductile Iron Casting
DCI2
None
A536, Gr. 65-45-12
N/A
E4034
Ductile Iron Casting
DCI4
None
Note 2
N/A
I0003
Bronze
BZ
None N/A
J0018
Reaction bonded silicon carbide
SC2
None N/A
J0020
Sintered silicon carbide
SC3
None N/A
L0009
Carbon Filled Teflon
TFEC
None N/A
L1001
Tetrafluoroethylene
TFE
None N/A
L1010
Ethylene Propylene Rubber
EPR
None N/A
L1017
Nitrile Butadiene Rubber
NBR
None N/A
L1103
Polysulphone
PS
None N/A
M1001
ISO 3506 Grade A2 Class 70
A270
None N/A
M1013
ISO 898/1 Class 8.8
88
None N/A
M3026
Carbon steel
SR5
None
A449, Type 1
N/A
Z0067
Protective Plated Carbon Steel
SRCD
None N/A
Z0L50
PFA lined sintered silicon carbide
S3PA
None N/A
Z0L51
Carbon filled PFA
CFPA
None N/A
Z0L52
Carbon filled fluoropolymer
CFTM
None N/A
Z0L54
Fluoropolymer lined fiberglass
EFP3
None N/A
Z0L64
Teflon lined A193, Gr. B7
B7TF
None N/A
Z0L65
Teflon lined A194, Gr. 2H
SRTF
None N/A
Z0L72
Teflon – Silicon Rubber – Carbon Steel
TSSR
None N/A
Z0M22
Viton – Carbon Steel
VSR
None N/A
Z0M35
PFA lined carbon filled fluoropolymer
CFTM
None N/A
Z0M36
Fluoropolymer lined NdFeB magnets
PFA
None N/A
Z0M37
Carbon steel - NdFeB magnets
SR
None N/A
Temperature ˚C
-29
-18
38
93
121
149
BAR
16
16
16
16
16
15.5
Temperature ˚F
-20 0 100
200
250
300
PSI
232
232
232
232
232
225
Temperature ˚C
-29
-18
38
93
149
BAR
17.2
17.2
17.2
16.2
14.8
Temperature ˚F
-20 0 100
200
300
PSI
250
250
250
235
215
Figure 3-3: Material cross-reference chart
1. The casting used for ISO pumps is E2025 and for ANSI pumps is E3020
2. Dual Spec. EN1563 Gr. JS1030 & A536 Gr. 65-45-12
Figure 3-4A: Pressure – Temperature Rating
ISO Pump with PN 16 Flanges – Material Group No. 1.0
Figure 3-4B: Pressure – Temperature Rating
ANSI Pump with Class 150 Flanges – Material Group No. 1.0
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4 INSTALLATION
4.1 Location
The pump should be located to allow room for access,
ventilation, maintenance, and inspection with ample
headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped.
Refer to the general arrangement drawing for the
pump set.
4.2 Part assemblies
The supply of motors and baseplates are optional.
As a result, it is the responsibility of the installer to
ensure that the motor is assembled to the pump and
aligned as detailed in section 4.5 and 4.8.
4.3 Foundation
4.3.1 Protection of openings and threads
When the pump is shipped, all threads and all
openings are covered. This protection/covering
should not be removed until installation. If, for any
reason, the pump is removed from service, this
protection should be reinstalled.
4.3.2 Rigid baseplates - overview
The function of a baseplate is to provide a rigid
foundation under a pump and its driver that maintains
alignment between the two. Baseplates may be
generally classified into two types:
Baseplates intended for grouted installation are
designed to use the grout as a stiffening member.
Stilt mounted baseplates, on the other hand, are
designed to provide their own rigidity. Therefore the
designs of the two baseplates are usually different.
Regardless of the type of baseplate used, it must
provide certain functions that ensure a reliable
installation. Three of these requirements are:
1. The baseplate must provide sufficient rigidity to
assure the assembly can be transported and
installed, given reasonable care in handling,
without damage. It must also be rigid enough
when properly installed to resist operating loads.
2. The baseplate must provide a reasonably flat
mounting surface for the pump and driver.
Uneven surfaces will result in a soft-foot
condition that may make alignment difficult or
impossible. Experience indicates that a
baseplate with a top surface flatness of 1.25
mm/m (0.015 in./ft) across the diagonal corners
of the baseplate provides such a mounting
surface. Therefore, this is the tolerance to which
we supply our standard baseplate. Some users
may desire an even flatter surface, which can
facilitate installation and alignment. Flowserve
will supply flatter baseplates upon request at
extra cost. For example, mounting surface
flatness of 0.17 mm/m (0.002 in./ft) is offered on
the Flowserve Type E “Ten Point” baseplate
shown in Figure 4-1.
3. The baseplate must be designed to allow the
user to final field align the pump and driver to
within their own particular standards and to
compensate for any pump or driver movement
that occurred during handling. Normal industry
practice is to achieve final alignment by moving
the motor to match the pump. Flowserve
practice is to confirm in our shop that the pump
assembly can be accurately aligned. Before
shipment, the factory verifies that there is
enough horizontal movement capability at the
motor to obtain a “perfect” final alignment when
the installer puts the baseplate assembly into its
original, top leveled, unstressed condition.
4.3.3 Stilt and spring mounted baseplates
Flowserve offers stilt and spring mounted baseplates.
(See Figure 4-2 for stilt mounted option.) The low
vibration levels of PolyChem pumps allow the use of
these baseplates - provided they are of a rigid
design. The baseplate is set on a flat surface with no
tie down bolts or other means of anchoring it to the
floor.
General instructions for assembling these baseplates
are given below. For dimensional information, please
refer to the appropriate Flowserve “Sales print.”
flowserve.com
USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Refer to Figure 4-3.
a) Raise or block up baseplate/pump above the
floor to allow for the assembly of the stilts.
b) Predetermine or measure the approximate
desired height for the baseplate above the floor.
c) Set the bottom nuts [2] above the stilt bolt head
[1] to the desired height.
d) Assemble lock washer [3] down over the stilt bolt.
e) Assemble the stilt bolt up through hole in the
bottom plate and hold in place.
f) Assemble the lock washer [3] and nut [2] on the
stilt bolt. Tighten the nut down on the lock
washer.
g) After all four stilts have been assembled,
position the baseplate in place, over the floor
cups [4] under each stilt location, and lower the
baseplate to the floor.
h) Level and make final height adjustments to the
suction and discharge pipe by first loosening the
top nuts and turning the bottom nuts to raise or
lower the baseplate.
i) Tighten the top and bottom nuts at the lock
washer [3] first then tighten the other nuts.
j) It should be noted that the connecting pipelines
must be individually supported, and that the stilt
mounted baseplate is not intended to support
total static pipe load.
Figure 4-3
d) Assemble the stilt bolt/bottom spring up through
hole in the bottom plate and hold in place.
e) Assemble top spring/cup assembly [3] down
over stilt bolt.
f) Assemble flat washer [5], lock washer [6] and
nuts [4] on the stilt bolt.
g) Tighten down top nuts, compressing the top
spring approximately 13 mm (0.5 in.). Additional
compression may be required to stabilize the
baseplate.
h) After all four stilts have been assembled,
position the baseplate in place, over the floor
cups [7] under each stilt location, and lower the
baseplate down to the floor.
i) Level and make final height adjustments to the
suction and discharge pipe by first loosening the
top nuts, and turning the bottom nuts to raise or
lower the baseplate.
j) Recompress the top spring to the compression
established in step g, and lock the nuts in place.
k) It should be noted that the connecting pipelines
must be individually supported, and that the
spring mounted baseplate is not intended to
support total static pipe loads.
Figure 4-4
4.3.3.2 Stilt/spring mounted baseplate assembly
Refer to Figure 4-4.
a) Raise or block up baseplate/pump above the
b) Set the bottom nuts [4] above the stilt bolt head
c) Assemble the lock washer [6] flat washer [5] and
instructions
floor to allow for the assembly of the stilts.
[1]. This allows for 51 mm (2 in.) upward
movement for the final height adjustment of the
suction/discharge flange.
bottom spring/cup assembly [2] down over the
stilt bolt [1].
4.3.3.3 Stilt/spring mounted baseplates - motor
alignment
The procedure for motor alignment on stilt or spring
mounted baseplates is similar to grouted baseplates.
The difference is primarily in the way the baseplate is
leveled.
a) Level the baseplate by using the stilt adjusters.
(Shims are not needed as with grouted
baseplates.)
b) After the base is level, it is locked in place by
locking the stilt adjusters.
c) Next the initial pump alignment must be
checked. The vertical height adjustment
provided by the stilts allows the possibility of
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slightly twisting the baseplate. If there has been
no transit damage or twisting of the baseplate
during stilt height adjustment, the pump and
driver should be within 0.38 mm (0.015 in.)
parallel, and 0.0025 mm/mm (0.0025 in./in.)
angular alignment. If this is not the case, check
to see if the driver mounting fasteners are
centered in the driver feet holes.
d) If the fasteners are not centered there was likely
shipping damage. Re-center the fasteners and
perform a preliminary alignment to the above
tolerances by shimming under the motor for
vertical alignment, and by moving the pump for
horizontal alignment.
e) If the fasteners are centered, then the baseplate
may be twisted. Slightly adjust (one turn of the
adjusting nut) the stilts at the driver end of the
baseplate and check for alignment to the above
tolerances. Repeat as necessary while
maintaining a level condition as measured from
the pump discharge flange.
f) Lock the stilt adjusters.
The remaining steps are as listed for new grouted
baseplates.
4.4 Grouting
a) The pump foundation should be located as close
to the source of the fluid to be pumped as
practical.
b) There should be adequate space for workers to
install, operate, and maintain the pump. The
foundation should be sufficient to absorb any
vibration and should provide a rigid support for
the pump and motor.
c) Recommended mass of a concrete foundation
should be three times that of the pump, motor
and base. Refer to Figure 4-5.
Foundation bolts are imbedded in the
concrete inside a sleeve to allow some movement of
the bolt.
Figure 4-5
d) Level the pump baseplate assembly. If the
baseplate has machined coplanar mounting
surfaces, these machined surfaces are to be
referenced when leveling the baseplate. This
may require that the pump and motor be
removed from the baseplate in order to
reference the machined faces. If the baseplate
is without machined coplanar mounting surfaces,
the pump and motor are to be left on the
baseplate. The proper surfaces to reference
when leveling the pump baseplate assembly are
the pump suction and discharge flanges. DO
NOT stress the baseplate.
e) Do not bolt the suction or discharge flanges of
the pump to the piping until the baseplate
foundation is completely installed. If equipped,
use leveling jackscrews to level the baseplate. If
jackscrews are not provided, shims and wedges
should be used. (See Figure 4-5.) Check for
levelness in both the longitudinal and lateral
directions. Shims should be placed at all base
anchor bolt locations, and in the middle edge of
the base if the base is more than 1.5 m (5 ft.)
long. Do not rely on the bottom of the baseplate
to be flat. Standard baseplate bottoms are not
machined, and it is not likely that the field
mounting surface is flat.
f) After leveling the baseplate, tighten the anchor
bolts. If shims were used, make sure that the
baseplate was shimmed near each anchor bolt
before tightening. Failure to do this may result in
a twist of the baseplate, which could make it
impossible to obtain final alignment.
g) Check the level of the baseplate to make sure
that tightening the anchor bolts did not disturb
the level of the baseplate. If the anchor bolts did
change the level, adjust the jackscrews or shims
as needed to level the baseplate.
h) Continue adjusting the jackscrews or shims and
tightening the anchor bolts until the baseplate is
level.
i) Check initial alignment. If the pump and motor
were removed from the baseplate proceed with
step j) first, then the pump and motor should be
reinstalled onto the baseplate using Flowserve’s
factory preliminary alignment procedure as
described in section 4.5, and then continue with
the following. As described above, pumps are
given a preliminary alignment at the factory. This
preliminary alignment is done in a way that
ensures that, if the installer duplicates the factory
conditions, there will be sufficient clearance
between the motor hold down bolts and motor foot
holes to move the motor into final alignment. If the
pump and motor were properly reinstalled to the
baseplate or if they were not removed from the
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baseplate and there has been no transit damage,
and also if the above steps where done properly,
the pump and driver should be within 0.38 mm
(0.015 in.) FIM (Full Indicator Movement) parallel,
and 0.0025 mm/mm (0.0025 in./in.) FIM angular.
If this is not the case, first check to see if the driver
mounting fasteners are centered in the driver feet
holes. If not, re-center the fasteners and perform a
preliminary alignment to the above tolerances by
shimming under the motor for vertical alignment,
and by moving the pump for horizontal alignment.
j) Grout the baseplate. A non-shrinking grout
should be used. Make sure that the grout fills
the area under the baseplate. After the grout
has cured, check for voids and repair them.
Jackscrews, shims and wedges should be
removed from under the baseplate at this time.
If they were to be left in place, they could rust,
swell, and cause distortion in the baseplate.
k) Run piping to the suction and discharge of the
pump. There should be no piping loads
transmitted to the pump after connection is
made. Recheck the alignment to verify that
there are no significant loads.
4.5 Initial alignment – Long-coupled
4.5.1 Horizontal initial alignment procedure
The purpose of factory alignment is to ensure that the
user will have full utilization of the clearance in the
motor holes for final job-site alignment. To achieve
this, the factory alignment procedure specifies that
the pump be aligned in the horizontal plane to the
motor, with the motor foot bolts centered in the motor
holes. This procedure ensures that there is sufficient
clearance in the motor holes for the customer to field
align the motor to the pump, to zero tolerance. This
philosophy requires that the customer be able to
place the base in the same condition as the factory.
Thus the factory alignment will be done with the base
sitting in an unrestrained condition on a flat and level
surface. This standard also emphasizes the need to
ensure the shaft spacing is adequate to accept the
specified coupling spacer.
The factory alignment procedure is summarized
below:
a) The baseplate is placed on a flat and level
workbench in a free and unstressed position.
b) The baseplate is leveled as necessary. Leveling
is accomplished by placing shims under the rails
of the base at the appropriate anchor bolt hole
locations. Levelness is checked in both the
longitudinal and lateral directions.
c) The motor and appropriate motor mounting
hardware is placed on the baseplate and the
motor is checked for any planar soft-foot
condition. If any is present it is eliminated by
shimming.
d) The motor feet holes are centered on the motor
mounting fasteners. This is done by using a
centering nut as shown in Figure 4-6.
Figure 4-6
e) The motor is fastened in place by tightening the
nuts on two diagonal motor mounting studs.
f) The pump is put onto the baseplate and leveled.
The foot piece under the bearing housing is
adjustable. It is used to level the pump, if
necessary. If an adjustment is necessary, add or
remove shims [3126.1] between the foot piece
and the bearing housing.
g) The spacer coupling gap is verified.
h) The parallel and angular vertical alignment is
made by shimming under the motor.
i) The motor feet holes are again centered on the
motor mounting studs using the centering nut.
At this point the centering nut is removed and
replaced with a standard nut. This gives
maximum potential mobility for the motor to be
horizontally moved during final, field alignment.
All four motor feet are tightened down.
j) The pump and motor shafts are then aligned
horizontally, both parallel and angular, by
moving the pump to the fixed motor. The pump
feet are tightened down.
k) Both horizontal and vertical alignment is again
final checked as is the coupling spacer gap.
See section 4.8, Final shaft alignment.
4.6 Piping
Protective covers are fitted to both the
suction and discharge flanges of the casing and must
be removed prior to connecting the pump to any pipes.
4.6.1 Suction and discharge piping
All piping must be independently supported, accurately
aligned and preferably connected to the pump by a
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short length of flexible piping. The pump should not
have to support the weight of the pipe or compensate
for misalignment. It should be possible to install suction
and discharge bolts through mating flanges without
pulling or prying either of the flanges. All piping must be
tight. Pumps may air-bind if air is allowed to leak into
the piping. If the pump flange(s) have tapped holes,
select flange fasteners with thread engagement at least
equal to the fastener diameter but that do not bottom
out in the tapped holes before the joint is tight.
The following is the recommended procedure for
attaching piping to the PolyChem M-series pump (see
section 6.5 for torque values)
Check the surface of both flanges (pump/pipe) to
ensure they are clean, flat, and without defects
Lubricate the fasteners
Hand tighten all of the fasteners in a crisscross
pattern
The fasteners should be torqued in increments –
based a crisscross pattern
o The first increment should be at 75%
of the full torque
o The second increment should be at the
full torque
o Verify that the torque value of the 1st
fastener is still at the full torque value
Retorque all fasteners after 24 hours or after the first
thermal cycle
Retorque all fasteners at least annually
4.6.2 Suction piping
To avoid NPSH and suction problems, suction piping
must be at least as large as the pump suction
connection. Never use pipe or fittings on the suction
that are smaller in diameter than the pump suction size.
Figure 4-7 illustrates the ideal piping configuration with a
minimum of 10 pipe diameters between the source and
the pump suction. In most cases, horizontal reducers
should be eccentric and mounted with the flat side up as
shown in Figure 4-8 with a maximum of one pipe size
reduction. Never mount eccentric reducers with the flat
side down. Horizontally mounted concentric reducers
should not be used if there is any possibility of entrained
air in the process fluid. Vertically mounted concentric
reducers are acceptable. In applications where the fluid
is completely de-aerated and free of any vapor or
suspended solids, concentric reducers are preferable to
eccentric reducers.
Figure 4-7 Figure 4-8
Avoid the use of throttling valves and strainers in the
suction line. Start up strainers must be removed shortly
before start up. When the pump is installed below the
source of supply, a valve should be installed in the
suction line to isolate the pump and permit pump
inspection and maintenance. However, never place a
valve directly on the suction nozzle of the pump.
Refer to the Durco Pump Engineering Manual and
the Centrifugal Pump IOM Section of the Hydraulic
Institute Standards for additional recommendations
on suction piping. (See section 10.)
Refer to section 3.4 for performance and operating
limits.
4.6.3 Discharge piping
Install a valve in the discharge line. This valve is
required for regulating flow and/or to isolate the pump
for inspection and maintenance.
When fluid velocity in the pipe is high,
for example, 3 m/s (10 ft/sec) or higher, a rapidly
closing discharge valve can cause a damaging
pressure surge. A dampening arrangement should
be provided in the piping.
4.6.4 ALLOWABLE NOZZLE LOADS
Introduction
Never use the pump as a support for piping.
Maximum Forces and moments allowed on pump
flanges vary based on the pump size. When these
forces and moments are minimized, there is a
corresponding reduction in misalignment, hot
bearings, worn couplings, vibration and possible
failure of the pump casing. The following points
should be strictly followed:
Prevent excessive external pipe load
Never draw piping into place by applying force to
pump flange connections
Do not mount expansion joints so that their force,
due to internal pressure, acts on the pipe flange
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Page 20 of 60
®
Temp. ˚C
-29
38
93
150
Temp. ˚F
-20
100
200
300
Correction Factors
0.89
0.89
0.83
0.78
Base Type
Grouted
Bolted
Stilt
Mounted
Type A
1.0
0.7
0.65
Type B - Polybase
1.0
N/A
0.95
Type C
N/A
1.0
1.0
Type D
1.0
0.8
0.75
Type E - PIP
1.0
0.95
N/A
Polyshield - Baseplate
/ Foundation
1.0
N/A
N/A
The PolyChem product line is designed to meet the
requirements of ISO 5199 and ANSI/HI 9.6.2.
Allowable nozzle loads for ISO pumps may be
calculated using ISO 5199 or ANSI/HI 9.6.2 by
selecting a comparable pump size.
Figure 4-9: Casing Material Correction Factors –
Material Group No. 1.0
Figure 4-10: Baseplate Correction Factors
4.6.4.1 PolyChem M-series Pumps
The following steps are based upon ANSI/HI 9.6.2.
All information necessary to complete the evaluation
is given below. For complete details please review
the standard.
a) PolyChem M-series pumps are only
manufactured from Ductile Iron. For reference
the “Material Group No.” for this material is 1.0
b) Find the “Casing Material Correction Factor” in
Figure 4-9 based upon the operating
temperature. Interpolation may be used to
determine the correction factor for a specific
temperature.
c) Find the “Baseplate Correction Factor” in
Figure 4-10. The correction factor depends
upon how the baseplate is to be installed
d) Locate the pump model being evaluated in
Figure 4-14 and multiply each load rating by the
casing correction factor. Record the adjusted
Figure 4-14 loads.
e) Locate the pump model being evaluated in
Figures 4-15 and 4-16 and multiply each load
rating by the baseplate correction factor. Record
the adjusted Figure 4-15 and 4-16 loads.
f) Compare the adjusted Figure 4-14 values (Step
D) to the values shown in Figure 4-13. The
lower of these two values should be used as the
adjusted Figure 4-13 values. (The HI standard
also asks that Figure 4-13 loads be reduced if
Figure 4-15 or 4-16 values are lower. Flowserve
does not follow this step.)
Figure 4-11: Coordinate System
g) Calculate the applied loads at the casing flanges
according to the coordinate system found in Figure
4-11. The 12 forces and moments possible are
Fxs, Fys, Fzs, Mxs, Mys, Mzs, Fxd, Fyd, Fzd, Mxd,
Myd and Mzd. For example, Fxd designates
Force in the “x” direction on the discharge flange.
Mys designates the Moment about the “y”-axis on
the suction flange.
h) Figure 4-12 gives the acceptance criteria
equations. For long-coupled pumps, equation sets
1 through 5 must be satisfied. For close coupled
pumps only equation sets 1 and 2 must be
satisfied.
i) Equation set 1: Each applied load is divided by the
corresponding adjusted Figure 4-13 value. The
absolute value of each ratio must be less than or
equal to one.
j) Equation set 2: The summation of the absolute
values of each ratio must be less than or equal to
two. The ratios are the applied load divided by the
adjusted Figure 4-14 values.
k) Equation sets 3 and 4: These equations are
checking for coupling misalignment due to nozzle
loading in each axis. Each applied load is divided
by the corresponding adjusted load from Figure 415 and 4-16. The result of each equation must be
between one and negative one.
l) Equation set 5: This equation calculates the total
shaft movement from the results of equations 3
and 4. The result must be less than or equal to
one.
flowserve.com
USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Page 21 of 60
®
Figure 4-12: Acceptance Criteria Equations
Set
Equations
Figure
Remarks
1
0.1,0.1,0.1,0.1,0.1,0.1
,0.1,0.1,0.1,0.1,0.1,0.1
______
______
adjzd
zd
adjyd
yd
adjxd
xd
adjzd
zd
adjyd
yd
adjxd
xd
adjzs
zs
adjys
ys
adjxs
xs
adjzs
zs
adjys
ys
adjxs
xs
M
M
M
M
M
M
F
F
F
F
F
F
M
M
M
M
M
M
F
F
F
F
F
F
Adjusted
4-13
Maximum
individual
loading
2
0.2
______
______
adjzd
zd
adjyd
yd
adjxd
xd
adjzd
zd
adjyd
yd
adjxd
xd
adjzs
zs
adjys
ys
adjxs
xs
adjzs
zs
adjys
ys
adjxs
xs
M
M
M
M
M
M
F
F
F
F
F
F
M
M
M
M
M
M
F
F
F
F
F
F
Adjusted
4-14
Nozzle
stress, bolt
stress,
pump
slippage
3
____
____
ysys
xszs
ys adjxs adjys adjzs adj
ydyd
xdzd
yd adjxd adjyd adjzd adj
FM
MM
A
FMMM
FM
MM
FMMM
0.10.1A
Adjusted
4-15
y-axis
movement
4
_____
______
ys
xszsxszs
xs adjzs adjxs adjys adjzs adj
ydyd
xdzdxdzd
xd adjyd adjzd adjxd adjyd adjzd adj
M
FFMM
B
FFMMM
FM
FFMM
FFFMMM
0.10.1B
Adjusted
4-16
z-axis
movement
5
0.122BA
-
Combined
axis
movement
Note: All of the above equations are found by dividing the applied piping loads by the adjusted figure values.
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Page 22 of 60
®
Pump Size
Suction
Discharge
Forces (N)
Moments (Nm)
Forces (N)
Moments (Nm)
Fxs
Fys
Fzs
Mxs
Mys
Mzs
Fxd
Fyd
Fzd
Mxd
Myd
Mzd
P_1.5x1-6
P_32-160
4670
3336
3336
976
231
231
3558
6005
13344
556
556
556
P_3x1.5-6
4670
5516
5560
1220
664
664
3558
6005
13344
678
746
692
P_3x2-6
P_65-160
4670
4670
4670
1220
298
298
3558
6005
13344
678
1356
692
P_1.5x1-8
P_40-200
4670
5382
5382
976
258
258
3558
6005
13344
488
488
488
P_ 2x1-10
P_32-250
10408
4270
4270
1722
298
298
6227
6005
14456
895
895
895
P_ 3x2-10
P_50-250
12010
6005
6583
1763
420
420
6227
6005
14456
759
759
759
P_ 4x3-10
P_65-250
10230
6005
6672
1763
420
420
6227
6005
14456
1627
1980
936
Pump Size
Suction
Discharge
Forces (lbf)
Moments (lbf∙ft)
Forces (lbf)
Moments (lbf∙ft)
Fxs
Fys
Fzs
Mxs
Mys
Mzs
Fxd
Fyd
Fzd
Mxd
Myd
Mzd
P_1.5x1-6
P_32-160
1050
750
750
720
170
170
800
1350
3000
410
410
410
P_3x1.5-6
1050
1240
1250
900
490
490
800
1350
3000
500
550
510
P_3x2-6
P_65-160
1050
1050
1050
900
220
220
800
1350
3000
500
1000
510
P_1.5x1-8
P_40-200
1050
1210
1210
720
190
190
800
1350
3000
360
360
360
P_ 2x1-10
P_32-250
2340
960
960
1270
220
220
1400
1350
3250
660
660
660
P_ 3x2-10
P_50-250
2700
1350
1480
1300
310
310
1400
1350
3250
560
560
560
P_ 4x3-10
P_65-250
2300
1350
1500
1300
310
310
1400
1350
3250
1200
1460
690
Figure 4-13: Maximum Individual Loading
SI Units
US Units
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Page 23 of 60
®
Pump Size
Suction
Discharge
Forces (N)
Moments (Nm)
Forces (N)
Moments (Nm)
Fxs
Fys
Fzs
Mxs
Mys
Mzs
Fxd
Fyd
Fzd
Mxd
Myd
Mzd
P_1.5x1-6
P_32-160
8985
3336
3336
2481
231
231
8985
6005
27756
556
556
556
P_3x1.5-6
8985
5516
9385
3105
664
664
8985
6005
27756
746
746
692
P_3x2-6
P_65-160
8985
4670
4670
3105
298
298
8985
6005
27756
1397
1397
692
P_1.5x1-8
P_40-200
8985
5382
5382
2481
258
258
8985
6005
27756
488
488
488
P_ 2x1-10
P_32-250
10408
4270
4270
4936
298
298
8985
6005
27756
895
895
895
P_ 3x2-10
P_50-250
12010
6005
6583
5058
420
420
8985
6005
27756
759
759
759
P_ 4x3-10
P_65-250
10230
6005
7295
5058
420
420
8985
6005
27756
1980
1980
936
Pump Size
Suction
Discharge
Forces (lbf)
Moments (lbf∙ft)
Forces (lbf)
Moments (lbf∙ft)
Fxs
Fys
Fzs
Mxs
Mys
Mzs
Fxd
Fyd
Fzd
Mxd
Myd
Mzd
P_1.5x1-6
P_32-160
2020
750
750
1830
170
170
2020
1350
6240
410
410
410
P_3x1.5-6
2020
1240
2110
2290
490
490
2020
1350
6240
550
550
510
P_3x2-6
P_65-160
2020
1050
1050
2290
220
220
2020
1350
6240
1030
1030
510
P_1.5x1-8
P_40-200
2020
1210
1210
1830
190
190
2020
1350
6240
360
360
360
P_ 2x1-10
P_32-250
2340
960
960
3640
220
220
2020
1350
6240
660
660
660
P_ 3x2-10
P_50-250
2700
1350
1480
3730
310
310
2020
1350
6240
560
560
560
P_ 4x3-10
P_65-250
2300
1350
1640
3730
310
310
2020
1350
6240
1460
1460
690
Figure 4-14: Maximum Combined Loading
SI Units
US Units
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Figure 4-15: Maximum Y-Axis Loading for Shaft Deflection
SI Units
US Units
Figure 4-16: Maximum Z-Axis Loading for Shaft Deflection
SI Units
US Units
4.6.5 Pump and shaft alignment check – Longcoupled
After connecting the piping, rotate the pump drive
shaft clockwise (viewed from motor end) by hand
several complete revolutions to be sure there is no
binding and that all parts are free. Recheck shaft
alignment (see section 4.5). If piping caused unit to
be out of alignment, correct piping to relieve strain on
the pump.
4.6.6 Auxiliary piping
4.6.6.1 Piping connection - Oil mist lubrication
system
The piping connections for an oil mist lubrication
system are shown below.
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4.7 Electrical connections
Electrical connections must be made by
a qualified Electrician in accordance with relevant
local national and international regulations.
It is important to be aware of the EUROPEAN
DIRECTIVE on potentially explosive areas where
compliance with IEC60079-14 is an additional
requirement for making electrical connections.
It is important to be aware of the EUROPEAN
DIRECTIVE on electromagnetic compatibility when
wiring up and installing equipment on site.
Attention must be paid to ensure that the techniques
used during wiring/installation do not increase
electromagnetic emissions or decrease the
electromagnetic immunity of the equipment, wiring or
any connected devices. If in any doubt contact
Flowserve for advice.
The motor must be wired up in
accordance with the motor manufacturer's instructions
(normally supplied within the terminal box) including
any temperature, earth leakage, current and other
protective devices as appropriate. The identification
nameplate should be checked to ensure the power
supply is appropriate.
See section 5.3, Direction of rotation
before connecting the motor to the electrical supply.
4.8 Final shaft alignment check – Long-
coupled
a) Level baseplate if appropriate.
b) Mount and level pump if appropriate. Level the
pump by putting a level on the discharge flange.
If not level, adjust the footpiece by adding or
removing shims [3126.1] between the footpiece
and the bearing housing.
c) Check initial alignment. If pump and driver have
been remounted or the specifications given below
are not met, perform an initial alignment as
described in section 4.5. This ensures there will
be sufficient clearance between the motor hold
down bolts and motor foot holes to move the
motor into final alignment. The pump and driver
should be within 0.38 mm (0.015 in.) FIM (full
indicator movement) parallel, and 0.0025 mm/mm
(0.0025 in./in.) FIM angular.
Stilt mounted baseplates
If initial alignment cannot be achieved with the
motor fasteners centered, the baseplate may be
twisted. Slightly adjust (one turn of the adjusting
nut) the stilts at the driver end of the baseplate
and check for alignment to the above tolerances.
Repeat as necessary while maintaining a level
condition as measured from the pump discharge
flange.
d) Run piping to the suction and discharge to the
pump. There should be no piping loads
transmitted to the pump after connection is
made. Recheck the alignment to verify that there
are no significant changes.
e) Perform final alignment. Check for soft-foot under
the driver. An indicator placed on the coupling,
reading in the vertical direction, should not
indicate more than 0.05 mm (0.002 in.) movement
when any driver fastener is loosened. Align the
driver first in the vertical direction by shimming
underneath its feet.
f) When satisfactory alignment is obtained the
number of shims in the pack should be minimized.
It is recommended that no more than five shims
be used under any foot. Final horizontal
alignment is made by moving the driver.
Maximum pump reliability is obtained by having
near perfect alignment. Flowserve recommends
no more than 0.05 mm (0.002 in.) parallel, and
0.0005 mm/mm (0.0005 in./in.) angular
misalignment. (See section 6.8.4.1)
g) Operate the pump for at least an hour or until it
reaches final operating temperature. Shut the
pump down and recheck alignment while the pump
is hot. Piping thermal expansion may change the
alignment. Realign pump as necessary.
4.9 Protection systems
The following protection systems are
recommended particularly if the pump is installed in a
potentially explosive area or is handling a hazardous
liquid. If in doubt consult Flowserve.
If there is any possibility of the system allowing the
pump to run against a closed valve or below minimum
continuous safe flow a protection device should be
installed to ensure the temperature of the liquid does
not rise to an unsafe level.
If there are any circumstances in which the system
can allow the pump to run dry, or start up empty, a
power monitor should be fitted to stop the pump or
prevent it from being started. This is particularly
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Page 26 of 60
®
Pump
PolyChem M-series
Group A
458 ml (15.5 fl. oz.)
Group 1
251 ml (8.5 fl. oz.)
Group B
946 ml (32 fl. oz.)
Group 2
946 ml (32 fl. oz.)
Mineral
oil
Quality mineral oil with rust and oxidation
inhibitors.
Synthetic
Royal Purple or Conoco SYNCON (or equivalent).
Some synthetic lubricants require Viton O-rings.
Grease
EXXON POLYREX EM (or compatible)
relevant if the pump is handling a flammable liquid. If
leakage of product from the pump can cause a hazard
it is recommended that an appropriate leakage
detection system is installed.
To prevent excessive surface temperatures at
bearings it is recommended that temperature or
vibration monitoring is carried out.
5 COMMISSIONING, STARTUP,
OPERATION AND SHUTDOWN
These operations must be carried
out by fully qualified personnel.
NEVER RUN THE PUMP DRY OR
WITHOUT PROPER PRIME (Pump flooded).
Operating the pump dry may cause immediate
damage to the bearings, magnets, etc..
5.1 Pre-commissioning procedure
5.1.1 Pre start-up checks
Prior to starting the pump it is essential that the
following checks be made. These checks are all
described in detail in the Maintenance section of this
manual.
Pump and motor properly secured to the baseplate
All fasteners tightened to the correct torque
Coupling guard in place and not rubbing
Rotation check, see section 5.3.
This is absolutely essential
Bearing lubrication
Pump instrumentation is operational
Pump is primed
Rotation of shaft by hand
As a final step in preparation for operation, it is
important to rotate the shaft by hand to be certain that
all rotating parts move freely, and that there are no
foreign objects in the pump casing.
5.2 Pump lubricants
5.2.1 Oil bath
The standard bearing housing bearings are oil bath
lubricated and are not lubricated by Flowserve.
Before operating the pump, fill the bearing housing to
the center of the oil sight glass with the proper type
oil. (See Figure 5-1 for approximate amount of oil
required - do not overfill.)
The oil level in the bearing housing must be
maintained at ±3 mm (±1/8 in.) from the center of the
sight glass. The sight glass has a 6 mm (¼ in.) hole
in the center of its reflector. The bearing housing oil
level must be within the circumference of the center
hole to ensure adequate lubrication of the bearings.
See Figure 5-2 for a general description of the lubricants
to be used and Figure 5-6 for recommended lubricants.
DO NOT USE DETERGENT OILS. The oil must be
free of water, sediment, resin, soaps, acid and fillers of
any kind. It should contain rust and oxidation inhibitors.
The proper oil viscosity is determined by the bearing
housing operating temperature as given in Figure 5-3.
To add oil to the housing, clean and then remove the
vent plug [6569.2] at the top of the bearing housing,
pour in oil until it is visually half way up in the sight glass
[3855]. Fill the constant level oiler bottle, if used, and
return it to its position. The correct oil level is obtained
with the constant level oiler in its lowest position, which
results in the oil level being at the top of the oil inlet pipe
nipple, or half way up in the sight glass window. Oil
must be visible in the bottle at all times.
In many pumping applications lubricating oil becomes
contaminated before it loses its lubricating qualities or
breaks down. For this reason it is recommended that
the first oil change take place after approximately 160
hours of operation, at which time, the used oil should be
examined carefully for contaminants. During the initial
operating period monitor the bearing housing operating
temperature. Record the external bearing housing
temperature. See Figure 5-4 for maximum acceptable
temperatures. The normal oil change interval is based
on temperature and is shown in Figure 5-5.
Figure 5-1: Amount of oil required
Figure 5-2: Lubricant description
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
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Maximum oil
temperature
ISO viscosity
grade
Minimum
viscosity index
Up to 71 °C (160 °F)
46
95
71-80 °C (160-175 °F)
68
95
80-94 °C (175-200 °F)
100
95
Lubrication
Temperature
Oil bath
82 °C (180 °F)
Oil mist
82 °C (180 °F)
Grease
94 °C (200 °F)
Lubricant
Under 71 °C
(160 °F)
71-80 °C
(160-175 °F)
80-94 °C
(175-200 °F)
Mineral oil
6 months
3 months
1.5 months
Synthetic oil
18 months
18 months
18 months
Centrifugal pump
lubrication
Oil
Splash lubrication
Oil mist lubrication
Viscosity
mm²/s 40 ºC
32
68
46
Temp. max. ºC (ºF)
65 (149)
80 (176)
-
Designation
according to
DIN51502 ISO VG
HL/HLP 32
HL/HLP 68
HL/HLP 46
Oil companies and lubricants
BP
BP Energol HL32
BP Energol HLP32
BP Energol HL68
BP Energol HLP68
BP Energol HL46
BP Energol HLP46
DEA
Anstron HL32
Anstron HLP32
Anstron HL68
Anstron HLP68
Anstron HL46
Anstron HLP46
Elf
OLNA 32
HYDRELEF 32
TURBELF 32
ELFOLNA DS32
TURBELF SA68
ELFOLNA DS68
TURBELF SA46
ELFOLNA DS46
Esso
TERESSO 32
NUTO H32
TERESSO 68
NUTO H68
TERESSO 46
NUTO H46
Mobil
Mobil DTE oil light
Mobil DTE13
MobilDTE24
Mobil DTE oil heavy medium
Mobil DTE26
Mobil DTE oil medium
Mobil DTE15M
Mobil DTE25
Q8
Q8 Verdi 32
Q8 Haydn 32
Q8 Verdi 68
Q8 Haydn 68
Q8 Verdi 46
Q8 Haydn 46
Shell
Shell Tellus 32
Shell Tellus 37
Shell Tellus 01 C 68
Shell Tellus 01 68
Shell Tellus 01 C 46
Shell Tellus 01 46
Texaco
Rando Oil HD 32
Rando Oil HD-AZ-32
Rando Oil 68
Rando Oil HD C-68
Rando Oil 46
Rando Oil HD B-46
Wintershall
(BASF Group)
Wiolan HN32
Wiolan HS32
Wiolan HN68
Wiolan HS68
Wiolan HN46
Wiolan HS46
Figure 5-3: Oil viscosity grades
Figure 5-4: Maximum external housing
temperatures
The maximum temperature that the
bearing can be exposed to is 105 °C (220 °F).
Bearing temperatures may be up to 16 °C (30 °F)
higher than the housing temperature.
Figure 5-5: Lubrication intervals*
* Assuming good maintenance and operation practices, and no
contamination.
Figure 5.6 Recommended oil lubricants
5.2.2 Grease
Do not fill the housing with oil when
greased bearings are used. The oil will leach the
grease out of the bearings and the life of the bearings
may be drastically reduced.
5.2.2.1 Grease for life
Double shielded or double sealed bearings
These bearings are packed with grease by the
bearing manufacturer and should not be relubricated.
The replacement interval for these bearings is greatly
affected by their operating temperature and speed.
Shielded bearings typically operate cooler.
5.2.3 Oil mist
The inlet port for all horizontal pumps is the plugged
½ in. NPT located at the top of the bearing housing.
A plugged ¼ in. NPT bottom drain is provided on the
bearing housing. See section 4.6.6.2, Piping connection - Oil mist lubrication system. Do not allow
oil level to remain above the center of the bearing
housing sight glass window with purge mist (wet
sump) systems.
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Page 28 of 60
®
5.3 Direction of rotation
5.3.1 Rotation check
5.3.1.1 Rotation check, Long-coupled pumps
It is absolutely essential that the
rotation of the motor be checked before connecting
the shaft coupling. All PolyChem M-series pumps
turn clockwise as viewed from the motor end. A
direction arrow is cast on the front of the casing as
shown in Figure 5-7. Make sure the motor rotates in
the same direction.
Figure 5-7
5.3.1.2 Rotation check, Close-coupled pumps
It is absolutely essential that the
rotation of the motor be checked. This check will
require operating the pump briefly, so the pump must
be filled with liquid. Never run a centrifugal pump dry.
To check rotation, perform the following steps:
a) Open the suction and discharge valves to allow
the pump to fill with liquid.
b) While watching the motor fan, bump the motor.
The proper direction of rotation for the pump is
clockwise as viewed from the motor end. A
direction arrow is cast on the front of the casing
as shown in Figure 5-7.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
(Lock out.)
c) If the motor rotates in the wrong direction, reverse
any two of the three leads to the motor (3 phase
current). Bump the motor again to ensure the
proper direction of rotation.
5.3.2 Coupling installation
Pumps are shipped without the spacer installed. If
the spacer has been installed to facilitate alignment,
then it must be removed prior to checking rotation.
Remove all protective material from the coupling and
shaft before installing the coupling.
Figure 5-8
5.4 Guarding
Guarding is supplied fitted to the pump set.
In member countries of the EU and EFTA, it is a legal
requirement that fasteners for guards must remain
captive in the guard to comply with the Machinery
Directive 2006/42/EC. When releasing such guards,
the fasteners must be unscrewed in an appropriate
way to ensure that the fasteners remain captive.
Power must never be applied to the
driver when the coupling guard is not installed.
Flowserve coupling guards are safety devices intended
to protect workers from inherent dangers of the rotating
pump shaft, motor shaft and coupling. It is intended to
prevent entry of hands, fingers or other body parts into a
point of hazard by reaching through, over, under or
around the guard. No standard coupling guard provides
complete protection from a disintegrating coupling.
Flowserve cannot guarantee their guards will completely
contain an exploding coupling.
5.4.1 Clam shell guard - standard
The standard coupling guard for all PolyChem Mseries pumps is the “clam shell” design and is shown
in Figure 5-9. It is hinged at the top and it can be
removed by loosening one of the foot bolts and sliding
the support leg out from under the cap screw (note
that the foot is slotted). The leg can then be rotated
upward and half of the guard can be disengaged
(unhinged) from the other. Only one side of the guard
needs to be removed. To reassemble simply reverse
the above procedure.
installed as advised by the coupling manufacturer.
The coupling (Figure 5-8) should be
Figure 5-9
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REFERENCE
CENTER
TRIM THIS END
MEASUREMENT STEP a)
The coupling guard shown in Figure 5-9 conforms to
the USA standard ASME B15.1, “Safety standard for
mechanical power transmission apparatus.”
Flowserve manufacturing facilities worldwide conform
to local coupling guard regulations.
5.4.2 ClearGuard™ - optional
Flowserve offers as an option a ClearGuard™, which
allows you to see the condition of the coupling (see
Figure 5-10). This guard can be used in place of the
existing clamshell guard described earlier.
Disassembly of the ClearGuard™ is accomplished by
removing the fasteners that hold the two
ClearGuard™ halves together followed by removing
the foot bolts and rotating the support leg out of the
slot on the guard.
Figure 5-10
Figure 5-11
5.4.3 Trimming instructions
In order to correctly fit the pump/motor configuration,
each guard must be trimmed to a specific length.
This trimming is done on the motor end of the guard.
a) Measure minimum distance from the center of
mounting hole in the baseplate to the motor.
If clam shell guard proceed to step c
b) Locate a reference center in the slot of the
ClearGuard™ coupling guard flange, see figure 5-
11. Transfer the length measurement to the guard
using this reference center.
c) Trim the motor end of the guard according to the
above measurement. Trimming is best done with a
band saw, but most other types of manual or power
saws give acceptable results. Care must be taken to
ensure that there is no gap larger than 6 mm (0.24
in.) between the motor and the coupling guard.
d) If motor diameter is smaller than guard
diameter, trim guard so that it extends over the
end of the motor as far as possible.
e) Deburr the trimmed end with a file or a sharp
knife if ClearGuard™. Care must be taken to
eliminate all sharp edges.
5.4.4 Assembly instructions
Clam shell guard
a) Mount support leg to each clam shell, figure 5-9.
b) Attach one half of the guard to the baseplate.
c) Engage the tabs of guard halves together.
d) Attach the second support leg to the baseplate.
ClearGuard™
a) Place the bottom and top halves of the guard
around the coupling.
b) Install the support legs by inserting and then
rotating the tab on the leg through the slot in the
guard until it comes through and locks the top
and bottom halves of the guard together.
c) Attach the support legs to the baseplate using
the fasteners and washers provided.
d) Install fasteners in the holes provided to secure
the guard flanges together.
5.5 Priming and auxiliary supplies
The PolyChem M-series centrifugal pump will not move
liquid unless the pump is primed. A pump is said to be
“primed” when the casing and the suction piping are
completely filled with liquid. Open discharge valves a
slight amount. This will allow any entrapped air to
escape and will normally allow the pump to prime, if the
suction source is above the pump. When a condition
exists where the suction pressure may drop below the
pump’s capability, it is advisable to add a low-pressure
control device to shut the pump down when the
pressure drops below a predetermined minimum.
5.6 Starting the pump
a) Open the suction valve to full open position. It is
very important to leave the suction valve open
while the pump is operating. Any throttling or
adjusting of flow must be done through the
discharge valve. Partially closing the suction valve
can create serious NPSH and pump performance
problems.
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Never operate pump with both the
suction and discharge valves closed. This could
cause an explosion.
b) Ensure the pump is primed. (See section 5.5.)
c) All cooling or heating, flush lines must be started
and regulated.
d) Start the driver (typically, the electric motor).
e) Slowly open the discharge valve until the desired
flow is reached, keeping in mind the minimum
continuous flow listed in section 3.4.4.
It is important that the discharge valve be
opened within a short interval after starting the driver.
Failure to do this could cause a dangerous build up of
heat, and possibly an explosion.
5.7 Running or operation
NEVER RUN THE PUMP DRY OR
WITHOUT PROPER PRIME (Pump flooded).
Operating the pump dry may cause immediate
damage to the bearings, magnets, etc..
5.7.1 Minimum continuous flow
Minimum continuous stable flow is the lowest flow at
which the pump should be operated. The minimum
continuous flow (capacity) is established as a
percentage of the best efficiency point (BEP). (See
section 3.4.4.)
5.7.2 Minimum thermal flow
All PolyChem M-series pumps also have a minimum
thermal flow. This is defined as the minimum flow
that will not cause an excessive temperature rise.
Minimum thermal flow is application dependent.
Do not operate the pump below
minimum thermal flow, as this could cause an excessive
temperature rise. Contact a Flowserve sales engineer
for determination of minimum thermal flow.
Avoid running a centrifugal pump at drastically reduced
capacities or with discharge valve closed for extended
periods of time. This can cause severe temperature rise
and the liquid in the pump may reach its boiling point. If
this occurs, the internal process-lubricated bearings may
be exposed to vapor, with no lubrication, and may be
damaged or fail within a very short period of time.
Continued running under these conditions when the
suction valve is also closed can create an explosive
condition due to the confined vapor at high pressure and
temperature.
Thermostats may be used to safeguard against over
heating by shutting down the pump at a predetermined
temperature.
Safeguards should also be taken against possible
operation with a closed discharge valve, such as installing
a bypass back to the suction source. The size of the
bypass line and the required bypass flow rate is a function
of the input horsepower and the allowable temperature
rise.
5.7.3 Reduced head
Note that when discharge head drops, the pump’s
flow rate usually increases rapidly. Check motor for
temperature rise as this may cause overload. If
overloading occurs, throttle the discharge.
5.7.4 Surging condition
A rapidly closing discharge valve can cause a
damaging pressure surge. A dampening
arrangement should be provided in the piping.
5.7.5 Operation in sub-freezing conditions
When using the pump in sub-freezing conditions
where the pump is periodically idle, the pump should
be properly drained or protected with thermal devices
which will keep the liquid in the pump from freezing.
5.7.6 Bearing monitoring
If the pump is operating in a potentially
explosive atmosphere temperature or vibration
monitoring of the bearings is recommended.
5.7.6.1 Temperature monitoring
If bearing temperatures are to be monitored it is
essential that a benchmark temperature is recorded at
the commissioning stage and after the bearing
temperature has stabilized.
Record the bearing temperature (t) and the
ambient temperature (ta)
Estimate the likely maximum ambient
temperature (tb)
Set the alarm at (t+tb-ta+5) ºC ((t+tb-ta+10) ºF)
and the trip at 100 ºC (212 ºF) for oil lubrication
and 105 ºC (220 ºF) for grease lubrication.
It is important, particularly with grease lubrication,
to keep a check on bearing temperatures. After
start up the temperature rise should be gradual,
reaching a maximum after approximately 1.5 to 2
hours. This temperature rise should then remain
constant or marginally reduce with time.
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For guidance, pumps generally fall under a
classification for rigid support machines within the
International rotating machinery standards and the
recommended maximum levels below are based on
those standards.
Alarm and trip values for installed
pumps should be based on the actual measurements
taken on the pump in the fully commissioned as new
condition. Measuring vibration at regular intervals will
then show any deterioration in pump or system
operating conditions.
5.8 Stopping and shutdown
5.8.1 Shutdown considerations
When the pump is being shutdown, the procedure
should be the reverse of the start-up procedure. First,
slowly close the discharge valve, shut down the
driver, and then close the suction valve. Remember
that closing the suction valve while the pump is
running is a safety hazard and could seriously
damage the pump and other equipment.
5.9 Hydraulic, mechanical and electrical
duty
5.9.1 Net positive suction head (NPSH)
Net positive suction head - available (NPSHA) is the
measure of the energy in a liquid above the vapor
pressure. It is used to determine the likelihood that a
fluid will vaporize in the pump. It is critical because a
centrifugal pump is designed to pump a liquid, not a
vapor. Vaporization in a pump will result in damage to
the pump, deterioration of the Total differential head
(TDH), and possibly a complete stopping of pumping.
Net positive suction head - required (NPSHR) is the
decrease of fluid energy between the inlet of the
pump, and the point of lowest pressure in the pump.
This decrease occurs because of friction losses and
fluid accelerations in the inlet region of the pump and
particularly accelerations as the fluid enters the
impeller vanes. The value for NPSHR for the specific
pump purchased is given in the pump data sheet, and
on the pump performance curve.
For a pump to operate properly the NPSHA must be
greater than the NPSHR. Good practice dictates that
this margin should be at least 1.5 m (5 ft) or 20%,
whichever is greater.
Ensuring that NPSHA is larger than
NPSHR by the suggested margin will greatly enhance
pump performance and reliability. It will also reduce
the likelihood of cavitation, which can severely
damage the pump.
5.9.2 Specific gravity (SG)
Pump capacity and total head in meters (feet) of liquid
do not change with SG, however pressure displayed
on a pressure gauge is directly proportional to SG.
Power absorbed is also directly proportional to SG. It
is therefore important to check that any change in SG
will not overload the pump driver or over pressurize
the pump.
5.9.3 Viscosity
For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity. Also for a given flow rate the power
absorbed increases with the increased viscosity, and
reduces with reduced viscosity. It is important that
checks are made with your nearest Flowserve office if
changes in viscosity are planned.
5.9.4 Pump speed
Changing the pump speed affects flow, total head,
power absorbed, NPSHR, noise and vibration levels.
Flow varies in direct proportion to pump speed. Head
varies as speed ratio squared. Power varies as speed
ratio cubed. If increasing speed, it is important to ensure
the maximum pump working pressure is not exceeded,
the driver and magnetic coupling is not overloaded,
NPSHA > NPSHR and that noise and vibration are within
local requirements and regulations.
6 MAINTENANCE
It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work is
carried out by authorized and qualified personnel who
have adequately familiarized themselves with the
subject matter by studying this manual in detail. (See
also section 1.6.)
Any work on the machine must be performed when it
is at a standstill. It is imperative that the procedure for
shutting down the machine is followed, as described
in section 5.8.
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On completion of work all guards and safety devices
must be re-installed and made operative again.
Before restarting the machine, the relevant
instructions listed in section 5, Commissioning, start up, operation and shut down must be observed.
Oil and grease leaks may make the
ground slippery. Machine maintenance must
always begin and finish by cleaning the ground
and the exterior of the machine.
If platforms, stairs and guard rails are required for
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
carried out. The positioning of these accessories
must not limit access or hinder the lifting of the part to
be serviced.
When air or compressed inert gas is used in the
maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
protection.
Do not spray air or compressed inert gas on skin.
Do not direct an air or gas jet towards other people.
Never use air or compressed inert gas to clean
clothes.
Before working on the pump, take measures to
prevent the pump from being accidentally started.
Place a warning sign on the starting device:
"Machine under repair: do not start."
With electric drive equipment, lock the main switch
open and withdraw any fuses. Put a warning sign on
the fuse box or main switch:
"Machine under repair: do not connect."
Never clean equipment with flammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
Refer to the parts list shown in section 8 for item
number references used throughout this section.
6.1 Maintenance schedule
It is recommended that a maintenance plan and
schedule be implemented, in accordance with these
User Instructions, to include the following:
a) Any auxiliary systems installed must be monitored,
if necessary, to ensure they function correctly.
b) Check for any leaks from gaskets and oil seals.
c) Check bearing lubricant level, and the remaining
hours before a lubricant change is required.
d) Check that the duty condition is in the safe
operating range for the pump.
e) Check vibration, noise level and surface
temperature at the bearings to confirm
satisfactory operation.
f) Check dirt and dust is removed from areas
around close clearances, bearing housings and
motors.
g) Check coupling alignment and re-align if
necessary.
6.1.1 Preventive maintenance
The following sections of this manual give instructions
on how to perform a complete maintenance overhaul.
However, it is also important to periodically repeat the
Pre start-up checks listed in section 5.1. These
checks will help extend pump life as well as the length
of time between major overhauls.
6.1.2 Need for maintenance records
A procedure for keeping accurate maintenance
records is a critical part of any program to improve
pump reliability. There are many variables that can
contribute to pump failures. Often long term and
repetitive problems can only be solved by analyzing
these variables through pump maintenance records.
6.1.3 Cleanliness
One of the major causes of pump failure is the
presence of contaminants in the bearing housing.
This contamination can be in the form of moisture,
dust, dirt and other solid particles such as metal
chips. It is very important that proper cleanliness be
maintained. Some guidelines are listed below.
After draining the oil from the bearing housing,
periodically send it out for analysis. If it is
contaminated, determine the cause and correct.
The work area should be clean and free from
dust, dirt, oil, grease etc.
Hands and gloves should be clean.
Only clean towels, rags and tools should be used.
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6.2 Spare parts
The decision on what spare parts to stock varies greatly
depending on many factors such as the criticality of the
application, the time required to buy and receive new
spares, the erosive/corrosive nature of the application,
and the cost of the spare part. Section 8 identifies all of
the components that make up each pump addressed in
this manual. Please refer to the Flowserve Durco Pump Parts Catalog for more information. A copy of this book
can be obtained from your local Flowserve sales
engineer or distributor/representative.
6.2.1 Ordering of spare parts
Flowserve keeps records of all pumps that have been
supplied. Spare parts can be ordered from your local
Flowserve sales engineer or from a Flowserve
distributor or representative. When ordering spare
parts the following information should be supplied:
1) Pump serial number
2) Pump size and type
3) Part name – see section 8
4) Part item number – see section 8
5) Material of construction (alloy)
6) Number of parts required
The pump size and serial number can be found on the
nameplate located on the bearing housing. See
Figure 3-1.
6.3 Recommended spares and
consumable items
On critical services where down time is particularly
crucial it may be best to stock a spare pump or a
rotating assembly allowing service to be quickly
restored. The damaged pump or assembly could
then be repaired and serve as a back-up.
6.4 Tools required
Do not perform maintenance on a steel workbench.
The magnets present in the pump are strongly
attracted to ferrous materials. Use a non-metallic
(such as wood or plastic) workbench instead. The
use of non metallic tools is also recommended. A
typical range of tools that will be required to maintain
these pumps is listed below.
Standard hand tools
Hand wrenches (Metric and SAE)
Socket wrenches (Metric and SAE)
Allen wrenches (Metric and SAE)
Torque wrench (Metric and SAE)
Soft mallet
Screwdrivers
Specialized equipment
Bearing pullers
Bearing induction heaters
Dial indicators
Flowserve Tool Kit (ISO and ANSI)
Arbor or bench press
Eyebolt
M12x1.75 (Metric)
1/2 -13UNC (SAE)
Shaft for torque testing (see Figures 6-2 and 6-3)
To simplify maintenance, it is recommended that the
Flowserve Tool Kit (shown in Figure 6-1) is used.
This tool kit includes a specialized wrench, which
simplifies installation and removal of the outer magnet
assembly on long-coupled pumps.
This tool kit can be ordered from your local Flowserve
sales engineer or from a Flowserve distributor or
representative
Figure 6-1
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(1.32/1.30)
(3.06/3.04)
(5.11/5.09)
(0.16/0.14)
(0.22/0.20)
(1.52/1.50)
(1.748/1.746Ø)
(1.499/1.497Ø)
(1.55/1.54)
(2.01/1.99Ø)
(0.50/0.49)
Drill and tap for hex head bolt
size to be determined by customer
fastener size not to exceed
M16 (ISO) or 5/8 (ANSI)
12.7
12.4
38.6
38.1
51.1
50.5
Ø
5.6
5.1
4.1
3.6
33.5
33.0
77.7
77.2
129.8
129.3
39.4
39.1
44.40
44.35
Ø
38.07
38.02
Ø
(1.52/1.50)
(0.50/0.49)
(2.30/2.28)
(6.51/6.49)
(0.14/0.12)
(0.32/0.30)
(2.64/2.62Ø)
(1.987/1.985Ø)
(1.78/1.76)
(1.968/1.966Ø)
Drill and tap for hex head bolt size to
be determined by customer fastener
size not to exceed M16 (ISO) or
5/8 (ANSI)
120°
67.1
66.6
Ø
38.6
38.1
12.7
12.4
50.47
50.42
Ø
8.1
7.6
3.5
3.0
45.2
44.7
58.4
57.9
165.4
164.9
49.99
49.94
Ø
Figure 6-2: Group A and 1
Figure 6-3: Group B and 2
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Item #
Comment
Size – Lubricated torque Nm (lbf•ft)
Group 1
Group A
Group 2
Group B
6570.1
Screw – Bearing housing foot
3/8 in. – 20 (15)
12 mm – 34 (25)
3/4 in. – 127 (94)
16 mm – 80 (59)
6570.2
Screw – End cover/brg housing
1/4 in. – 11 (8)
6 mm – 11 (8)
3/8 in. – 41 (30)
10 mm – 41 (30)
6570.3
Screw – Outer magnet flange
1/4 in. – 11 (8)
1/4 in. – 11 (8)
1/4 in. – 11 (8)
1/4 in. – 11 (8)
6570.4
Screw – Adapter/motor
1/2 in. – 11 (8)
1/2 in. – 11 (8)
5/8" – 20 (15)
5/8" – 20 (15)
6570.5
Screw – Revese rotation
5/16 in. – 7 (5)
5/16 in. – 7 (5)
3/8 in. – 7 (5)
3/8 in. – 7 (5)
6570.6
Screw – Lantern/ Brg housing
1/2 in. – 15 (11)
12 mm – 15 (11)
N/A
N/A
6570.7
Screw – Retaining ring
N/A
N/A
3/8 in. – 34 (25)
10 mm – 34 (25)
6570.8
Screw – Brg housing/Brg holder
N/A
N/A
3/8 in. – 15 (11)
10 mm – 15 (11)
6570.9
Screw – Hub
5/16 in. – 24 (18)
5/16 in. – 24 (18)
5/8" – 20 (15)
5/8" – 20 (15)
6580
Nut – Casing stud
1/2 in. – 34 (25)
1/2 in. – 34 (25)
5/8 in. – 61 (45)
16 mm – 61 (45)
Flange Size
mm (in.)
Number
Of Bolts
Bolt Dia.
mm (in.)
Bolt Torque
Nm (lbf•ft)
32 (1.3)
4
16 (0.63)
91 (67)
40 (1.6)
4
16 (0.63)
99 (73)
50 (2.0)
4
16 (0.63)
124 (91)
65 (2.6)
4
16 (0.63)
153 (112)
80 (3.1)
8
16 (0.63)
110 (81)
Flange Size
in. (mm)
Number
Of Bolts
Bolt Dia.
in. (mm)
Bolt Torque
Nm (lbf•ft)
1 (25.4)
4
0.63 (16)
34 (25)
1 ½ (38.1)
4
0.63 (16)
75 (55)
2 (50.8)
4
0.63 (16)
102 (75)
3 (76.2)
4
0.63 (16)
149 (110)
4 (101.6)
8
0.63 (16)
129 (95)
Non metallic
spacer
Impeller
[2200]
Thrust Journal
[3043]
6.5 Fastener torques
Figure 6-4: Recommended pump fastener torques - SI (US)
Note: 1) For Non-lubricated threads increase the listed value by 25%.
Figure 6-5: Recommended flange fastener torques - SI (US)
ISO Pump with PN16 Flanges
ANSI Pump with Class 150 Flanges
6.6 Impeller
6.6.1 Replacement
The impeller could have sharp edges,
which could cause an injury. It is very important to
wear heavy gloves.
Prior to installing the impeller [2200]
onto the shaft [2100.1] the thrust journal [3043] must
be installed.
a) Place the impeller [2200] onto a flat surface with
the inlet facing up, refer to figure 6-6.
b) Align the slot on the thrust journal [3043] with the
molded pin on the impeller.
c) Press the thrust journal into the impeller until it is
seated flat.
It may be necessary to utilize an arbor press
to aid in the assembly of the thrust journal into the
impeller. If an arbor press is utilized a nonmetallic
spacer should be placed between the ram of the
press and the thrust journal. This spacer must be flat
and the entire surface area of the thrust journal
should be covered.
Figure 6-6
d) Press the impeller assembly onto the silicon
carbide shaft.
It may be necessary to utilize an arbor press
to aid in the assembly of the impeller to the shaft. If
an arbor press is utilized a nonmetallic spacer should
be placed between the ram of the press and the
recently installed thrust journal. This spacer must be
flat and the entire surface area of the thrust journal
should be covered. See figure 6-7 and 6-8.
6.6.2 Trimming
If a new impeller of maximum diameter has been
acquired and needs trimming or if an existing impeller
needs trimming this is accomplished by turning
(machining). It is recommended that this trimming
operation be performed by a Flowserve
representative. However, if this cannot be
accommodated the following guidelines should be
followed.
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P_3x1.5-6 & P_3x2-6
Trim Diameter
Front Shroud
Diameter
mm
inch
mm
inch
158.75 (a)
(6.250)
158.75
(6.250)
155.58 (a)
(6.125)
155.58
(6.125)
152.40
(6.000)
158.75
(6.250)
149.23
(5.875)
156.74
(6.171)
146.05
(5.750)
153.61
(6.048)
142.88
(5.625)
150.49
(5.925)
139.70
(5.500)
147.37
(5.802)
136.53
(5.375)
144.25
(5.679)
133.35
(5.250)
141.12
(5.556)
130.18
(5.125)
138.00
(5.433)
127.00
(5.000)
134.87
(5.310)
123.83
(4.875)
131.75
(5.187)
120.65
(4.750)
128.63
(5.064)
117.48
(4.625)
125.51
(4.941)
114.30
(4.500)
122.38
(4.818)
P_3x2-10
Trim Diameter
Front Shroud
Diameter
mm
inch
mm
inch
254.00
(10.000)
10.417
(10.417)
250.83
(9.875)
10.297
(10.297)
247.65
(9.750)
10.176
(10.176)
244.48
(9.625)
10.056
(10.056)
241.30
(9.500)
9.935
(9.935)
238.13
(9.375)
9.815
(9.815)
234.95
(9.250)
9.694
(9.694)
231.78
(9.125)
9.574
(9.574)
228.60
(9.000)
9.453
(9.453)
225.43
(8.875)
9.333
(9.333)
222.25
(8.750)
9.212
(9.212)
219.08
(8.625)
9.092
(9.092)
215.90
(8.500)
8.971
(8.971)
212.73
(8.375)
8.850
(8.850)
209.55
(8.250)
8.730
(8.730)
206.38
(8.125)
8.609
(8.609)
203.20
(8.000)
8.489
(8.489)
200.03
(7.875)
8.368
(8.368)
196.85
(7.750)
8.248
(8.248)
193.68
(7.625)
8.127
(8.127)
190.50
(7.500)
8.007
(8.007)
187.33
(7.375)
7.886
(7.886)
184.15
(7.250)
7.766
(7.766)
180.98
(7.125)
7.645
(7.645)
177.80
(7.000)
7.525
(7.525)
174.63
(6.875)
7.405
(7.405)
171.45
(6.750)
7.294
(7.294)
168.28
(6.625)
7.194
(7.194)
165.10
(6.500)
7.110
(7.110)
Front
Shroud
Diameter
Trim
Diameter
30°
20°
Front
Shroud
Diameter
Trim
Diameter
All impellers are fully trimmable
however certain models must be angled trimmed.
See the below chart for these exceptions.
a) Obtain a machining arbor from a Flowserve
representative.
b) Carefully mount the arbor into a lathe. Take care
to minimize the runout of the machining arbor.
c) Install the impeller for trimming.
Pump Models P_3x1.5-6 and P_3x2-6
Pump Models P_3x2-10 and P_4x3-10
Notes:
(a) Straight cut to be made when impeller trim is greater than
152.40 mm (6.000 in.).
(b) Interpolate between shown dimensions for 1.57 mm (0.062 in.)
trim increments.
Notes:
(a) Interpolate between shown dimensions for 1.57 mm (0.062 in.)
trim increments.
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
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P_4x3-10
Trim Diameter
Front Shroud
Diameter
mm
inch
mm
Inch
254.00
(10.000)
N/A
N/A
250.83
(9.875)
N/A
N/A
247.65
(9.750)
265.31
(10.445)
244.48
(9.625)
262.27
(10.325)
241.30
(9.500)
259.23
(10.206)
238.13
(9.375)
256.18
(10.086)
234.95
(9.250)
253.14
(9.966)
231.78
(9.125)
250.10
(9.847)
228.60
(9.000)
247.06
(9.727)
225.43
(8.875)
244.02
(9.607)
222.25
(8.750)
240.98
(9.487)
219.08
(8.625)
237.94
(9.368)
215.90
(8.500)
234.90
(9.248)
212.73
(8.375)
231.86
(9.128)
209.55
(8.250)
228.82
(9.009)
206.38
(8.125)
225.78
(8.889)
203.20
(8.000)
222.73
(8.769)
200.03
(7.875)
219.69
(8.649)
196.85
(7.750)
216.65
(8.530)
193.68
(7.625)
213.61
(8.410)
190.50
(7.500)
210.57
(8.290)
187.33
(7.375)
207.53
(8.170)
184.15
(7.250)
204.49
(8.051)
180.98
(7.125)
201.45
(7.931)
177.80
(7.000)
198.40
(7.811)
174.63
(6.875)
195.37
(7.692)
171.45
(6.750)
192.52
(7.580)
168.28
(6.625)
189.96
(7.479)
165.10
(6.500)
187.77
(7.393)
Figure 6-8: Group B and 2 pumps
6.7 Pump removal and disassembly
a) Before performing any maintenance, disconnect
the driver from its power supply and lock it off line.
Lock out power to driver to prevent
personal injury.
b) Close the discharge and suction valves, and
drain all liquid from the pump.
c) Close all valves on auxiliary equipment and
piping, then disconnect all auxiliary piping.
d) Decontaminate the pump as necessary.
Notes:
Interpolate between shown dimensions for 1.57 mm (0.062 in.) trim
increments.
Figure 6-7: Group A and 1 pumps
If Flowserve PolyChem M-series
pumps contain dangerous chemicals, it is important to
follow plant safety guidelines to avoid personal injury
or death.
Small amounts of liquid may be trapped in the
casing and/or containment area. Proper
decontamination is the responsibility of the user.
Drain and flush the pump before proceeding.
The PolyChem M-series pump is designed to handle
corrosive, toxic, and hazardous process fluids and
may need to be decontaminated prior to any
disassembly
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
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6.7.1 Pump removal
6.7.1.1 Long-coupled PolyChem M-series
pumps
a) Remove coupling guard.
b) Remove the spacer from the spacer coupling.
c) Remove the cap screws holding the bearing
housing and casing feet to the baseplate.
d) Remove the fasteners attaching the suction and
discharge piping to the pump.
e) Attach lifting equipment to the pump, placing it in
light tension to support the pump.
f) Move the pump assembly away from the piping
(towards the motor) and rotate the unit out.
g) The pump can now be moved to the repair shop.
6.7.1.2 Close-coupled PolyChem M-series
pumps
a) Remove the fasteners holding the motor and or
lantern and casing feet to the baseplate.
b) Remove the fasteners attaching the suction and
discharge piping to the pump.
c) Attach lifting equipment to the pump, placing it in
light tension to support the pump.
d) Move the pump assembly away from the piping.
e) The pump can now be moved to the repair shop.
6.7.2 Pump removal – less casing
Group A & 1 pumps are assembled vertically
and the casing is required during the
process. Therefore is is strongly
recommended that the entire pump is
removed as described in 6.7.1. above
Group B & 2 pumps can be removed, leaving the
casing installed in the piping, as described in
6.7.2.1 and 6.7.2.2.
6.7.2.1 Long-coupled PolyChem M-series
pumps
a) Remove coupling guard.
b) Remove the spacer from the spacer coupling.
c) Remove the cap screw(s) holding the bearing
housing foot to the baseplate.
d) Attach lifting equipment to the pump, placing it in
light tension to support the pump when it is
removed from the casing.
e) Remove all casing stud nuts [6572].
f) Move the pump assembly away from the casing
(towards the motor) and rotate the unit out,
leaving the casing in place (Figure 6-9).
Figure 6-9
g) Inspect the casing [1100] and the thrust bearing
bushing [3041] located in the casing for wear,
corrosion, or defects.
h) The pump less casing [1100] can now be moved
to the repair shop.
6.7.2.2 Close-coupled PolyChem M-series
pumps
a) Remove the fasteners holding the motor and or
lantern to the baseplate.
b) Attach lifting equipment to the pump, placing it in
light tension to support the pump when it is
removed from the casing.
c) Remove all casing stud nuts [6572].
d) Move the pump assembly away from the casing,
leaving the casing in place (Figure 6-10).
Figure 6-10
e) Inspect the casing [1100] and the thrust bearing
bushing [3041] for wear, corrosion, or defects.
f) The pump less casing [1100] can now be moved
to the repair shop.
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6.7.3 Drive end removal - without breaking
process containment
By following the steps in section 6.7.3.1 or
6.7.3.2, the process fluid is contained and the power
end can be completely removed. This procedure does
not preclude the use of personal protective gear.
Personnel should follow their standard plant safety
practices.
The magnetic coupling will remain engaged
even after the fasteners that attach the drive end to
the wet end have been removed. This is due to the
strong radial and axial forces associated with the
magnetic coupling.
7
Do not attempt to remove the drive end
from the wet end without using the jackbolts. The
magnetic force can cause severe personal injury.
Be sure to separate the inner and
outer magnet assemblies evenly. Cocking of the two
can result in serious damage to the magnets and/or
containment shell. It is best to alternatively give each
bolt a turn to ensure proper and even separation.
6.7.3.1 Long-coupled PolyChem M-series
pumps
Figure 6-11: Group A and 1 pumps
Figure 6-12: Group B and 2 pumps
a) Remove coupling guard.
b) Remove the spacer coupling.
c) Loosen the cap screw(s) holding the bearing
housing foot to the baseplate.
d) To remove the power end from the wet end, on
Group A and 1 pumps remove the four (4)
bearing housing/lantern fasteners [6570.6]. On
Group B and 2 pumps remove the six (6) bearing
housing/bearing holder fasteners [6570.8].
e) Screw the two (2) square head jackbolts [6575]
in the lantern (Group A and 1 pumps) or bearing
housing (Group B and 2 pumps) through the
threaded holes until each comes into contact
with its mating part. (see figure 6-11 and 6-12).
Continue to screw all jackbolts in evenly to
detach the wet end from the power end. (Figure
6-13 and 6-14)
It may be necessary to move the motor to
complete step e).
f) The power end can now be moved to the repair
shop.
Figure 6-13: Group A and 1 pumps
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Figure 6-14: Group B and 2 pumps
6.7.3.2 Close-coupled PolyChem M-series
pumps
Figure 6-15: Group A and 1 pumps
c) Screw the two (2) square head jackbolts [6575]
in the lantern through the threaded holes until
each comes into contact with its mating part.
(Figure 6-15 and 6-16) Continue to screw both
jackbolts evenly to disengage the motor from the
wet end of the pump. (Figure 6-17 and 6-18)
d) The drive end can now be moved to the repair
shop.
Figure 6-17: Group A and 1 pumps
Figure 6-18: Group B and 2 pumps
Figure 6-16: Group B and 2 pumps
a) Loosen the fasteners (if applicable) holding the
motor to the baseplate.
b) To remove the motor from the wet end, on Group
A and 1 pumps remove the four (4) motor
flange/lantern fasteners [6570.6]. On Group B
and 2 pumps remove the six (6) lantern/bearing
holder fasteners [6570.8].
6.7.4 Removal of drive end from the wet end
The magnetic coupling will remain engaged
even after the fasteners that attach the drive end to
the wet end have been removed. This is due to the
strong radial and axial forces associated with the
magnetic coupling.
Do not attempt to remove the drive end
from the wet end without using the jackbolts. The
magnetic force can cause severe personal injury.
Be sure to separate the inner and
outer magnet assemblies evenly. Cocking of the two
can result in serious damage to the magnets and/or
containment shell. It is best to alternatively give each
bolt a turn to ensure proper and even separation.
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Nonmetallic
Material
Key [6700.2]
Holder
[3830]
Impeller
[2200]
Inner
Magnet
[0220]
Shaft
2100.1
Nonmetallic
Spacer
On Group A and 1 pumps; if the pump
being disassembled has been pulled less casing,
upon removal of the drive end (outer magnet) the
remaining wet end components will no longer be held
together by either magnetism or bolting. Care needs
to be exercised to prevent damaging the wet end
components. On Group B and 2 pumps an eyebolt
should be installed at the 12 o’clock position on the
bearing holder [3830]. An appropriate lifting device
should be attached to the eyebolt, placing it in light
tension to support the pump.
6.7.4.1 Long-coupled PolyChem M-series
pumps
Refer to section 6.7.3.1 steps d and e.
6.7.4.2 Close-coupled PolyChem M-series
pumps
Refer to section 6.7.3.2 steps b and c.
6.7.5 Disassembly of wet end
c) The assembly comprised of the impeller [2200],
shaft [2100.1], holder [3830], an inner magnet.
[0220] should be removed from the lantern.
d) This assembly should be placed on a nonmetallic
surface under an arbor press. See Figure 6-20.
e) Using a nonmetallic spacer, press the square
end of the shaft [2100.1] until it is disengaged
from the impeller [2200].
Make sure that the shaft is free to
travel downward. Do not allow the shaft to fall as it is
being pressed free of the impeller and inner magnet.
Figure 6-20
Take care when handling the internal
bearings of the pump - journals, bushings, and shaft.
These parts are easily chipped and damaged.
6.7.5.1 Group A and 1 pumps
a) Place the wet end assembly on the face of the
lantern. See Figure 6-19.
Figure 6-19
b) Remove the impeller [2200].
If the impeller remains attached to the shaft
it may be necessary to utilize an arbor press to aid in
its removal as well as the removal of the inner
magnet. If an arbor press is utilized, a nonmetallic
spacer should be placed between the ram of the
press and the shaft.
f) Remove the impeller [2200] and holder [3830].
g) Continue pressing the end of the shaft [2100.1]
until it disengages from the inner magnet [0220].
h) Remove the key [6700.2] from the shaft.
i) Place the holder [3830] under the arbor press
and again using a nonmetallic spacer press the
inboard bushing [3300] until it becomes
disengaged.
j) Remove the containment shell [3500] from the
lantern [1340].
6.7.5.2 Group B and 2 pumps
a) The wet end assembly should be supported
horizontally. A tapped hole is located at the 12
o’clock position on the holder [3830] so that an
eyebolt can be engaged. An appropriate lifting
device should be attached to the eyebolt, placing
it in light tension to support the wet end. See
Figure 6-21.
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Impeller
[2200]
Holder
[3830]
Nonmetallic
Material
Inner Magnet
Key
[6700.2]
Shaft
[2100.1]
Nonmetallic
Spacer
Figure 6-21
The retainer ring [2530] is
manufactured from carbon steel and may attach to
the containment shell [3500] upon removal due to the
presence of magnets in the inner magnet assembly.
b) Remove the twelve (12) retainer
ring/containment shell cap screws [6570.7].
Remove the retainer ring [2530]. In the event the
retainer ring is lodged in place, two (2) tapped
holes have been provided on this ring to aid in its
removal. The recently removed cap screws can
be used for this purpose.
c) Remove the containment shell [3500]. See
Figure 6-22.
Figure 6-22
magnet. If an arbor press is utilized, a nonmetallic
spacer should be placed between the ram of the
press and the shaft.
e) The assembly comprised of the impeller [2200],
shaft [2100.1], holder [3830], and inner magnet
[0220] should be placed on a nonmetallic surface
under an arbor press. See Figure 6-23.
f) Using a nonmetallic spacer, press the end of the
shaft [2100.1] until it is disengaged from the
impeller [2200].
Make sure that the shaft is free to
travel downward. Do not allow the shaft to fall as it is
being pressed free of the impeller and inner magnet.
Figure 6-23
g) Remove the impeller [2200] and holder [3830].
h) Continue pressing the end of the shaft [2100.1]
until it disengages from the inner magnet [0220].
i) Remove the keys [6700.2] from the shaft.
j) Place the holder [3830] under the arbor press in
the same orientation as shown in Figure 6-23.
Using a nonmetallic spacer press the inboard
bushing [3300] until it becomes disengaged.
k) Remove o-ring [4610.2] from holder [3830] and
discard.
6.7.6 Disassembly of drive end
d) Remove the impeller [2200].
it may be necessary to utilize an arbor press to aid in
its removal as well as the removal of the inner
If the impeller remains attached to the shaft
Be aware of strong magnetic forces of
the outer magnets. Keep magnetic material away
from these magnets. Observe previous warnings
concerning these magnets.
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Bearing
Cover
[3260]
Bearing Housing
[3200]
Outer Magnet
[0230]
Shaft [2100.2]
& Bearings
[3011]
Washer
[4260]
6.7.6.1 Long-coupled PolyChem M-series
pumps
Figure 6-24
This procedure is necessary if the outer
magnet assembly, anti-friction bearings or oil seals
must be replaced. See Figure 5-5 for
recommendations on ball bearing relubrication
intervals.
a) Mount the power end to the work bench.
b) Drain the oil in the bearing housing by removing
the bearing housing drain plug [6569.1]. Put the
bearing housing drain plug back into place after
the bearing housing is drained.
c) Remove the Trico oiler/site gage [3855] (Figure 6-
25) and oil level tag (Figure 6-26) from the bearing
housing.
d) Mount the drive shaft/coupling key [6700] and a
Flowserve impeller wrench onto the shaft.
e) Remove reverse rotation screw [6570.5] with an
allen wrench. The threads are right hand.
f) Unscrew the outer magnet/flange assembly
[0230] from the drive shaft [2100.2]. With the
impeller wrench handle pointing to the right when
viewed from the magnet side of the bearing
housing [3200], grasp the magnet firmly. Spin it
rapidly in a counterclockwise direction so that the
wrench handle makes a solid impact with the
work surface to the left of the housing. After
several sharp raps, the outer magnet/flange
assembly should be free and easily removed. It
is recommended that the magnet assemblies be
stored in plastic bags to avoid the necessity to
clean later.
g) Remove the three (3) bearing cover fasteners
[6570.3] and bearing cover [3260]. Remove the
bearing cover/bearing housing O-ring [4610.9]
and discard. Pull the drive shaft and bearing
assembly out of the bearing housing in one
straight motion. Avoid cocking the assembly in
the housing. Remove the wavy washer [4260].
h) If lip seals [4310.1] and [4310.2] (see Figure 6-
27) are used, they should be removed from the
bearing cover [3260] and bearing housing [3200]
and discarded.
Figure 6-25
Figure 6-26
Figure 6-27
i) If bearing isolators are removed from either the
bearing cover [3260] or bearing housing [3200]
they must not be reused, discard appropriately.
j) If necessary, remove the bearing housing foot
[3134] by unscrewing the footpiece fastener
[6570.4] from the bearing housing. A shim [3126]
may also be present.
k) If the ball bearings [3011] need to be replaced,
remove the bearings from the drive shaft. If the
bearings are to be replaced and the drive shaft
reused, extra care should be taken so as not to
damage the drive shaft. Remove the bearings
with a bearing puller. Even pressure should be
applied. It is recommended that the bearings not
be reused if they are removed from the drive
shaft.
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Jackbolt
[6575]
Hub
[7200]
Outer Magnet
Flange [0231]
Lantern
[1340]
Hub
[7200]
Fastener & Lockwasher
Outer Magnet
Flange [0231]
Keep contaminants out of the bearing
housing and bearings.
6.7.6.2 Close-coupled PolyChem M-series
pumps
Figure 6-28: Group A and 1 pumps
Figure 6-29: Group B and 2 pumps
c) Remove the fasteners [6570.9] that attach the
outer magnet flange [0231] to the hub [7200].
d) To remove the motor flange [0231], remove the
four (4) motor flange/motor fasteners [6570.4].
e) The outer magnet flange [0231] can be
separated from the outer magnet [0230] by
removing fasteners [6570.3].
Group B and 2 pumps:
a) Loosen the fasteners [6570.9] that attaches the
outer magnet assembly [0230] to the hub [7200].
See Figure 6-29.
b) To remove the lantern [1340], remove the four
(4) lantern/motor fasteners [6570.4].
c) Loosen the set screws that attaches the hub
[6814] to the motor, pull the hub off the shaft.
d) The outer magnet flange [0231] can be
separated from the outer magnet [0230] by
removing fasteners [6570.3].
6.8 Examination of parts
Cleaning/inspection
All parts should be thoroughly cleaned and inspected.
New anti-friction bearings, O-rings, gaskets and lip
seals should be used (if so equipped). Any parts that
show wear or corrosion should be replaced with new
genuine Flowserve parts.
This procedure is necessary only if the
outer magnet assembly [0230] or motor must be
replaced.
Group A and 1 pumps:
a) Loosen the set screw that attaches the outer
magnet assembly [0230] to the motor shaft. See
Figure 6-28.
b) Remove the outer magnet assembly [0230] from
the motor shaft. As a disassembly aide, a
threaded hole has been provided in the center of
the outer magnet flange [0231] to enable the
outer magnet flange to be jacked off of the motor
shaft. One of the square head jackscrews [6575]
from the lantern [1340] can be used for this step.
It is important that only non-flammable,
non-contaminated cleaning fluids are used. These fluids
must comply with plant safety and environmental
guidelines.
Critical measurements and tolerances
To maximize reliability of pumps, it is important that
certain parameters and dimensions are measured
and maintained within specified tolerances. It is
important that all parts be checked. Any parts that do
not conform to the specifications should be replaced
with new Flowserve parts.
Parameters that should be checked by users
Flowserve recommends that the user check the
condition of the individual pump components
whenever maintenance is performed. It is described
in more detail below.
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Figure 6-30: Wet end allowable wear
Axial Allowable Bearing Wear (total) 0.38 mm (0.015 in)
Diametrical Allowable Bearing Wear (total) 0.61 mm (0.024 in)
Liner Allowable Wear 25% of thickness
AS NEW DIMENSIONS – NOMIINAL
AXIAL BEARING FEATURES
Group A and 1
Group B and 2
Thrust Journal and Bushing
Thickness
4.78 (0.188)
6.35 (0.250)
Shell Thrust Bushing Depth
95.89 (3.775)
112.27 (4.420)
Shaft Shoulder Thickness
5.21 (0.205)
7.9 (0.31)
Pump Model
Impeller Height
Casing Depth
32-160
49.99 (1.968)
70.79 (2.787)
65-160
50.50 (1.988)
85.24 (3.356)
40-200
51.26 (2.018)
84.89 (3.342)
1.5x1-6
48.97 (1.928)
74.73 (2.942)
3x1.5-6
52.27 (2.058)
78.87 (3.105)
3x2-6
52.27 (2.058)
78.87 (3.105)
1.5x1-8
49.48 (1.948)
75.82 (2.985)
32-250
57.66 (2.270)
92.91 (3.658)
50-250
58.17 (2.290)
93.24 (3.671)
65-250
63.25 (2.490)
98.08 (3.862)
2x1-10
57.66 (2.270)
95.76 (3.770)
3x2-10
56.90 (2.240)
94.92 (3.737)
4x3-10
63.25 (2.490)
101.35 (3.990)
RADIAL BEARING FEATURES
Group A and 1
Group B and 2
Bushing Inside Diameter
38.13 (1.501)
50.04 (1.970)
Shaft Outside Diameter
38.087 (1.4995)
50.000 (1.9685)
ADDITIONAL COMPONENT FEATURES
Group A and 1
Group B and 2
Shell Inside Diameter
124.89 (4.917)
195.83 (7.71)
Inner Magnet
O.D.
121.92 (4.800)
190.04 (7.482)
I.D.
44.450 (1.7500)
50.533 (1.9895)
Width
12.75 (0.502)
12.75 (0.502)
Key Width
12.57 (0.495)
12.57 (0.495)
Note: Dimensions shown above are in millimeters (inches).
Bushing
I.D.
Thrust
Bearing
Depth
Inside
Diameter
Bushing
I.D.
Bearing
Holder
Shoulder Thickness
Outside
Diameter
Outside
Diameter
Width
Inside Diameter
Outside Diameter
6.8.1 Wet End
a) Inspect the bushings, thrust journals and shaft
for wear. Total diametrical and axial wear limits
are shown in Figure 6-30.
b) Inspect the casing, impeller, holder, inner
magnet and containment shell for wear,
corrosion and defects. The nominal liner
thickness for all components is 3.18 mm (0.125
inches).
Figures 6-31 through 6-36 have been provided as a
guide for identifying the features listed in the table.
Figure 6-31: Shell
Figure 6-32: Shaft
Figure 6-33: Bushing
Figure 6-34: Inner Magnet
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USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
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Pump
Group
Pump
Prefix
Magnet
Torque at 20°C (68°F)
N-m (lbf-in)
Poles
Length
A & 1
PA 8 31.8 (1.25)
18 (160)
PB
12
31.8 (1.25)
26 (230)
PC
12
63.5 (2.50)
61 (540)
B & 2
PJ
10
63.5 (2.50)
47 (420)
PK
16
63.5 (2.50)
77 (680)
PL
16
86.4 (3.40)
111 (983)
ThrustBearing
Width
Depth
Thrust
Bearing
Thrust
Bearing
Height
Figure 6-35: Impeller
Figure 6-36: Casing
6.8.2 Impeller drive
a) The condition of the impeller drive mechanism
should be checked whenever maintenance is
performed.
b) Measure the circumferential movement “M” of
the impeller when it is mounted on the shaft.
c) Verify the impeller diameter “D”.
d) Substitute values “M” and “D” into the equation
and if the answer is less than or equal to 10 then
the impeller can be reused.
M ÷ (0.017 x (D ÷ 2)) ≤ 10 Reuse the impeller
> 10 Replace impeller or insert
Figure 6-37: Impeller Drive Check
6.8.3 Magnetic Coupling
MAGNETIC FIELD PRESENT
Do not use the silicon carbide shaft to
check the torque rating of the magnetic coupling. If
the magnetic coupling must be checked, a metallic
shaft similar to that shown in section 6.4 (Tools
required) must be substituted.
There are a total of six magnetic
couplings. Three for the Group A and 1 pumps and
three for the Group B and 2 pumps. It is imperative
that the appropriate inner magnet assembly be
matched with the corresponding outer magnet.
This test can only be performed on a longcoupled pump, you must have a means to prevent the
rotation of the outer magnet.
Figure 6-38: Magnetic Coupling Torques
Note: Length dimensions shown in millimeters (inches).
a) Reassemble the pump (see section 6.9)
substituting a metallic shaft (see section 6.4) for
the silicon carbide shaft.
b) Install the Flowserve impeller wrench and key
onto the input shaft of the pump. The wrench
handle should be touching the workbench
towards the right as you are facing the suction
flange of the pump.
c) Utilizing a torque wrench and socket (an
extension may be necessary) place it onto the
hex head protruding from the end of the metallic
shaft.
d) Rotate the wrench and determine if you can
achieve the torque values shown in Figure 6-37
for the magnetic coupling being evaluated.
Do not exceed the values listed in
Figure 6-38.
e) If the noted value is obtained you can reuse the
coupling provided there is no other damage. If
on the other hand the value was not reached you
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PolyChem M-series
Feature mm (in)
Group A and 1
Group B and 2
Bearing
OD
79.992/79.987
(3.1493/3.1491)
110.000/109.985
(43304/43301)
ID
35.000/34.989
(1.3780/1.3775)
50.000/49.987
(1.9685/1.9680)
Shaft OD
35.014/35.004
(1.3785/1.3781)
50.013/50.003
(1.9690/1.9686)
Housing ID
80.020/80.005
(3.1504/3.1498)
110.023/110.007
(4.3316/4.3310)
Fit
Bearing/Housing
0.033L/0.013L
(0.0013L/0.0005L)
0.038L/0.008L
(0.0015L/0.0003L)
Fit
Bearing/Shaft
0.025T/0.004T
(0.0010T/0.0001T)
0.026T/0.003T
(0.0010T/0.0001T)
will need to replace either the inner (most likely)
or outer magnet assembly.
6.8.4 Power End
a) Inspect the outer magnet for wear and condition
of potting compound that exists between the
magnet poles.
b) Inspect the anti-friction bearings for scoring,
pitting, scratches or rust. If any of these
conditions exists or if the bearings have been
removed from the shaft the bearings should be
replaced.
c) In order to ensure proper bearing fits, the shaft
(OD), bearings (ID and OD), and bearing
housing (ID) should be checked. A micrometer
can be used to check the OD dimensions and an
inside caliper the ID dimensions. See Figure 6-
39.
Figure 6-39
6.8.4.1 Alignment
Misalignment of the pump and motor shafts can
cause the following problems:
Failure of the motor and/or pump bearings
Failure of the coupling
Excessive vibration/noise
The schematics below show the technique for a
typical rim and face alignment using a dial indicator.
It is important that this alignment be done after the
flanges are loaded, and at typical operating
temperatures. If proper alignment cannot be
maintained a close coupled arrangement and/or
stilt/spring mounting should be considered.
Alignment
Many companies today are using laser alignment
which is a more sophisticated and accurate
technique. With this method a laser and sensor
measure misalignment. This is fed to a computer with
a graphic display that shows the required adjustment
for each of the motor feet.
See section 4.8 for recommended final shaft
alignment limits.
6.8.4.2 Vibration analysis
Vibration analysis is a type of condition monitoring
where a pump’s vibration “signature” is monitored on
a regular, periodic basis. The primary goal of
vibration analysis is extension on MTBPM. By using
this tool Flowserve can often determine not only the
existence of a problem before it becomes serious, but
also the root cause and possible solution.
Modern vibration analysis equipment not only detects
if a vibration problem exists, but can also suggest the
cause of the problem. On a centrifugal pump, these
causes can include the following: unbalance,
misalignment, defective bearings, resonance,
hydraulic forces, cavitation and recirculation. Once
identified, the problem can be corrected, leading to
increased MTBPM for the pump.
Flowserve does not make vibration analysis
equipment; however Flowserve strongly urges
customers to work with an equipment supplier or
consultant to establish an on-going vibration analysis
program.
6.9 Assembly of pump
It is important that all pipe threads be
sealed properly. Flowserve does not recommend the
use of PTFE tape as a thread sealant.
Flowserve has investigated and tested alternate
sealants and has identified two that provide an
effective seal and have the same chemical resistance
as the tape. These are La-co Slic-Tite and Bakerseal.
Both products contain finely ground PTFE particles in
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Pump
Group
Type of bearing
Inboard and outboard
single row, deep groove
A & 1
Oil bath / mist –
Open
1
6307-C3
Greased for life –
double shielded
2
6307-2ZC3
B & 2
Oil bath / mist –
Open
1
6310-C3
Greased for life –
double shielded
2
6310-2ZC3
an oil based carrier. They are supplied in a paste
form which is brushed onto the male pipe threads.
Flowserve recommends using one of these paste
sealants.
Full thread length engagement is required for all
fasteners.
Refer to Figure 6-4 for recommended bolt
torques.
6.9.1 Power end assembly – Long Coupled
6.9.1.1 Bearing installation
Mounting of bearings on shafts must be done in a
clean environment. Bearing and power end life can
be drastically reduced if even very small foreign
particles work their way into the bearings. Wear clean
gloves.
Bearings should be removed from their protective
packaging only immediately before assembly to limit
exposure to possible contamination. After removing
the packaging they should only come in contact with
clean hands, fixtures, tools and work surfaces.
The chart shown in Figure 6-40 gives the part numbers
for bearings in Flowserve PolyChem pumps. Note that
the term “inboard bearing” refers to the bearing nearest to
the casing. “Outboard bearing” refers to the bearing
nearest to the motor.
Both bearings have a slight interference
fit which requires that they be pressed on the shaft with
an arbor or hydraulic press. Even force should be
applied to only the inner race. Never press on the outer
race, as the force will damage the balls and races.
An alternate method of installing bearings is to heat
the bearings to 93 °C (200 °F) by means of an oven
or induction heater. With this approach the bearing
must be quickly positioned on the shaft.
Never heat the bearings above 110°C (230°F). To do
so will likely cause the bearing fits to permanently
change, leading to early failure.
1) These bearings are open on both sides. They are lubricated by
oil bath or oil mist.
2) These bearings are shielded on both sides. They come pregreased by the bearing manufacturer. The user does not need to
regrease these bearings. The shields do not actually contact the
bearing race, so no heat is generated.
3) All bearing configurations are supplied only with steel cages
a) Install the inboard bearing [3011.1] on the shaft
[2100.2] until it is positioned against the shoulder.
b) Allow the inboard bearing to cool before installing
the outboard bearing.
c) Install the outboard bearing [3011.2] on the shaft
[2100.2] until it is positioned against the shoulder.
d) Allow the outboard bearing to cool and then check
bearings for ease of rotation.
6.9.1.2 Power end seals
Lip seals
If lip seals were used install new lip seals in the bearing
cover [3260] and the housing [3200]. The lip seals
[4310.1 and 4310.2] are double lip style, the cavity
between these two lips should be 1/2 to 2/3 filled with
grease. When installing this part, the large
metal face on the lip seal must face away from the
bearings.
Labyrinth seals
The following are general installation instructions
regarding the VBXX Inpro seal. Follow the
instructions provided with the seal by the
manufacturer.
The elastomer O-ring located on the OD of the seal
has been sized to overfill the groove in which it is
located. When installing the seal into its
corresponding housing, in addition to compressing the
O-ring a certain amount of material may shear off.
This sheared material should be removed. An arbor
press should be used to install the seal.
Install the inboard seal in the bore of the bearing
housing with the single expulsion port positioned at
the 6 o’clock position.
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Hub [7200]
Installation
Studs
Hub and end of
motor shaft must
be aligned
Motor
shaft
Install the outboard seal in the bore of the bearing
cover with the single expulsion port positioned at the
6 o’clock position.
Magnetic seals
Follow the installation instructions provided by the
manufacturer.
6.9.1.3 Bearing cover/shaft/power end assembly
a) Clean the interior surfaces of the bearing
housing and cover with a non-flammable solvent
cleaner.
b) Place the wavy washer [4260] in the bearing
housing [3200]. Slide the shaft [2100.2] with
anti-friction bearings installed into the bearing
housing [3200] (Figure 6-24).
The axial location of the shaft/anti-friction
bearing assembly is accomplished after the bearing
cap is installed and the wavy washer is compressed.
The compression results in preloading the anti-friction
bearings which is essential for proper bearing
operation.
c) Install a new O-ring [4610.9] into the bearing
cover [3260] utilizing a small amount of grease to
hold it in place.
d) Place the bearing cover [3260] onto the shaft
[2100.2] slide it towards the bearing housing
[3200] and then secure it with the three (3)
fasteners [6570.3].
e) Reinstall the following items onto the bearing
housing; oil level tag (Figure 6-25 and 6-26) and
combination Trico oiler/site gage [3855],
vent/breather [6569.2] and drain plug [6569.1].
f) Attach the outer magnet flange [0231] to the
outer magnet [0230] using socket head cap
screws [6570.3].
g) Install the Flowserve impeller wrench and key
onto the input shaft of the pump. The wrench
handle should be touching the workbench
towards the right as you are facing the suction
flange of the pump.
h) Screw the outer magnet flange assembly onto
the drive shaft.
i) Using gloves, raise the impeller wrench until it is
parallel with the work bench (but still facing
towards the right as you face the suction flange
of the pump), spin the outer magnet rapidly in a
clockwise direction to impact the impeller
wrench on the work bench. After several sharp
raps, the outer magnet assembly should be tight.
The threads are right hand.
j) Insert the flat head cap screw [6570.8] into the
center of the outer magnet flange and tighten.
Again the threads are right hand tight.
k) The assembly of the power end is complete.
6.9.2 Power end assembly – Close Coupled
6.9.2.1 Group A and 1
a) Attach a new motor gasket [4590.2] and lantern
gasket [4590.1] to the motor flange [6540].
b) Mount the motor flange [6540] to the motor with
four (4) socket head cap screws [6570.4] see
Figure 6-17.
c) Attach the outer magnet flange [0231] to the
outer magnet [0230] using socket head cap
screws [6570.3].
d) Attach the hub [7200] to the outer magnet
assembly using the four (4) fasteners [6570.9]
supplied with the hub, see Figure 6-28.
e) Place the key supplied with the motor in the
motor keyway and mount the outer magnet
assembly onto the motor shaft. Engage the
assembly onto the motor shaft till the face of the
outer magnet flange [6540] contacts the end of
the shaft. This ensures the proper axial location
of the magnet poles.
f) Tighten the set screw in the hub to secure the
outer magnet assembly to the motor shaft.
6.9.2.2 Group B and 2
a) Attach a new motor gasket [4590] to the lantern
[1340].
b) Place the key supplied with the motor in the
motor keyway and mount the hub [7200] to the
shaft. The end of the hub must be aligned with
end of the shaft, see figure 6-41.
Figure 6-41
c) Tighten the set crews in the hub to secure it to
the motor shaft, figure 6-29.
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Non metallic
spacer
Casing
[1100]
Pin
[6810.2]
Thrust bushing
[3041]
Non metallic
spacer
Bushing
[3300]
Bearing
holder
[3830]
Non metallic
spacer
Key
[6700.2]
Inner Magnet
[818/220]
Shaft
[2100.1]
Install two (2) 5/8-11UNC-2B studs (180°
apart) into the hub to aid in installation of the outer
magnet assembly. These two studs will be later
removed.
d) Mount lantern [1340] to the motor with four (4)
hex head cap screws [6570.4].
e) Attach the outer magnet flange [0231] to the
outer magnet [0230] using socket head cap
screws [6570.3].
f) Place the outer magnet assembly into the lantern
[1340] and use the installation studs as a guide
to support the assembly until two (2) of the
fasteners [6570.9] and corresponding lock
washers can be installed. See Figure 6-29
g) Remove the installation studs and replace them
with the remaining two (2) fasteners [6570.9] and
lock washers.
6.9.3 Wet end assembly
The first part of these instructions pertain to both the
Group A and 1 plus Group B and 2 pump models.
In the assembly of the wet end it will be
necessary to utilize an arbor press to aid in the
assembly of the silicon carbide bearings into their
mating components. When utilizing an arbor press a
nonmetallic spacer must be placed between the ram
of the press and corresponding silicon carbide
bearing. The spacer must be flat and the entire
surface area of the component being pressed must be
covered.
a) The casing [1100] should placed on its suction
flange. The surface on which the suction flange
is placed must be flat and care must be taken to
protect the casing liner, see Figure 6-42.
Figure 6-42
c) Press the inboard bushing [3300] into the
bearing holder [3830], see figure 6-43.
On Group A and 1 pumps take care to align
the flat on the bushing with the flat on the bearing
holder. On Group B and 2 pumps visually align the
key slots in the bushing with the as molded keys in
the bearing holder.
Figure 6-43
d) Install key(s) [6700.2] into the key slot(s) located
on the silicon carbide shaft [2100.1].
e) Press the shaft [2100.1] into the inner magnet
[0220], see Figure 6-44.
Figure 6-44
b) Install pin [6810.2] into casing [1100] followed by
the installation of the thrust bushing [3041] taking
care to align the slot with the pin.
6.9.3.1 Group A and 1
a) Place the lantern [1340] on a work bench with
the flange incorporating the lifting lug towards the
work bench, see Figure 6-45.
b) Install the containment shell [3500] into the
lantern followed by the inner magnet/shaft
assembly and then the bearing holder/bushing.
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Bearing
holder
[3830]
Bushing
[545.1/212]
Lantern
[1340]
Containment shell
[817/224]
Shaft
[2100.1]
Lifting
Lug
O.B.
Bushing
Impeller
[2200]
Non metallic
spacer
Figure 6-45
c) Rotate the bearing holder [3830] so that holes
are located at the 3, 6, 9, and 12 o’clock
positions with the flat being forced to be at the 12
o’clock position, which is in line with the lifting
lug.
d) See section 6.6 for impeller assembly.
e) Install the casing [1100] onto the lantern/bearing
holder with studs and nuts [6572 and 6580].
6.9.3.2 Group B and 2
a) Install gasket [4610.1] into groove on bearing
holder [3830]
b) To continue the assembly process the bearing
holder should be support horizontally. A tapped
hole is located at the 12 o’clock position on the
holder [3830] so that an eyebolt can be engaged.
An appropriate lifting device should be attached
to the eyebolt, placing it in light tension to
support the wet end. See Figure 6-45.
Figure 6-45
d) Place the containment shell [3500] over the inner
magnet followed by retaining ring [2530].
The retainer ring [2530] is
manufactured from carbon steel and may attach to
the containment shell [3500] upon installation due to
the presence of magnets in the inner magnet
assembly.
e) Install and tighten the twelve (12) retainer
ring/containment shell cap screws [6570.7].
f) See section 6.6 for impeller assembly.
g) Install the casing [1100] onto the bearing holder
with studs and nuts [6572 and 6580].
6.9.4 Mounting the wet end to the power end
Do not attempt to assemble the drive
end to the wet end without using the jackbolts. The
magnetic force can cause severe personal injury.
Be sure to engage the inner and outer
magnet assemblies evenly. Cocking of the two can
result in serious damage to the magnets and/or
containment shell. It is best to alternatively give each
bolt a turn to ensure proper and even separation.
Thread the entire length of the square head
jackbolts [6575] through the bearing housing or
lantern.
a) Slide the wet end towards the power end until
the jackbolts [6575] engage in the recess
provided for it.
b) Turn the jackbolts [6575] counterclockwise to
allow the wet end to slowly engage into the
power end. Alternate from one bolt to the other
to prevent the unit from cocking.
c) Once the mating surfaces are in contact, install
fasteners [6570.6] for Group A and 1 and
[6570.8] for Group B and 2.
c) Install the inner magnet/shaft assembly through
the bushing [3300] that is located in the bearing
holder [3830].
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Pump not reaching design flow rate
Pump not reaching design head (TDH)
No discharge or flow with pump running
Pump operates for short period, then loses prime
Excessive noise from wet end
Excessive noise from power end
Pump exhibits increased or higher than anticipated power consumption
Pump exhibits decreased or lower than anticipated power consumption
PROBABLE CAUSES
POSSIBLE REMEDIES
Insufficient NPSH. (Noise may not
be present.)
Recalculate NPSH available. It must be greater than the NPSH required by
pump at desired flow. If not, redesign suction piping, holding number of
elbows and number of planes to a minimum to avoid adverse flow rotation as
it approaches the impeller.
System head greater than
anticipated.
Reduce system head by increasing pipe size and/or reducing number of
fittings. Increase impeller diameter. (nb: Increasing impeller diameter
may require use of a larger motor.)
Entrained air. Air leak from
atmosphere on suction side.
1. Check suction line gaskets and threads for tightness.
2. If vortex formation is observed in suction tank, install vortex breaker.
3. Check for minimum submergence
Entrained gas from process.
Process generated gases may require larger pumps.
Speed too low.
Check motor speed against design speed.
Direction of rotation wrong.
After confirming wrong rotation, reverse any two of three leads on a three
phase motor. The pump should be disassembled and inspected before it
is restarted.
Impeller too small.
Replace with proper diameter impeller. (NOTE: Increasing impeller
diameter may require use of a larger motor.)
Plugged impeller, suction line or
casing which may be due to a
product or large solids.
1. Reduce length of fiber when possible.
2. Reduce solids in the process fluid when possible.
3. Consider larger pump.
Wet end parts (casing, bearing
holder, impeller, containment shell)
worn, corroded or missing.
Replace part or parts.
Not properly primed.
Repeat priming operation, recheck instructions. If pump has run dry,
disassemble and inspect the pump before operation.
Impeller rubbing.
Check wet end bearings for wear.
Damaged bushings pump shaft,
thrust bearings or impeller.
Replace damaged parts.
Abnormal fluid rotation due to
complex suction piping.
Redesign suction piping, holding the number of elbows and planes to a
minimum to avoid adverse fluid rotation as it approaches the impeller.
Magnetic coupling decoupled due to
excessive temperature or excessive
horsepower requirements.
1. Check process temperature to verify it’s within operating limits of
pump.
2. Check horsepower required by the process to verify it is within the
operating limits of the coupling size.
3. Replacement of the magnet assemblies may be necessary if the
magnets overheated and were permanently damaged. A static torque
test of the magnetic coupling may be necessary. Contact your
Flowserve representative for details.
Inner magnet rubbing shell.
Check for damaged or worn pump shaft and bushings.
7 FAULTS; CAUSES AND REMEDIES
The following is a guide to troubleshooting problems with Flowserve PolyChem pumps. Common problems are
analyzed and solutions offered. Obviously, it is impossible to cover every possible scenario. If a problem
exists that is not covered by one of the examples, then refer to one of the books listed in section 10 Additional
sources of information or contact a Flowserve sales engineer or distributor/representative for assistance.
FAULT SYMPTOM
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Pump not reaching design flow rate
Pump not reaching design head (TDH)
No discharge or flow with pump running
Pump operates for short period, then loses prime
Excessive noise from wet end
Excessive noise from power end
Pump exhibits increased or higher than anticipated power consumption
Pump exhibits decreased or lower than anticipated power consumption
PROBABLE CAUSES
POSSIBLE REMEDIES
Bearing contamination appearing on
the raceways as scoring, pitting,
scratching or rusting caused by
adverse environment and entrance of
abrasive contaminants from
atmosphere.
1. Work with clean tools in clean surroundings.
2. Remove all outside dirt from housing before exposing bearings.
3. Handle with clean dry hands.
4. Treat a used bearing as carefully as a new one.
5. Use clean solvent and flushing oil.
6. Protect disassembled bearing from dirt and moisture.
7. Keep bearings wrapped in paper or clean cloth while not in use.
8. Clean inside of housing before replacing bearings.
9. Check oil seals and replace as required.
10. Check all plugs and tapped openings to make sure that they are
tight.
Brinelling of bearing identified by
indentation on the ball races, usually
caused by incorrectly applied forces
in assembling the bearing or by
shock loading such as hitting the
bearing or drive shaft with a hammer.
When mounting the bearing on the drive shaft use a proper size ring and
apply the pressure against the inner ring only. Be sure when mounting a
bearing to apply the mounting pressure slowly and evenly.
False brinelling of bearing identified
again by either axial or
circumferential indentations usually
caused by vibration of the balls
between the races in a stationary
bearing.
1. Correct the source of vibration.
2. Where bearings are oil lubricated and employed in units that may be
out of service for extended periods, the drive shaft should be turned over
periodically to relubricate all bearing surfaces at intervals of one to three
months.
Thrust overload on bearing identified
by flaking ball path on one side of the
outer race or in the case of maximum
capacity bearings, may appear as a
spalling of the races in the vicinity of
the loading slot. (Please note:
maximum capacity bearings are not
recommended) These thrust failures
are caused by improper mounting of
the bearing or excessive thrust loads.
Follow correct mounting procedures for bearings.
Misalignment identified by fracture of
ball retainer or a wide ball path on
the inner race and a narrower cocked
ball path on the outer race.
Misalignment is caused by poor
mounting practices or defective drive
shaft. For example, bearing not
square with the centerline or possibly
a bent shaft due to improper
handling.
Handle parts carefully and follow recommended mounting procedures.
Check all parts for proper fit and alignment.
Bearing damaged by electric arcing
identified as electro- etching of both
inner and outer ring as a pitting or
cratering. Electrical arcing is caused
by a static electrical charge
emanating from belt drives, electrical
leakage or short circuiting.
1. Where current shunting through the bearing cannot be corrected, a
shunt in the form of a slip ring assembly should be incorporated.
2. Check all wiring, insulation and rotor windings to be sure that they are
sound and all connections are properly made.
3. Where pumps are belt driven, consider the elimination of static
charges by proper grounding or consider belt material that is less
generative.
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Pump not reaching design flow rate
Pump not reaching design head (TDH)
No discharge or flow with pump running
Pump operates for short period, then loses prime
Excessive noise from wet end
Excessive noise from power end
Pump exhibits increased or higher than anticipated power consumption
Pump exhibits decreased or lower than anticipated power consumption
PROBABLE CAUSES
POSSIBLE REMEDIES
Bearing damage due to improper
lubrication, identified by one or more
of the following:
1. Abnormal bearing temperature
rise.
2. A stiff cracked grease
appearance.
3. A brown or bluish discoloration of
the bearing races.
1. Be sure the lubricant is clean.
2. Be sure proper amount of lubricant is used. The constant level oiler
supplied with Flowserve pumps will maintain the proper oil level if it is
installed and operating properly. In the case of greased lubricated
bearings, be sure that there is space adjacent to the bearing into which it
can rid itself of excessive lubricant, otherwise the bearing may overheat
and fail prematurely.
3. Be sure the proper grade of lubricant is used.
Outer magnet assembly rubbing
bearing housing or containment
shell.
1. Check integrity of ball bearings.
2. Make sure drive shaft is not bent.
3. Make sure outer magnet assembly has not come unscrewed due to
incorrect motor rotation.
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8 PARTS LIST AND DRAWINGS
8.1 PolyChem Group A and 1 Close Coupled
8.2 PolyChem Group A and 1 Long Coupled
Drawing taken from CY61190-1
Drawing taken from CY61191-0
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8.3 PolyChem Group B and 2 Close Coupled
8.4 PolyChem Group B and 2 Long Coupled
Drawing taken from CY61192-1
Drawing taken from CY61193A-0
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Item Numbers
Description
0220
Inner Magnet Assembly
0230
Outer Magnet Assembly
0231
Flange-Outer Magnet
1100
Casing
1340
Lantern
2100.1
Power End Shaft
2100.2
Pump Shaft
2200
Impeller
2905
Wave Spring Washer
3011.1
Power End Bearing-Inboard
3011.2
Power End Bearing-Outboard
3041
Thust Bearing-Casing
3043
Thrust Bearing-Impeller
3134
Bearing Housing Foot
3200
Bearing Housing
3260
Bearing Housing End Cover
3300
Bushing
3500
Containment Shell
3830
Bearing Holder
3853
Nipple *
3856
Constant level oiler Oiler *
3858
Oil Sight Glass
3891
Tag-Oil Level *
4310.1
Oil Seal-Inboard
4310.2
Oil Seal-Inboard
4590.1
Gasket-Lantern
4590.2
Gasket-Motor Flange/Motor
4610
0-Ring Bearing End Cover
6540
Motor Flange
6569.1
Plug-Brg Housing Drain
6569.2
Brg Housing Vent
6570.1
Screw-Bearing Housing Foot
6570.2
Screw-End Cover/Brg Housing
6570.3
Screw-Outer Magnet Flange
6570.4
Screw-Motor Flange/Motor
6570.5
Screw-Reverse Rotation
6570.6
Screw-Lantern/Bearing Housing
5670.9
Screw-Hub
6572
Casing Stud
6575
Jack screw *
6580
Casing Stud Nut
6700.1
Coupling Key
6700.2
Key-Pump Shaft
6810.1
Outer Magnet Rub Pins
6810.2
Anti Rotation Pin-Casing
6814
Set Screw-Motor Hub
Item Numbers
Description
0220
Inner Magnet Assembly
0230
Outer Magnet Assembly
0231
Flange-Outer Magnet
1100
Casing
1340
Lantern
2100.1
Power End Shaft
2100.2
Pump Shaft
2200
Impeller
2530
Retaining Ring-Shell
2905
Wave Spring Washer
3011.1
Power End Bearing-Inboard
3011.2
Power End Bearing-Outboard
3041
Thust Bearing-Casing
3043
Thrust Bearing-Impeller
3126
Shim
3134
Bearing Housing Foot
3200
Bearing Housing
3260
Bearing Housing End Cover
3300
Bushing
3500
Containment Shell
3830
Bearing Holder
3853
Grease nipple *
3856
Constant level oiler *
3858
Oil sight glass
3891
Tag-Oil Level *
4310.1
Oil Seal-Inboard
4310.2
Oil Seal-Inboard
4590
Gasket-Motor Flange/Motor
4610.1
0-Ring Bearing End Cover
4610.2
O-Ring Bearing Holder
6569.1
Plug-Brg Housing Drain
6569.2
Brg Housing Vent
6570.1
Screw-Bearing Housing Foot
6570.2
Screw-End Cover/Brg Housing
6570.3
Screw-Outer Magnet Flange
6570.4
Screw-Lantern/Motor
6570.5
Screw-Reverse Rotation
6570.7
Screw-Retaining Ring
6570.8
Screw-Lantern / Bearing holder
6570.9
Screw-Hub
6572
Casing Stud
6575
Jack screw *
6579.4
Screw-Motor Flange/Motor
6580
Casing Stud Nut
6700.1
Coupling Key
6700.2
Key-Pump Shaft
6810.1
Outer Magnet Rub Pins
6810.2
Anti Rotation Pin-Casing
6814
Set Screw-Motor Hub
7200
Motor Hub
8.5 PolyChem Group A and 1
8.6 PolyChem Group B and 2
* Not shown in the drawings
flowserve.com
USER INSTRUCTIONS PolyChem M-SERIES ENGLISH 71569218 07-11
Page 58 of 60
®
9 CERTIFICATION
Certificates determined from the contract
requirements are provided with these instructions
where applicable. Examples are certificates for CE
marking and ATEX marking etc. If required, copies of
other certificates sent separately to the Purchaser
should be obtained from Purchaser for retention with
these User Instructions.
10 OTHER RELEVANT
DOCUMENTATION AND MANUALS
10.1 Supplementary User Instructions
Supplementary instructions such as for a driver,
instrumentation, controller, seals, sealant systems etc
are provided as separate documents in their original
format. If further copies of these are required they
should be obtained from the supplier for retention with
these User Instructions.
10.2 Change notes
If any changes, agreed with Flowserve Pump
Division, are made to the product after it is supplied, a
record of the details should be maintained with these
User Instructions.
10.3 Additional sources of information
The following are excellent sources for additional
information on Flowserve PolyChem S-series pumps,
and centrifugal pumps in general.