Flowserve N-Series Worthington User Manual

Worthington

N-Series of Thrust Pot

for Vertical, Multistage Pumps

USER INSTRUCTIONS

Installation

Operation

Original Instructions PCN= 26999948 07-14 (E)

Maintenance

N-SERIES OF THRUST POT USER INSTRUCTIONS ENGLISH 07/14

CONTENTS

PAGE

1.0 INTRODUCTION AND SAFETY ............................ 3

1.1 G

ENERAL

1.2 CE

1.3 D

ISCLAIMER

1.4 C

OPYRIGHT

1.5 D

UTY CONDITIONS

1.6 S

AFETY

................................................................. 3

MARKING AND APPROVALS

................................ 3

............................................................. 3

................................................... 3

.................................................................... 4

2.0 TRANSPORT AND STORAGE ............................. 7

2.1 C

ONSIGNMENT RECEIPT AND UNPACKING

2.2 H

ANDLING

2.3 L

IFTING

2.4 S

TORAGE

2.5 R

ECYCLING AND END OF PRODUCT LIFE

................................................................ 7

.................................................................... 7

................................................................. 7

............... 7

................. 7

3.0 COMMISSIONING START-UP, OPERATION

AND SHUTDOWN .......................................................... 8

3.1 P

UMP LUBRICANTS

3.2 O

PERATION

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

............................................................ 10

4.0 MAINTENANCE ..................................................... 10

4.1 G

ENERAL

4.2 M

AINTENANCE SCHEDULE

4.3 S

PARE PARTS

4.4 R

ECOMMENDED SPARES

4.6 D

ISASSEMBLY

4.7 A

SSEMBLY

............................................................... 10

..................................... 10

........................................................ 10

....................................... 11

........................................................ 12

............................................................. 12

5.0 FAULTS; CAUSES AND REMEDIES ................ 13

6.0 PARTS LIST AND DRAWINGS ........................... 14

6.1 A

6.2 A

6.3 A

SSEMBLY SSEMBLY SSEMBLY

0N-1N ................................................. 14

3N-7N ................................................. 15

8N ....................................................... 16

7.0 CERTIFICATION .................................................... 17

8.0 OTHER RELEVANT DOCUMENTATION AND

MANUALS ..................................................................... 17

8.1 S

UPPLEMENTARY USER INSTRUCTIONS

8.2 C

HANGE NOTES

8.3 A

DDITIONAL SOURCES OF INFORMATION

8.4 A

BBREVIATIONS

..................................................... 17

..................................................... 18

................ 17

.............. 17

Page 2 of 20

N-SERIES OF THRUST POT USER INSTRUCTIONS ENGLISH 07/14

1.0 INTRODUCTION AND SAFETY

instructions. Where applicable this document incorporates information relevant to these Directives. To establish Approvals and if the product itself is CE Marked check the serial number plate and the Certification.

1.1 General

These Instructions must always be kept close to product's operating location or directly with the product.

Flowserve's products are designed, developed and manufactured with state-of-the-art technologies in modern facilities. The unit is produced with great care and commitment to continuous quality control, utilizing sophisticated quality techniques, and safety requirements. Flowserve is committed to continuous quality improvement and being at service for any further information about the product in its installation and operation or about its support products, repair and diagnostic services. These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements and applicable safety and health laws/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.

1.3 Disclaimer

Information in these User Instructions is believed to be complete and reliable. However, in spite of all of the efforts of Flowserve Corporation to provide comprehensive instructions, good engineering and safety practice should always be used.

Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorized Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by Flowserve's warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in their use.

1.4 Copyright

1.5 Duty conditions

This product has been selected to meet the specifications of your purchaser order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.

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

Page 3 of 20

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 Flowserve´s written agreement before start up.

N-SERIES OF THRUST POT USER INSTRUCTIONS ENGLISH 07/14

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.

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

field" safety instructions where non-compliance would affect personal safety, pacemakers, instruments or stored data sensitive to magnetic fields.

This symbol indicates explosive atmosphere 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.

indicates an important instruction in the assembly process.

This symbol indicates potential risks

connected with extremely high temperatures.

This symbol indicates safety

This symbol indicates "strong magnetic

The sign is not a safety symbol but

1.6.2 Personnel qualification and training

All personnel involved in the operation, installation, inspection and maintenance of the unit must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required the operator may commission the manufacturer / supplier to provide applicable training. Always co-ordinate repair activity with operations and health and safety personnel, and follow all plant safety requirements and applicable safety and health laws/regulations.

1.6.3 Safety action

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

NEVER DO MAINTENANCE WORK WHILST THE UNIT IS CONNECTED TO POWER

GUARDS MUST NOT BE REMOVED WHILE

PUMP IS OPERATIONAL

MOTOR ROTATION WITH COUPLING ELEMENT/ PINS REMOVED Starting in reverse direction of rotation will damage the pump.

LUBRICATION (See section 3.0, Commissioning, startup, operation and shutdown.)

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.

ONLY CHECK DIRECTION OF

ENSURE CORRECT

NEVER RUN THE PUMP DRY

DO NOT RUN THE PUMP AT

This symbol indicates potential risks

connected with extremely low temperatures.

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 lbs) use a crane

Page 4 of 20

HANDLING COMPONENTS

Temperature class

N-SERIES OF THRUST POT USER INSTRUCTIONS ENGLISH 07/14

corresponding to the mass and in accordance with current local regulations.

HOT AND COLD PARTS If hot or freezing components or auxiliary heating supplies can present a danger to operators, they must be shielded to avoid accidental contact. If complete protection is not possible, the machine access must be limited to maintenance staff only.

Bearing housings must not be insulated

and drive motors and bearings may be hot.

If the temperature is greater than 80 °C (175 °F) o r below -5 °C (20 °F) in a restricted zone, or exceeds local regulations, action as above shall be taken.

1.6.4 Products used in potentially explosive

atmospheres

Measures are required to:

• Avoid excess temperature

• Prevent dry running

• Prevent the generation of sparks

• Maintain the pump to avoid hazard

The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection. For ATEX, both electrical and non-electrical equipment must meet the requirements of European Directive 94/9/EC. Always observe the regional legal Ex requirements eg Ex electrical items outside the EU may be required certified to other than ATEX eg IECEx, UL.

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed.

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 IIC135ºC (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)

b = Control of ignition source (in accordance with EN13463-6) 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 temperature class and must not exceed the values in the table that follows.

to EN13463-1

T6 T5

* 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.

Maximum surface

temperature permitted

85 °C (185 °F)

100 °C (212 °F)

Temperature limit of

liquid handled *

Consult Flowserve Consult Flowserve

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 the pump could be

Page 5 of 20

N-SERIES OF THRUST POT USER INSTRUCTIONS ENGLISH 07/14

installed in different hazarous atmospheres. In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in the particular hazardous atmosphere.

If an explosive atmosphere exists during the installation, do not attempt to check the direction of rotation by starting the pump unfilled. Even a short run time may give a high temperature resulting from contact between rotating and stationary components.

Where there is any risk of the pump being run against a closed valve generating high liquid and casing external surface temperatures, fit an external surface temperature protection device.

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

In dirty or dusty environments, make regular checks and remove dirt from areas around close clearances, bearing housings and motors.

1.6.4.4 Preventing dry running

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 4.0, Maintenance.)

ENSURE THAT THE THRUST POT IS

PROPERLY FILLED ANS DOES NOT RUN DRY Ensure that the oil level is as per section 3.1.4.

The bearing temperature shall be monitored by means of a PT 100, surface contact type.

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 application sthe coupling must be selected

to comply with 94/9/EC. Correct coupling alignment must be maintained.

1.6.4.6 Maintenance to avoid the hazard

CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION

The responsibility for compliance with maintenance instructions is with the plant operator.

To avoid potential explosion hazards during maintenance, the tools, cleaning and painting materials used must not give rise to sparking or

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